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btsr IS3 Series Operating Manual

Yarn control system
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Yarn Control System
Operating Manual
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  • Page 1 %(67#7(&+12/2*,(6#678'<#)#5(6($5&+# Yarn Control System Operating Manual (1*/,6+#...
  • Page 3 SMART 64 H / 200 K & IS3.. YARN CONTROL SYSTEM Operating Manual ENGLISH...
  • Page 4 BTSR reserves the right to change in any time the contents of this manual, without notice. For any technical or commercial problem, please contact your local BTSR dealer or call directly BTSR customer service centre.

  • Page 5: Table Of Contents

    Chapter 1 - OVERVIEW System Components ..............................1.1 System’s Operating Principles ..........................1.1 Special Features of SMART 64 H / 200 K System....................1.1 General Features of SMART BTSR systems ......................1.2 Chapter 2 – TECHNICAL DATA AND INSTALLATION Technical Features ..............................2.1 Installation ..................................2.1 Electrical connections ............................2.1...
  • Page 6 Table of contents P2 Programming Level ............................3.18 BROKE G: Error Tolerance for Broken Yarn (global)..................3.18 UNCUT G: Error Tolerance for Uncut Yarn (global) ..................3.19 P3 Programming Level ............................3.20 BK D0nn: Error Tolerance for Broken Yarn (on D0nn sensor) ..............3.20 UC D0nn: Error Tolerance for Uncut Yarn (on D0nn sensor) ................3.21 P4 Programming Level ............................3.22 SENS G: Sensitivity (global)..........................3.22 DELAY G: Reaction Time (global)........................3.23...
  • Page 7 ,1752'8&7,21 ,1752'8&7,21 ,1752'8&7,21# # # # Congratulations for choosing a BTSR product. With our SMART 64 H / 200 K yarn control system, you get an innovative, unique solution, able to offer you multiple advantages concerning quality control of your production.
  • Page 8 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 9 Overview 4# 4# 4# 4#0 0 0 0 #29(59,(: #29(59,(: #29(59,(: #29(59,(:# # # # 6\VWHP#&RPSRQHQWV# The SMART 64 H / 200 K system includes a control/programming terminal and a variable number of IS3.. type sensors connected to the terminal using a single multi-port interface cable.
  • Page 10 The system automatically learns the sequence of yarns used by the textile machine. ƒ#IS3.. Sensors (Image Smart Scanning Sensor) (BTSR Patents) The sensors of the IS3.. series are connected to the SMART control terminal by means of a simple multi-connector cable, thus making quite easy the system installation task.

  • Page 11: Chapter 2 - Technical Data And Installation

    Technical Data and installation 5# 5# 5# 5#² ² ² ² #7(&+1,&$/#'$7$#$1'#,167$//$7,21 #7(&+1,&$/#'$7$#$1'#,167$//$7,21 #7(&+1,&$/#'$7$#$1'#,167$//$7,21 #7(&+1,&$/#'$7$#$1'#,167$//$7,21# # # # 7HFKQLFDO#)HDWXUHV# 60$57#97#+#2#533#.#7HUPLQDO# Power supply voltage 15 Vac or 24 Vdc ± 10% Maximum Absorption 100 mA Dimensions 135 x 95 x 40 mm Temperature range 0°...

  • Page 12: Installation

    200K → → → → App. B Technical Data and installation ([DPSOH#RI#*HQHULF#$SSOLFDWLRQ#&RQQHFWLRQ#RQ#6PDOO#&LUFXODU#.QLWWLQJ#0DFKLQHV# Concerning all electrical systems, it is a suggested rule to ensure that the ground cable (GND) is connected to the sensor support. - 2.2 - SMART 64 H / 200 K...
  • Page 13 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.
  • Page 14 200K → → → → App. B Technical Data and installation 50ZD\#&DEOH#IURP#RQH#0DOH#WR#7ZR#)HPDOH# MA2FE 70ZD\#&DEOH#IURP#RQH#0DOH#WR#)RXU#)HPDOH# MA4FE 7UDQVIRUPHUV#IRU##60$57#97#+# TRF1524/100VA Output 15/24 Vac 100VA (can be used with up to 32 sensors) Output 24 Vac/300VA (can be used with more than 32 sensors) TRF24/300VA (PSU10A) 6WDELOLVHG#3RZHU#6XSSO\#ZLWK#57#9GF#RXWSXW/#43$#3HDN/#9$#...

  • Page 15: Chapter 3 - Operating

    #23(5$7,1*# # # # 60$57#97#+#2#533#.#7HUPLQDO#)HDWXUHV# As in all SMART BTSR systems, the operation of SMART 64 H / 200 K system is controlled by just 5 membrane buttons and it is monitored by a LCD graphic display, which guides the operator through all programming and administration phases of the system, by means of straight-forward messages which can be understood clearly and immediately.
  • Page 16 Operating 1(;7#&<#EXWWRQ# During the parameters setting phase, within a programming menu, it allows you to increase the numeric value of current filed. If it is kept continuously pressed, the numeric field increases more quickly. When the system is in control condition (CONTROL nnnnn displayed and red Led on, inside the CONTROL button), pressing the NEXT CY button activates the NEXT CYCLE function: - The system is disabled for a complete control cycle...
  • Page 17 Operating 2SHUDWRU·V#PHVVDJH#$UHD=# The menu choices, or settings for the selected function during programming or SMART setup phase of the system as well as service messages are displayed here with large 64 H size fonts (1,5 x 0,8 cm), easy to read even from a distance, when the system is running normally.
  • Page 18 Operating 7\SHV#RI#,6611#VHQVRUV# The IS3.. Sensors are available in different typology to satisfy the specific requirements of each installation/application. The following diagram shows in detail the codes for the various models of sensors depending on possible variations. Example: IS3NHS means: New generation high sensitivity narrow sensor. )XQFWLRQ#RI#WKH#,6611#6HQVRUV# The IS3..
  • Page 19 Operating ,QVWDOODWLRQ#RI#WKH#,6611#6HQVRUV# The installation of IS3.. Sensors is an extremely simple operation as there is only one multi-connector cable, which allows the chained interconnection of all sensors, and their connection to the control terminal SMART 64 H / 200 K or to the power supply PSU 10A.
  • Page 20 Operating 6HWWLQJV#WKDW#DIIHFW#WKH#VHQVRU#GHWHFWLRQ#IHDWXUHV# The IS3.. series sensors are not simply detecting the presence of the yarn, but they are working as true micro-computers. They provide a digital signal output, which reflects the condition of the yarn within the detection area: ƒ# Normal yarn running condition ƒ# Yarn stopped or broken condition...
  • Page 21 Operating 3URJUDPPLQJ#H[DPSOHV#IRU#)B67$572)B6723#DQG#UHOHYDQW#VHQVRU#GHOD\V# As the diagram shows, if the F_START and F_STOP value is set low (e.g. = 2), 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 of the diagram).
  • Page 22 200K → → → → App. B Operating 3UHOLPLQDU\#RSHUDWLRQV#IRU#XVLQJ#WKH#60$57#97#+#WHUPLQDO# ò Just after installation and before beginning to use the system, check that all the connectors are plugged in properly. 6\VWHP## Power on the system and check that the graphic display shows sequentially, for a VWDUW#XS# few seconds, the two screens shown on the left side of this page: (Installed software version)
  • Page 23 Operating 2SHUDWLQJ#6HTXHQFHV# The SMART 64 H / 200 K system allows the following set of functions to be carried out: á Programming the parameters that affect the system operation, through 6 interactive menus: P1 ÷ P5 e PX. Activating a LEARN cycle, during which the sequence of yarns used by knitting machine to produce the sample product, will be stored.
  • Page 24 Operating $FWLYDWLQJ#WKH#/HDUQLQJ#&\FOH# +/($51, # - 3.10 - SMART 64 H / 200 K...
  • Page 25 200K → → → → App. B Operating 'LVSOD\#0HVVDJHV#GXULQJ#WKH#&RQWURO#3KDVH# ò To restore the normal operating conditions, press RESET and refer to Chapter 4 “Troubleshooting and Maintenance”. SMART 64 H / 200 K - 3.11 -...
  • Page 26 Operating 6XPPDU\#'LDJUDP#RI#60$57#97#+#2#533#.#3URJUDPPLQJ2&RQILJXUDWLRQ#0HQX# - 3.12 - SMART 64 H / 200 K...

  • Page 27: Sync: Proxy / Encoder Pulse Divisor

    Operating 34#3URJUDPPLQJ#/HYHO# &21752/# Î Î Î Î # --34--# The P1 level allows you to program the following functions: • Characteristics of proxy/encoder signal (PRX) • Characteristics of machine zero signal (ZPX) • Tolerance on phase errors • Numbering of connected IS3.. devices •...

  • Page 28: Zero: Machine Zero Signal Divisor

    200K → → → → App. B Operating ZERO: Machine Zero Signal Divisor The ZERO parameter indicates the divisor of machine zero pulses (ZPX). Allowed values [001 ÷ 099]; Default [001] : increases 0nn : decreases 0nn : Alternatively selects the logical level of machine zero signal: either Negative (N) or Positive (P).

  • Page 29: Devices: Is3.. Devices Connected To The System

    Operating DEVICES: IS3.. Devices Connected to the System The DEVICES parameter indicate the number of IS3.. devices currently connected and configured. During the first installation you will have to set the number of IS3.. sensors and proceed with the automatic numbering of such sensors. Subsequently, you will use this function when it will be necessary to remove, add or replace individual sensors.

  • Page 30: Replacing A Sensor

    Operating When the display shows the DEVICES nnn screen, press to start the single sensor numbering. Update (if necessary) the 0nn number, for instance: - If you replace a sensor, the 0nn number does not change - If you add a sensor, the 0nn must be increased by 1. Press to continue.

  • Page 31: Key_Cod: Password To Access The Programming Menus

    WARNING: If you set a password it will be necessary to enter it each time you access P1 ÷ P5 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 32: P2 Programming Level

    Operating 35#3URJUDPPLQJ#/HYHO# &21752/# Î Î Î Î # --35--# The P2 level allows you to program the following functions: • Tolerance of allowed errors for broken yarn (global to all sensors) • Tolerance of allowed errors for uncut yarn (global to all sensors) While the system is in control condition, press and hold for 3 seconds When the **P1** label appears, press to select the P2 programming level.

  • Page 33: Uncut G: Error Tolerance For Uncut Yarn (Global)

    Operating UNCUT G: Error Tolerance for Uncut Yarn (global) With the UNCUT G function it is possible to assign a global tolerance value (i.e. identical to all connected sensors) for uncut yarn. Lxx = minimum allowed value for uncut yarn Hyy = maximum allowed value for uncut yarn The SMART 64 H / 200 K will automatically calculate the most suitable tolerance (ranging between the minimum and maximum value) for each connected sensor.

  • Page 34: P3 Programming Level

    Operating 36#3URJUDPPLQJ#/HYHO# &21752/# Î Î Î Î # --36--# The P3 level allows you to program the following functions: • Tolerance of allowed errors for broken yarn (on a single sensor) • Tolerance of allowed errors for uncut yarn (on a single sensor) While the system is in control condition, press and hold for 3 seconds When the **P1** label appears, press twice to select the P3 programming...

  • Page 35: Uc D0Nn: Error Tolerance For Uncut Yarn (On D0Nn Sensor)

    Operating UC D0nn: Error Tolerance for Uncut Yarn (on D0nn sensor) With the UC D0nn function it is possible to assign an individual tolerance value (i.e. customized on each individual sensor) for uncut yarn. Lxx = minimum value for uncut yarn Hyy = maximum value for uncut yarn D0nn = sensor nn.

  • Page 36: P4 Programming Level

    Operating 37#3URJUDPPLQJ#/HYHO# &21752/# Î Î Î Î # --37--# The P4 level allows you to program the following functions: • sensitivity (global to all sensors) • reaction time (global to all sensors). While the system is in control condition, press and hold for 3 seconds When the **P1** label appears, press three times to select the P4 programming level.

  • Page 37: Delay G: Reaction Time (Global)

    Operating DELAY G: Reaction Time (global) The DELAY G function allows you to adapt the sensors to the characteristics of yarn being processed (for instance the elasticity) by properly defining the sensor reaction time prior to signal a failure. The following 8 predefined values (tttt) can be programmed.

  • Page 38: P5 Programming Level

    Operating 38#3URJUDPPLQJ#/HYHO# &21752/# Î Î Î Î # --38--# The P5 level allows you to program the following functions: • sensitivity (for a single sensor) • reaction time (for a single sensor). While the system is in control condition, press and hold for 3 seconds When the **P1** label appears, press four times to select the P5 programming level.

  • Page 39: D0Nn: Reaction Time (On D0Nn Sensor)

    Operating DE D0nn: Reaction Time (on D0nn sensor) The DE D0nn function allows you to adapt the sensors to the characteristics of yarn being processed (for instance the elasticity) by properly defining the sensor reaction time prior to signal a failure. The following 8 predefined values (tttt) can be programmed.

  • Page 40: Test_Se: Sensors Test

    Operating 7(67#)XQFWLRQV# &21752/# Î# --7(67--# The TEST menu allows you to perform the following: • test of sensors connected to SMART 64 H / 200 K terminal • test of communication line efficiency between SMART 64 H / 200 K and connected sensors.

  • Page 41: Test_Co: Testing The Efficiency Rate Over The Communications Line Between The Smart 64 H / 200 K Terminal And Sensors

    Operating Press to select the next sensor and check that the Red LED of the selected sensor is flashing. Repeat this test on all connected sensors. Press to move to the next function (TEST_CO). TEST_CO: Testing the Efficiency Rate over the Communications Line between the SMART 64 H / 200 K terminal and Sensors This function allows to check the perfect operation of the communications line...

  • Page 42: F_Start: Start Frequency

    Operating 3;#3URJUDPPLQJ#/HYHO# &21752/# Î Î Î Î # --3;--# The PX level allows you to program the following functions: • START frequency (global to all sensors) • STOP frequency (global to all sensors) • Machine stop speed • Auto-correction self learning While the system is in control condition, press and hold for 3 seconds When the display shows **P1**, press again and hold for 3 seconds This screen indicates that the PX programming level has been activated.

  • Page 43: F_Stop: Stop Frequency

    Operating F_STOP: STOP Frequency This function allows you to program the STOP frequency applied to all sensors connected to SMART 64 H / 200 K terminal. The STOP frequency is the minimum yarn image variation frequency below which the sensor indicates the yarn still condition (red LED on). For more details please refers to “Settings that affect the sensor detection features”...

  • Page 44: Auto_C: Auto-Correction

    Operating AUTO_C: Auto-Correction The AUTO_C function (if enabled) allows you to neglect some types of errors that would cause useless machine stops, due to the fact that, during the learning cycle the yarn moved in wrong way. For instance, if the AUTO_C function is enabled (ON) and for 3 consecutive cycles, within a range of 6 cycles, a sensor detects either a BROKE or an UNCUT failure with respect to the learning cycle, then SMART 64 H / 200 K will not consider those 3 production cycles as wrong, but rather it will assume that the...

  • Page 45: Target Settings, With Machine Stationary

    Operating 6HWWLQJ#WKH#3URGXFWLRQ#7$5*(7# &21752/# Î Î Î Î # --7$5*(7--# The TARGET function allows you to set the number of stockings/body blanks to be produced within a given working session. This setting must be performed when the machine is stationary. The set value is loaded into a SMART 64 H / 200 K register. During the production phase, the control of stockings/body blanks produced is carried out using 2 counters.

  • Page 46: Target And Count/Reject Counters Reading, With Machine Running

    Operating This screen indicates the current value of "Good Stockings/Body Blanks” counter (COUNT). When setting a new TARGET, you will have the possibility to clear this counter pressing simultaneously This screen indicates the current value of "Rejected Stockings/Body Blanks” counter (REJECT). When setting a new TARGET, you will have the possibility to clear this counter pressing simultaneously Press...
  • Page 47 Operating 5HDGLQJ25HVHWWLQJ#WKH#%52.(#DQG#81&87#&RXQWHUV# &21752/# Î Î Î Î # 7%.278&#&2817# This function allows you to display the error counters for broken yarn and uncut yarn: Overall errors detected by all connected sensors Errors detected by each individual sensor Prior to leave the function you will have the possibility to reset the counters. 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 64 H / 200 K terminal.
  • Page 48 Operating Page intentionally left blank - 3.34 - SMART 64 H / 200 K...

  • Page 49: Chapter 4 - Troubleshooting And Maintenance

    Reload the parameters and custom settings in P1 ÷ P2 and PX menus. If the problem persists, contact your BTSR reseller. ™# The replacement of the system’s lithium battery may be required. ™# Power off and on the system. If the...

  • Page 50: Troubleshooting

    ò 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 51 Troubleshooting and Maintenance 7HPSRUDU\#6HQVRU#'LVDEOLQJ# When the system stops the machine due to a faulty sensor (Error Dxx) and the faulty sensor signalling persists after you have turned off and on again the system, if you cannot immediately replace the sensor, you may temporarily disable it to avoid continuous machine stops.
  • Page 52 5HSDLUV# Any repair intervention on the SMART 64 H / 200 K terminal must be executed by specialised personnel from BTSR. Any intervention attempt by non authorised personnel, voids the warranty terms. - 4.4 -...
  • Page 53 12. Power on the system and check that: All the Leds embedded inside the buttons are on. Fig. 3 The display shows “ BTSR Ver. n.n ” (n.n = version of the new installed software). ò If the ERROR RAM message appears, press RESET and reload the parameters, noted at the beginning.
  • Page 54 200K → → → → App. B Troubleshooting and Maintenance 3DUDPHWHUV#6XPPDU\#7DEOH# To facilitate and to speed up the operation of restoring the configuration values, it is suggested to take note of the defined settings. The following table is intended to help you in this task (make copy of the form for future use).

  • Page 55: Appendix A - Quick Reference

    Appendix A – Quick Reference 48,&.#5()(5(1&( 48,&.#5()(5(1&(# # # # 48,&.#5()(5(1&( 48,&.#5()(5(1&( The following flow-charts show briefly the operating sequences which are required to complete all the functions available on the SMART 64 H / 200 K. 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 56 200K → → → → App. B Appendix A – Quick Reference 6\PEROV#NH\# - A.2 - SMART 64 H / 200 K...
  • Page 57 Appendix A – Quick Reference 6\PEROV#NH\# SMART 64 H / 200 K - A.3 -...
  • Page 58 Appendix A – Quick Reference 6\PEROV#NH\# - A.4 - SMART 64 H / 200 K...
  • Page 59 Appendix A – Quick Reference 6\PEROV#NH\# SMART 64 H / 200 K - A.5 -...
  • Page 60 Appendix A – Quick Reference 6\PEROV#NH\# - A.6 - SMART 64 H / 200 K...

  • Page 61: Appendix B - Differences Between Smart 64 H And Smart 200 K

    Appendix B – Differences between SMART 64 H and SMART 200 K ',))(5(1&(6#%(7:((1#60$57#97#+#$1'#60$57#533#. ',))(5(1&(6#%(7:((1#60$57#97#+#$1'#60$57#533#. ',))(5(1&(6#%(7:((1#60$57#97#+#$1'#60$57#533#. ',))(5(1&(6#%(7:((1#60$57#97#+#$1'#60$57#533#.# # # # ([DPSOH#RI#*HQHULF#$SSOLFDWLRQ#&RQQHFWLRQ#RQ#/DUJH#&LUFXODU#.QLWWLQJ#0DFKLQHV# Concerning all electrical systems, it is a suggested rule to ensure that the ground cable (GND) is connected to the sensor support. SMART 64 H / 200 K - B.1 -...
  • Page 62 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.
  • Page 63 Appendix B – Differences between SMART 64 H and SMART 200 K 50ZD\#&DEOH#IURP#RQH#0DOH#WR#7ZR#)HPDOH# MA2FE MA2FE3 Separate ground output 70ZD\#&DEOH#IURP#RQH#0DOH#WR#)RXU#)HPDOH# MA4FE 7UDQVIRUPHUV#IRU##60$57#533#.# TRF1524/100VA Output 15/24 Vac 100VA (can be used with up to 32 sensors) TRF24/300VA Output 24 Vac/300VA (can be used with more than 32 sensors) (PSU10A) 6WDELOLVHG#3RZHU#6XSSO\#ZLWK#57#9GF#RXWSXW/#43$#3HDN/#9$# FRQWLQXRXV#...
  • Page 64 Appendix B – Differences between SMART 64 H and SMART 200 K 3UHOLPLQDU\#RSHUDWLRQV#IRU#XVLQJ#WKH#60$57#533#.#WHUPLQDO# ò Just after installation and before beginning to use the system, check that all the connectors are plugged in properly. 6\VWHP## Power on the system and check that the graphic display shows sequentially, for a VWDUW#XS# few seconds, the two screens shown on the left side of this page: (Installed software version)
  • Page 65 Appendix B – Differences between SMART 64 H and SMART 200 K 'LVSOD\#0HVVDJHV#GXULQJ#WKH#&RQWURO#3KDVH# ò To restore the normal operating conditions, press RESET and refer to Chapter 4 “Troubleshooting and Maintenance”. SMART 64 H / 200 K - B.5 -...
  • Page 66 Appendix B – Differences between SMART 64 H and SMART 200 K ZERO: Machine Zero Signal Divisor The ZERO parameter indicates the divisor of machine zero pulses (ZPX). Allowed values [001 ÷ 099]; Default [001] : increases 0nn : decreases 0nn : Alternatively selects the logical level of machine zero signal: either Negative (N) or Positive (P).
  • Page 67 Appendix B – Differences between SMART 64 H and SMART 200 K If you select ZERO R, when the zero signal is active SMART 200 K always controls the same PRX and the display shows “CONTROL 0001”. As the system controls, but does not increase the number of synchronism pulses (PRX), it is fundamental that, when the ZERO signal is active, the yarn running sequence remains unchanged.
  • Page 68 Appendix B – Differences between SMART 64 H and SMART 200 K 3DUDPHWHUV#6XPPDU\#7DEOH# To facilitate and to speed up the operation of restoring the configuration values, it is suggested to take note of the defined settings. The following table is intended to help you in this task (make copy of the form for future use).
  • Page 69 Appendix B – Differences between SMART 64 H and SMART 200 K SMART 64 H / 200 K - B.9 -...
  • Page 70 Appendix B – Differences between SMART 64 H and SMART 200 K Page intentionally left blank - B.10 - SMART 64 H / 200 K...
  • 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 – 09/99...

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