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Summary of Contents for btsr SMART 3000TW
- Page 1 SMART 3000TW & IS3.. YARN CONTROL SYSTEM Operating Manual ENGLISH...
- Page 2 Copyright 2001 - BTSR - All rights reserved. This manual is intended for the users of the SMART 3000TW system. It is suggested to carefully read the instruction reported in this manual before making the connections and use the system.
- Page 3 External RESET Connection (RST - EXT)......................2.5 Chapter 3 – OPERATING SMART 3000TW Terminal Features........................3.1 Meaning of Red Leds inside the SMART 3000TW Terminal’s ................3.2 SMART 200 INT-TW 485 Interface Board Features ..................... 3.4 IS3.. Sensors Features..............................3.5 Types of IS3..
- Page 4 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 terminal and all Sensors connected to the various Boards ..........3.39 PX Programming Level ............................3.40 F_START: START Frequency ...........................3.40 F_STOP: STOP Frequency ..........................3.41...
- Page 5 INTRODUCTION INTRODUCTION Congratulations for choosing a BTSR product. With our SMART 3000TW yarn control system, you get an innovative, unique solution, able to offer you multiple advantages concerning quality control of your production. SMART 3000TW has been designed for applications on large warping machines that use in continuous mode a large number of yarns (up to 1920) during the entire working cycle.
- Page 6 Indicates a particularly sensitive situation which could have an effect on the safety or proper operation of the system. IS3.. The IS3.. BTSR sensor family includes a number of variants; these are indicated by the letters following IS3. The symbol IS3.. generally indicates all the variants of the IS3 sensor.
- Page 7 Special Features of SMART 3000TW System The SMART 3000TW system has a set of unique features which make it a true microcomputer dedicated to programming/control of production and statistical analysis of technical faults.
- Page 8 ! Easy Monitoring Besides the information provided on the graphical display of SMART 3000TW terminal, each IS3.. series sensor has a red LED that, when flashing, indicates the location of the yarn technical fault, making the operator intervention easier.
- Page 9 1 fuse 5 x 20 – 1A Installation The installation of the SMART 3000TW system depends on the type of target application, on the number of SMART 200 INT-TW 485 Interface Board, on the number of machine sections (Side) and on the type of priority used (i.e. Rows / Columns / Bars Priority).
- Page 10 SMART 200 INT-TW 485 Sensor Interface Boards As described on chapter 1, the SMART 3000TW can manage up to 1920 IS3.. sensors connected through Interface Boards (Board 1 ÷ 8). The Boards communicate with SMART 3000TW Terminal using a RS485 Serial Line.
- Page 11 Technical Data and Installation 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. SMART 3000TW - 2.3 -...
- Page 12 The following table lists at glance the types and lengths of the main connecting cables, which BTSR may provide. For further details and queries about the cables and options available, please contact your local dealer. SMART Power cables (I/O Connector)
- Page 13 In case of installation in environments subject to electromagnetic interferences, we recommend to install the ferrite cores on connection cables between SMART 3000TW technical and PSU10A power supply and between power supply and sensors. SMART 3000TW...
- Page 14 Technical Data and Installation Page intentionally left blank - 2.6 - SMART 3000TW...
- Page 15 3 – OPERATING SMART 3000TW Terminal Features As in all SMART BTSR systems, the operation of SMART 3000TW system is controlled by just 5 membrane buttons and it is monitored by a LCD graphic display, which guides the operator through all programming and administration phases of the system, by means of straight-forward messages which can be understood clearly and immediately.
- Page 16 Meaning of Red Leds inside the SMART 3000TW Terminal During normal operation, the SMART 3000TW terminal signals the current working condition through the status of Leds embedded in the five function buttons. The meaning of Leds is the following:...
- Page 17 The WAIT label indicates that the button you are pressing has a timed function, for instance if you press ENTER while the system is in Control condition, the WAIT label indicates that, if you keep the button pressed for 3 seconds you will access the P1 menu. SMART 3000TW - 3.3 -...
- Page 18 System running in Learn mode (LEARN nnnn displayed and Red LED of Control button Off). Board running the automatic sensor numbering function (once all the sensors connected to the Board have been numbered, this LED turn off). Indication of external synchronism signal (PRX). Indication of machine stopped. - 3.4 - SMART 3000TW...
- Page 19 IS3.. is full programmable for an easy fitting to the control of any type of yarn/application. Types of IS3.. sensors for SMART 3000TW The IS3.. Sensors are available in two typologies (W and N) to satisfy the specific requirements of each installation/application.
- Page 20 If the condition is permanent, replace the sensor. Green LED FLASHING Indicates a technical fault in the sensor(e.g. a loss of Red LED FLASHING stored data). Try to reprogram the sensor. If the fault remains, replace the sensor. - 3.6 - SMART 3000TW...
- Page 21 Stop Frequency (F_STOP) This setting indicates the minimum frequency of image variation, below which the sensor signals that the yarn runs normally (red LED ON). It can be programmed to a value between 1 and 10. SMART 3000TW - 3.7 -...
- Page 22 " 50 ms is the suggested value for very high running speed of the yarn. " 200 ms is the suggested value for normal yarns. " 500 ms is the suggested value for elastic yarns. - 3.8 - SMART 3000TW...
- Page 23 Operating Interface Board Hardware Coding The recognition 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 To each of these priorities, a different sensor numbering mode is applied. The following page shows 3 typical examples of creels with 2, 4 and 8 Sections (Sides) respectively, according to which it will be possible to arrange the Logical Sensor Identification. - 3.10 - SMART 3000TW...
- Page 25 Operating Sensor Array 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). SMART 3000TW - 3.11 -...
- Page 26 “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). - 3.12 - SMART 3000TW...
- Page 27 Operating 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). SMART 3000TW - 3.13 -...
- Page 28 Operating 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. - 3.14 - SMART 3000TW...
- Page 29 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).
- Page 30 If the problem is due to the fact that one (or more) Board was added after the last stored configuration, you will have to correctly re-configure the system according to the number of Boards and Sensors you actually want to use. - 3.16 - SMART 3000TW...
- Page 31 Operating Operating Sequences The SMART 3000TW system allows the following set of functions to be carried out: Programming the parameters that affect the system operation, through 5 interactive menus: P1 ÷ P4 and PX. Activating a LEARN cycle, during which the number of yarns used by the "...
- Page 32 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 ERROR_L Dxxx B0n is displayed.
- Page 33 Operating Display Messages during the Control Phase During the Control phase, the display of SMART 3000TW Terminal will show the error messages (if any), which depend on how the system was configured. A) If the Logical sensor identification (menu P2) has not been programmed, the...
- Page 34 Operating C) If the Bars priority has been programmed within menu P2: SMART 3000TW under Control phase (no failure detected!) Alternate Machine STOP due to broken yarn (BROKE) on Device connected to Bar xx (Side N). nnn = Total stops occurred on Device.
- Page 35 Operating Summary Diagram of SMART 3000TW Programming/Configuration Menu SMART 3000TW - 3.21 -...
- Page 36 : decreases nnn Example: If SYNC is programmed as 008 = a PRX pulse will be generated every 8 proxy pulses. Proxy signal PRX signal Press to confirm and move to the next parameter (RESET). - 3.22 - SMART 3000TW...
- Page 37 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 nnn : decreases nnn Set the desired value and press to move to the next parameter (DEVICES). SMART 3000TW - 3.23 -...
- Page 38 If you want to operate with Bars priority and LAMP 485 devices, then you must first program the Bars priority function with menu P2, and after return to menu P1 to define the lamp sensors numbering. - 3.24 - SMART 3000TW...
- Page 39 LAMPS BOARD 02 screen will appear. Repeat the procedure described for numbering of Board 01, until you complete the numbering of all devices. When the numbering phase is complete, the system will automatically move to the next function (KEY_COD). SMART 3000TW - 3.25 -...
- Page 40 When the numbering phase is complete, the system will automatically move to the NUMBER LAMPS function (providing that the Bars priority is currently active in menu P2) or to the KEY_COD function. In any case, press twice to resume the CONTROL function. - 3.26 - SMART 3000TW...
- Page 41 WARNING: If you set a password it will be necessary to enter it each time you access P1 ÷ P4 and PX menus. If you forget the 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).
- Page 42 When you enter the P2 Programming Level, you will have to complete the “Logical” configuration of the whole machine in order to provide the CPU of SMART 3000TW Terminal with all the parameters needed to build the “correct sensor mapping”. Therefore you will not be allowed to exit the P2 Programming Level just pressing the RESET button.
- Page 43 = No. last sensor connected to row / column / bar 01 of section A. ssss eeee : increases the eeee number by 1 : decreases the eeee number by 1 : increases the eeee number by 10 : decreases the eeee number by 10 to continue SMART 3000TW - 3.29 -...
- Page 44 Column Priority (10 Columns and 8 Sensors for each column) DEFINE SIDE DEFINE until COL = 10 ! DEFINE 0001 column of until H = 0008 0008 Section A DEFINE 0009 until H = 0016 0016 DEFINE 0017 0024 until H = 0024 - 3.30 - SMART 3000TW...
- Page 45 0160 DEFINE SIDE DEFINE until COL = 10 $ DEFINE column of 0161 Section C 0168 And so on until: Last column of 0233 0240 Section C DEFINE SIDE DEFINE until COL = 10 $ SMART 3000TW - 3.31 -...
- Page 46 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. - 3.32 -...
- Page 47 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 system and move to the next parameter: UNCUT G.
- Page 48 Select the desired values using: : increases the value : decreases the value Example: Programming 012, SMART 3000TW will stop the machine after 12 consecutive errors (detected within the same cycle). The UNCUT G function may be disabled (or re-enabled) pressing and holding for 3 seconds the ENTER button.
- Page 49 Board and move to the next function (DELAY G). If one of the sensors does not reply correctly, on ERROR Dxxx B0n on message appears. In this case, press RESET and refer to chapter 4 “Troubleshooting”. SMART 3000TW - 3.35 -...
- Page 50 If one of the sensors does not reply correctly, on ERROR Dxxx B0n on message appears. In this case, press RESET and refer to chapter 4 “Troubleshooting”. From **P4** press to select a new menu or press to resume the control condition (CONTROL nnnn). - 3.36 - SMART 3000TW...
- Page 51 The TEST menu allows you to perform the following: test of sensors connected to SMART 200 INT-TW 485. test of communication line efficiency between SMART 3000TW, SMART 200 INT-TW 485 Boards and connected sensors. While the system is in control condition, press and hold for 3 seconds When the **P1** label appears, press four times to select the TEST menu.
- Page 52 This function is enabled only if you activated the Priority Bars function on P2 menu, and it allows you to check the communication between SMART 3000TW and (one by one) the LAMPS 485 devices connected to the Boards. In this way you can check that: •...
- Page 53 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...
- Page 54 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).
- Page 55 F_STOP: STOP Frequency This function allows you to program the STOP frequency applied to all sensors connected to SMART 3000TW terminal. The STOP frequency is the minimum yarn image variation frequency below which the sensor indicates the yarn still condition (red LED on).
- Page 56 While the system is in control condition, press and hold for 3 seconds xxxx indicates the overall number of errors due to broken yarn (TOTAL 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.
- Page 57 The SMART system does System halted, ! Power off and on the system. If the not accept keyboard probably due to a problem persists, contact your BTSR inputs. sudden over-voltage reseller. load. (e.g. Thunder and lightning)
- Page 58 Error with Board 0y. If the fault is not included in this table, please contact your local BTSR reseller, giving a detailed description of the kind of fault and the conditions in which it occurred. In the case where the BTSR Technical Service...
- Page 59 Troubleshooting and Maintenance Initial Board Configuration When the ERROR RAM message appears an SMART 3000TW display, at Power-on (for instance after a software Update), operate as follows: Press RESET n indicates the Number of detected Boards. If n corresponds to the number of Boards actually connected, press ENTER.
- Page 60 This procedure is very useful, in case of defective sensor, as the system can still work, waiting for the sensor replacement. ATTENTION: as soon as possible the faulty sensor must be replaced by an authorized Technician. - 4.4 - SMART 3000TW...
- Page 61 During the learning cycle, pay attention not to touch the yarns and not to stop the machine. 3. At the end of the learning cycle the SMART 3000TW must automatically start the control phase (CONTROL nnnn displayed), nnnn indicates the number of sensors detected with yarn running.
- Page 62 Troubleshooting and Maintenance Updating the Software Version on SMART Terminals The software updating on BTSR SMART terminals is a relatively easy operation. However it must be carried out following scrupulously the instructions given in this manual and using the indicated tools to avoid damaging the equipment and/or microprocessor contacts.
- Page 63 Leds as well as the display are off. Fig. 1 Disconnect all connectors (IS3.. Connection, Connection Port RS485 e I/O SMART 3000TW Computer) from the Board in question. Remove the Board from its moving (For instance from Box BX5040FSST).
- Page 64 BROKE G UNCUT G SENS G DELAY G F_START F_STOP H_SPEED BARS BOARD 1 BOARD 2 BOARD 3 BOARD 4 BOARD 5 BOARD 6 BOARD 7 BOARD 8 Sensor No. From SECTIONS ROWS PRIORITY COLUMNS BARS - 4.8 - SMART 3000TW...
- Page 65 The following flow-charts show briefly the operating sequences 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;...
- Page 66 Appendix A – Quick Reference Symbols Key - A.2 - SMART 3000TW...
- Page 67 Appendix A – Quick Reference Symbols Key SMART 3000TW - A.3 -...
- Page 68 Appendix A – Quick Reference Symbols Key - A.4 - SMART 3000TW...
- Page 69 Appendix A – Quick Reference Symbols Key SMART 3000TW - A.5 -...
- Page 70 Appendix A – Quick Reference Page intentionally left blank - A.6 - SMART 3000TW...
- Page 71 DISTRIBUTOR 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...