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Vandewiele PROTECHNA ARRAYCAM 5420 Service Manual

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Art. Nr. 14192
S-E-0717/10.18/E
Service Manual
ARRAYCAM
5420
for Tricot Machines
Software-Version 2.0.52 - revision October 2018
PROTECHNA Herbst GmbH & Co KG
Lilienthalstr. 9
85579 Neubiberg
Germany
Telefon +49 (0)89 608 114-0
Fax
+49 (0)89 608 114-48
E-Mailinfo@protechna.de
Internet www.protechna.de

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  • Page 1 Art. Nr. 14192 S-E-0717/10.18/E Service Manual ARRAYCAM 5420 for Tricot Machines Software-Version 2.0.52 - revision October 2018 PROTECHNA Herbst GmbH & Co KG Lilienthalstr. 9 85579 Neubiberg Germany Telefon +49 (0)89 608 114-0 +49 (0)89 608 114-48 E-Mailinfo@protechna.de Internet www.protechna.de...
  • Page 3 Copyright This handbook is protected by copyright. All rights are reserved. On no account may this document, nor any part of it, be copied, reproduced, minimised or translated with mechanical or electronic aids, without written permission from PROTECHNA Herbst GmbH & Co KG. The information contained in this handbook has been carefully checked and found to be correct.

  • Page 4: Table Of Contents

    Contents General Safety instructions ....................6 Protechna-Service ....................8 System description Control unit ......................9 Lighting Power Supply ..................14 Camera system ....................15 Laser light barriers ....................18 Lighting ....................... 19 Service menu Passwords ......................20 Date and Time ..................... 21 Logging of messages, warnings and errors ............
  • Page 5 Recovery procedures ..................45 5.3.1 Recovery procedure 1 - Internal flash damaged ..........45 5.3.2 Recovery procedure 2 ..................48 Saving the service file ..................51 Restoring the factory settings ................51 Connecting to the Linux file system via WinSCP ..........52 5.6.1 Download and Install WinSCP ................

  • Page 6: General

    General Safety instructions  Always obey all warnings and instructions that are displayed or indicated on the unit itself, or are mentioned in this manual.  This unit is sensitive to electrostatic discharges, which can damage its internal parts and impair their normal operation.
  • Page 7 Use for the intended purpose in the sense of point 1.1.2.c EC Machinery Directive Point 1 The ArrayCam 5420 system is intended for monitoring fabric on textile warp knitting machines and may be mounted and operated only on such machines. The EMC requirements to DIN/EN 50082-2 and DIN/EN 50081 part 2 for industrial equipment are satisfied.

  • Page 8: Protechna-Service

    Protechna Service Installation service We strongly recommend that at least the initial installation of the PROTECHNA units is performed by our service technicians. The customer will thereby receive professional installation and setting up of the system, together with instruction in the correct use of it. This installation service is available at minimal costs and is normally available in all areas.

  • Page 9: System Description

    System description Control unit The control unit 5420 (below) has a total of 16 keys:  2 x 4 keys each, arranged vertically  6 keys arranged horizontally  1 back key  1 confirmation key The mains switch is located on the back of the control unit. The mains switch for the lighting power supply unit (above) is located on the back of the unit.
  • Page 10 Backside view Power supply for the lighting power supply unit Lighting Power supply for the ArrayCam traverse Warning lamp Impulse signal Ethernet for Earth the ArrayCam USB for firmware updates Power supply to the control unit (from the machine)
  • Page 11 MAINS IN Pin assignment of the 7-pin Power supply (male) plug Mains connection (100V-240V AC 50-60Hz) View of the pin side (to the unit) Pin-No. Meaning AC-IN (phase) (brown) AC-IN (neutral) (blue) HV-Reset (white) Stop contact (black) Stop contact (black) HV-Reset (white) Earth (green/yellow) MAINS OUT...
  • Page 12 PULSE Pin assignment of the 4-pin Machine impulse signal connection (female) socket View of the socket side The SYN+ voltage output is protected by a Polyswitch fuse rated 1.1 A . Pin-No. Meaning SYN1 (pulse input bipolar) +24V (1.1 A) SYN+ SYN2 (pulse input bipolar) 24V DC Pin assignment of the M12 4-...
  • Page 13 Optional: Connection of the laser light barriers Shown is one channel consisting of transmitter (T) and receiver (R). Pin assignment of the RJ45 socket8-pin View of the socket side when looking at the back of the control unit. Function R (eceiver) Receiver + Receiver - Function...

  • Page 14: Lighting Power Supply

    Lighting power supply 24 V power supply for the camera Pin assignment of the M16 lighting 6-pin (female) socket View of the socket side Function Remark +24 V power supply +24 V +24 V power supply +24 V power supply 0V power supply 0V The plug on the gray cable is connected to the "Mains out"...

  • Page 15: Camera System

    Camera system All cables for the electrical connections must be shielded in every case. For the 24 V power supply cable and for the Sercos interface ETH the screen must be connected to the casing of the M12 connector on the camera side. However, for the two EtherCAT connections EC IN and EC OUT the screen must not be connected at the camera side.
  • Page 16 Display elements of the camera traverse LED 24V DC 24V power supply not present green 24V power supply present LED ETH no Ethernet connection green Ethernet Link yellow Ethernet Activity LED EC LA without significance LED EC RN without significance LED ST Normal operation of the camera system.
  • Page 17 Service area of the camera traverse The service area (1) is located on the side of the master modules with the cable connections, un- der the service cover (2). A Windows PC can be connected to the service-LAN-port (3) via a LAN-cable (CAT6e).

  • Page 18: Laser Light Barriers

    laser light barriers Transmitter Pin assignment of the socket M16 3-pin female A-coded View of the socket side Pin-Nr. Meaning Transmitter + Ground Transmitter - Receiver Pin assignment of the plug M16 3-pin male A-coded View of the pin plug side Pin-Nr.

  • Page 19: Lighting

    Lighting First lighting module 24 V DC Pin assignment of the pin 24 V power supply for the camera plug M16 6-pin lighting A-coded View of the pin side Function Remark +24 V power supply +24 V +24 V power supply +24 V power supply 0V power supply 0V...

  • Page 20: Service Menu

    Service menu Passwords Select the "Service" menu in the menu bar of the main screen. If you are not registered yet, enter the service password. You are then on page 1 of 3 of the service menu, in the submenu "User " Hint: The path to reach each submenu is always displayed in row 2 of corresponding submenu.

  • Page 21: Date And Time

    Date and Time Select the menu "Service" in the menu bar of the main screen. Select the submenu "Date time" then. Date (dd mm yy): In the 3 number fields the actual date (day, month, year) can be entered. Time (hh mm ss): In the 3 number fields the actual time (hours, minutes, seconds) can be en tered.

  • Page 22: Logging Of Messages, Warnings And Errors

    Logging of messages, warnings and errors Select the menu "Service" in the menu bar of the main screen. Select one of the „Logging“ subme- nus „All“ or „Err/warn“ or „Errors“. The keys have the following functions Arrow left: scroll back by date Arrow right: scroll forward by date Wast paper bin: delete the current entry (highlighted)

  • Page 23: System Check Of The Camera System

    System check of the Camera system Select the "Service" menu in the menu bar of the main screen. Press the "Next" button and you get to page 2 of the service menu. Then select the submenu "Diagnostics ext.". Technical information about the system status of the connected camera system can be called up here (read only): Frame Rate: Image refresh rate of the cameras...
  • Page 24 24V_CAM1 / V Voltage of camera bus 1 24V_CAM0 / V Voltage of camera bus 0 24V_PS / V Voltage at the motherboard 24V / V Voltage at the input to the power supply unit The normal values for the various voltages should be approx. 24 Volt. I_CAM / mA Power consumption of all the connected cameras should be approx.

  • Page 25: Machine Settings

    Machine settings Select the "Service" menu in the menu bar of the main screen. Press the "Next" button and you get to page 3 of the service menu. Then select the submenu "Machine.". Machine no.: Machine number (do not change this parameter) The following parameters can be set: Auto.

  • Page 26: Network Configuration

    Network configuration Select the "Service" menu in the menu bar of the main screen. Press the "Next" button and you get to page 2 of the service menu. Then select the submenu "Network.". Here the current network settings are displayed (read only). IP-address: Network address Subnet-mask:...

  • Page 27: Advanced Camerasettings

    Advanced camerasettings Select the "Service" menu in the menu bar of the main screen. Press the "Next" button twice and you get to page 3 of the service menu. Then select the submenu "Camera.". Gauge (needles/inch): Gauge of the machine (number of needles per inch) Exposure time (ms): Exposure time in ms Auto Exposure:...

  • Page 28: Advanced Laser Light Barrier Settings

    Envelope mode The left column displays the setting of camera surveillance module 1. The right column displays the setting of camera surveillance module 2. Sets the method used to generate the envelope. The following settings are available: Factor The envelope curve is determined by the transmitted signal multiplied by a factor Offset The envelope curve is determined by the transmitted signal plus an added offset Threshold...

  • Page 29: Check Laser Light Barrier Function

    Check the laser light barrier function Laser (transmitter) not lighting up  Supply cable to the transmitter not plugged in  Supply cable to the transmitter plugged in incorrectly  Channel not activated  Laser defective Reception level deviation more than -10% (when newly installed) ...

  • Page 30: Check The Lighting Function

    No thread signal  Channel not activated  Supply cable to the transmitter and/or receiver not plugged in  Supply cable to the transmitter and/or receiver plugged in incorrectly  Laser defective  Receiver defective Level error display channel x ...

  • Page 31: Service

    Service All service work may only be carried out by a trained electrician. Control unit 5.1.1 Replacing the backup battery The backup battery is located in the casing of the control unit and supplies the real-time clock of the system. If it is necessary to replace this battery, please use exclusively the battery type CR 2032 (Lithium button cell 3 V;...

  • Page 32: Performing A Firmware Update On The Control Unit

    Installing the backup battery Insert the new backup-battery slightly tilted into the holder and press it down until it snaps. Check that the polarity is correct. The positive pole of the battery (with the labelling) must face upwards. The negative pole faces towards the circuit board Closing the housing The contact blades for the Finally please carefully place the upper housing...
  • Page 33 Start the update process To start the update process for the control unit, proceed like below: 1. Power off the control unit. 2. Plug in the USB stick at the back of the control unit. The USB stick must be formatted with FAT32. 3.
  • Page 34 7. After confirm the actual update process begins. Never switch off the control unit until the update process has been completed! The camera system could become inoperable and would have to be replaced! 8. The control unit will write the internal flash memory first and will finish with a verify. 9.

  • Page 35: Camera Traverse

    Camera traverse 5.2.1 Replacing the backup battery The backup battery is located under the service cover of the camera traverse and supplies the real- time clock of the system. Please use exclusively the battery type CR 2032 (Lithium button cell 3 V; nominal diameter 20 mm;...

  • Page 36: Updating The Software Of The Camera Systems

    5.2.2 Updating the software of the camera traverse The software update for the ArrayCam is a two-step procedure. In the first step the update file is copied to the camera (via the control unit), in a second step the camera system is updating its internal software by its own.
  • Page 37 4. The control unit will read the update file from the USB stick and send it to the camera. 5. After the upload is finished, the camera will start the update process and is rebooting. After some seconds the connection to the control unit will be interrupted. Automatic update procedure After the update file has been copied to the camera, the system will reboot automatically.
  • Page 38 The status LED’s at the connection panel of the ArrayCam master module showing the status / progress of the update procedure. The whole procedure is running through the following stages described below… LED Status: “ST” is orange The Linux system is running and is starting the update process of the SD card.
  • Page 39 LED Status: “ST” is blinking green The hardware of the system is rebooting / the Linux system is starting up. LED Status: “ST” is orange The Linux system is running and is starting the camera software. LED Status: “ST” is orange “L2”...

  • Page 40: Performing A Software Update Of The Camera Traverse By Ftp

    5.2.2.2 Performing a software update of the camera traverse by FTP Copy the update file to the camera In case the update procedure via the control unit is not working, it is possible to manually transfer the update file to the camera and to trigger the update by restarting the camera. Please follow the procedure below: For this you need a Windows PC on which the camera update files are stored and the FTP client program "WinSCP"...
  • Page 41 4. Answer the question with “ja". 5. The left part of the window shows the local computer, the right part shows the directories of the camera system. In the right part, navigate to the directory "/mnt/service" of the camera. In the left part navigate to the local directory that contains the update package and highlight the package that is to be installed.
  • Page 42 8. After the upload is finished please synchronize the file system of the camera to make sure the file is completely written to the flash memory of the camera. 9. You can now close WinSCP and restart the camera. The update procedure will now run in the same way as described in the chapter before (Automatic update procedure).

  • Page 43: Updating The Software Of The Camera Systems Via Sd Card

    5.2.2.3 Updating the software of the camera systems via SD card For a software update via the SD card you will require a SD card with the update package prepared by Protechna. The SD card of the camera system is accessible via the service cover on the camera traverse.

  • Page 44: Trouble Shooting The Update Process

    5.2.3 Trouble shooting the update process If the update process fails – the status LEDs “L2” / “L3” / “L4” are not green after at least 10 minutes of waiting - there are three different possibilities how to handle this. 5.2.3.1 The update of the internal flash failed The following LED status displays a failure during...

  • Page 45: Recovery Procedures

    Recovery procedures 5.3.1 Recovery procedure 1 – Internal flash damaged The internal flash is the primary boot device of the camera system and is normally used to start up the Linux system and to run the camera software. If the internal flash is damaged the Linux system cannot properly start up anymore which prevents the camera software from running.
  • Page 46 After about 10 seconds, the camera software is running and the system will be back online. Now copy the update file to the camera as de- scribed for the normal update procedure and re- boot. (see chapter 5.2.2) LED Status: “ST” is blinking green The hardware of the system is rebooting / the Linux system is starting up.
  • Page 47 LED Status: “ST” is orange The Linux system is running and is starting the camera software. After about 10-20 seconds, the system will be back online. Close the cover of the service port appropriately with the three screws. If anything goes wrong and not as described as above, it is very likely that the internal flash cannot be recovered.

  • Page 48: Recovery Procedure 2

    5.3.2 Recovery procedure 2 This procedure is necessary if the internal flash cannot be recovered or if there is any additional damage to the SD card. In this case, it is necessary to recover the system by using a so-called recovery SD card.
  • Page 49 LED Status: “ST” is blinking green The hardware of the system is rebooting / the Linux system is starting up from the SD card. LED Status: “ST” is orange The Linux system is running and is starting the recovery process for the internal flash. LED Status: “ST”...
  • Page 50 After about 10-20 seconds, the system will be back online at the online. Close the cover of the service port appropriately with the three screws. If this recovery process is also not working, the system might be damaged more severely. Contact your responsible service partner for further assistance.

  • Page 51: Saving The Service File

    Saving the service file The description can be found in the Arraycam user manual under chapter 9.3 Restoring the factory settings Restoring the factory settings must be performed only when the machine is stopped. First open the service cover. Keep the SW1 key depressed for 2 seconds. Please do not confuse this with the Reset key SW2.

  • Page 52: Connecting To The Linux File System Via Winscp

    Connecting to the Linux file system via WinSCP The camera is running on Linux system, that is providing access to the internal file system via a SCP connection. By using the WinSCP software it is possible to access that file system. 5.6.1 Download and Install WinSCP Download WinSCP from www.winscp.net...

  • Page 53: Connect The Laptop To The Service Port Of The Camera

    3. In the properties dialog enter the IP address “192.168.3.100” and the subnet mask “255.255.255.0”. 4. Close the dialog. The Ethernet port of the laptop is now running with the IP address 192.168.3.100 and fits the network segment of the camera. 5.6 .3 Connect the laptop to the service port of the camera Open the service cover at the camera and connect the RJ45 cable to the RJ45 jack.

  • Page 54: Connect To The Camera With Winscp

    5.6 .4 Connect to the camera with WinSCP To connect to the file system of the camera you have to start and to setup WinSCP. Please proceed like below: 1. Start WinSCP and enter the connection details and click “Login” to connect: ...

  • Page 55: Navigate In The Directory

    5.6 .5 Navigate in the directory After successfully connecting to the file system of the camera you will see two directory trees. The left part of the window contains the directory tree for your laptop, the right part is the directory tree for the camera.

  • Page 56: Creating New Folders

    5.6 .6 Creating new folders Within each directory tree you can create a new folder by clicking the “New” item from the menu bar. Enter the name of the directory in the upcoming dialog and click “Ok”. 5.6 .7 Download files from the camera You can download files from the camera with the following procedure: ...

  • Page 57: Upload Files To The Camera

    5.6 .8 Upload files to the camera You can upload files to the camera in the same way as downloading files. Go to the right directories and select the files you want to upload in the directory tree of your laptop (left pane). Then click “Upload”...

  • Page 58: Synchronize The File System Of The Camera

    5.6 .10 Synchronize the file system of the camera Especially when uploading large files to the camera it might be necessary to synchronize the file system of the camera, especially if you want to restart the camera after uploading a file (i.e. when you upload an update file).

  • Page 59: Backup The Configuration Of The Camera

    3. After the “Sync” is finished you will see the command added to the result window. You can leave the terminal window and are safe to restart the camera. Backup the configuration of the camera Sometimes it might be necessary to have a backup of the camera configuration. To back up the camera configuration proceed like below: 1.

  • Page 60: Download The Camera Logs

    Download the camera logs Sometimes it will be necessary to retrieve the log files from the camera and download them. To download these files, proceed like below: 1. Open a connection with WinSCP. Open the folder on your laptop where you want to download the files to and open the following directory “/mnt/logging/”...
  • Page 61 3. Select all the log files and download them.

  • Page 62: A Repair Instructions

    Repair instructions Exchanging the mainboard of the camera traverse Before the mainboard is removed you must copy the configuration files "CameraArray.cfg" and "CameraArray.cfg.master" to a PC and copy them back again once the mainboard has been exchanged. Connect a Windows PC via a LAN cable to the service LAN port of the camera traverse and change the connection settings as described in the installation manual in Appendix A.
  • Page 63 Swing open the cover (2) as shown in the photo, taking care not to damage the cables . Disconnect the earth cable (3). Then cut through the cable ties (6) at both of the camera connecting cables (7). Then cover with mainboard can be removed.
  • Page 64 After the mainboard has been installed the files must be reloaded. To do so, please establish a connection again. Select the correct directories and click on “Upload” (Hochladen). You must check the owner of the files that are uploaded (shown on the right-hand side) and change it if necessary.

  • Page 65: A2 Exchanging A Camera Module In The Camera Traverse

    Exchanging a camera module in the camera traverse Removing the camera  First switch off the camera system.  Remove the cover at the relevant position. If it is the camera next to the electronics connections that must be changed, firstly the mainboard must be removed (see chapter B.1). ...
  • Page 66 Installing the camera  Lay the cables in the duct provided (5) and place the foam pad (6) over it.  Install the new camera module at the marked position.  Plug in the previously marked cables at the correct positions. Make sure that the connectors are correctly locked.

  • Page 67: A3 Focussing The Camera

    Focussing the camera The cameras are installed at a distance of 930 mm or 1125 mm between the camera casing and the fabric. If the distance varies significantly from these values (deviation > +/-100 mm) or if the cameras are incorrectly set, then they must be re-focussed. To do this, please remove the cover at the respective camera.

  • Page 68: B Maintenance And Cleaning

    Maintenance and cleaning  Keep the covers of the cameras and the lighting equipment clean.  Avoid putting fingerprints on the covers of the cameras. Use only a dry non-linting cloth to clean the covers of the cameras.  Before cleaning the unit or removing or installing any options, always disconnect the unit from the power supply.
  • Page 69 For your notes...

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