bianco SK3 User manual

Needle path detector
SK3
User’s manual
WARNING! Prototype versions bear no indication of SW version.
This manual applies to program versions 1.2 and higher

SK3 NEEDLE PATH DETECTOR
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FOREWORD ...........................................................................................................................................................................3
SET-UPS AND CONFIGURATIONS...................................................................................................................................4
POSSIBLE CONFIGURATIONS: ................................................................................................... 4
Parts making up the SK3 needle path detectors:.......................................................................... 4
SCHEMATIC VIEW OF PHOTODETECTOR FITTED TO BASKET:............................................................................5
INSTALLATION:.....................................................................................................................................................................6
Upgrading a photodetector:.......................................................................................................... 6
Images illustrating the de-installation procedure:....................................................................... 7
Fitting the completion kit EE5900010226:................................................................................. 9
Images illustrating the completion kit installation procedure:................................................. 10
Installing an SK3 kit:..................................................................................................................... 12
Images illustrating the installation procedure of an SK3 kit:................................................... 13
Calibration and alignment of the projector with the microcamera: ................................. 14
Calibration by means of an oscilloscope:.................................................................................... 14
Calibration by means of VDTEX SW:........................................................................................ 18
UPGRADING THE SOFTWARE................................................................................................... 22
INDICATORS AND CONTROLS:......................................................................................................................................30
USING THE EQUIPMENT: .................................................................................................................................................32
ELECTRONIC CONTROL UNITS .....................................................................................................................................34
Protective fuses.............................................................................................................................. 36
Indicator LED’s............................................................................................................................... 36
Setting switches and jumpers.................................................................................................... 38
Test points....................................................................................................................................... 41
Terminal strips................................................................................................................................ 42
DIAGNOSTICS .....................................................................................................................................................................45
Fault finding table.......................................................................................................................... 45
TECHNICAL DATA..............................................................................................................................................................46
Humidity - operating......................................................................................................................... 46

SK3 NEEDLE PATH DETECTOR
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FOREWORD
Letter from the engineering team:
The design of this new needle path detectors was prompted by the intention of BIANCO
S.p.A. to be present on the market as a benchmark in terms of performance, capability and
service, by enhancing the technological content, and hence the added value of the machines
supplied.
This policy and the trust accorded to our engineering team has kindled the enthusiasm and
dedication we already feel for our job, which now appears more attractive and interesting
than ever. For this reason, we are grateful to the company management and express our
hope to be able to repay their trust with products in keeping with their expectations and, first
and foremost, with customer requirements.
Hw ad hoc:
In the design of the SK3 detector, we started out by considering the objectives to be reached,
without setting for ourselves any time or cost limitations.
Only after defining the characteristics of each individual part, a market survey got underway to
assess actual feasibility.
Since we were unwilling to accept any compromise, the design of the optical and mechanical
parts proved rather complex, and after a number of experiments, it became focused on the
present-day solution, where each individual part is made to measure according to stringent
construction principles.
The electronic components are mostly derived from the automotive and military markets and
are certified to operate in particularly adverse environmental conditions. For the computation
parts, it was decided to combine a microcontroller and a digital signal processor (DSP), both
of them very powerful, so as to be able to reserve the DSP to mathematical computations
also and use the microcontroller and its peripherals for control and service tasks. The visual
sensor is a new generation device, more performing than traditional CCD’s; from the few top-
performing visual sensors available on the market, we selected one already adopted by
medical centres, with superior capabilities in terms of sensitivity and signal/noise ratio.
Sw that “sees and sees to it”:
The software monitors the system’s operation and working conditions on a continuous basis,
warns the operator of any anomaly and at the same, if necessary, takes action to by-pass the
problem.
Upgrade your machine:
The computation algorithms implemented at present should already be able to create an
appreciable gap compared to competing products. At all events, new algorithms will be
implemented in the forthcoming SW versions. To download the upgrades is easy (all you
need is a portable PC), and they can be received by electronic mail or regular mail. Soon a
downloading feature will be activated in the official web site of Bianco (www.bianco-spa.com).
Thank you for choosing Bianco, we hope the performance levels offered by the product will
meet your expectations in every respect.
The design team of the R&D division

SK3 NEEDLE PATH DETECTOR
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SET-UPS AND CONFIGURATIONS
POSSIBLE CONFIGURATIONS:
•Depending on type of installation, the SK3 needle path detector is available in two different
configurations.
•Each configuration can be supplemented by a “completion kit”, selected from a choice of versions
available, that makes it possible to adapt the detector to different assembly layouts.
•Regardless of the configuration selected and the kit applied, it is possible to add a number of
optional devices.
The foregoing is summarised in the table below:
1 Configuration from panel 2 Stand alone
configuration
Completion kit
1 TGL80 upgrade kit -
basket
HH1001004003 HH1001004003
2 TGL80 upgrade kit - air
slit
(Note 1) (Note 1)
3 TGL90 upgrade kit -
basket
HH1001004003 HH1001004003
4 TGL90 upgrade kit -air
slit
(Note 1) (Note 1)
5 Line SK1 assembly kit HH1001004003 HH1001004003
Options
1 Giant Display (Note 1)
2 Vdtex (Note 2)
3 OP16 (Note 1)
Note 1) Not yet available
Note 2) Only for installation and technical service operations
Parts making up the SK3 needle path detectors:
Bianco ordering code Description
1 Configuration from panel
1.1 HH1001004002 Infrared projector for transparency lighting
1.2 HH1001004001 Microcamera with IR projector for reflex lighting
1.3 EE5900010156 Control electronics with board and transformer
2 Stand alone configuration
2.1 HH1001004002 Infrared projector for transparency lighting
2.2 HH1001004001 Microcamera with IR projector for reflex lighting
2.3 EE5900010157 Control electronics with box without transformer
3 HH1001004003 Completion kit
3.1 L2700010031 Projector support
3.2 L2700010007 Cutter support
3.3 A1800C91402 Cam spacer
3.4 A1800C91403 Limit switch rod with cam
3.5 FF4115-2DN IP67 limit switch with washer
3.6 A1800012596 Bracket for microcamera support
3.7 A1800012505 Blade guard

SK3 NEEDLE PATH DETECTOR
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M. Microcamera con
proiettore IR per
illuminazione in
riflessione
C. Stecche
cesto
Schematic view of photodetector fitted to basket:
U. Adjustable U bracket to
support slit assembly
V. Basket
Opening/Closing
handwheel
P
U
S
M
C
T. Connection box for
connections to limit
switches &
microcamera
P. Infrared
projector for
transparency
lighting
S. Microcamera support
C. Basket rods

SK3 NEEDLE PATH DETECTOR
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INSTALLATION:
Completion kits are necessary when you wish to install an SK3 needle patch detector.
Depending on type of installation, it is necessary to choose the most appropriate completion
kit.
The mounting procedures for the SK3 described below use the various kits available.
Upgrading a photodetector:
We provide below the instructions to de-install an earlier version photodetector and then
replace it with an SK3.
Three cases are envisaged:
•Upgrading a TGL80 equipped with basket.
•Upgrading a TGL90 equipped with basket.
•Upgrading a TGLSK3 prototype Rev.
Materials needed:
•Small sized screwdriver for the terminals.
•2.5, 4 and 6 mm sized Allen wrenches
•8 mm long socket wrench
•8 and 13 mm wrenches
De-installation procedure:
1. Disconnect all the cables from the box installed aboard the basket. N.B. all wires are
shown in the wiring diagram of the machine, nevertheless we recommend marking the
cables, terminal strips and number of terminal for each connection, in order to avoid
problems and facilitate the upgrading process.
2. Disconnect the limit switch and remove it by mechanical means.
3. Remove the box fitted to the basket (it is fastened by 4 nuts).
4. Remove the box supporting plate (it is fastened by two bolts).
5. Remove the projector (fastened by a bolt).
6. Remove the photodetector (fastened by two bolts).
7. Remove the mechanical parts supporting the photodetector (fastened by a socket head
screw).
8. Pull out the motor after realising it by means of an ad hoc lever.
9. Remove the bracket supporting the motor and the projector (fastened by 4 bolts).
10.Remove the U bracket connecting the motor support to the basket truck (fastened by 4
bolts, 2 per part).
Now we can proceed with the mounting of the completion kit needed for the installation of the
SK3 detector.

SK3 NEEDLE PATH DETECTOR
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Images illustrating the de-installation procedure:
1)Disconnect the cables from the box fitted to the basket 2)Disconnect the limit switch and remove it
3) Remove the electronics box 4) Remove the box supporting plate
5) Remove the projector 6) Remove the photodetector

SK3 NEEDLE PATH DETECTOR
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7) Remove bracket+photodetector support 8) Remove motor assembly
9) Remove bracket supporting motor/projector 10) Remove U bracket

SK3 NEEDLE PATH DETECTOR
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Fitting the completion kit EE5900010226:
The completion kit in question must be used in all cases of installation on a basket, i.e.: for
upgrade purposes after de-installing the previous photodetector version, or when fitting the
photodetector onto a new line.
Materials needed:
•2.5, 4 and 6 mm sized Allen wrenches
•8 mm long socket wrench
•8 and 13 mm wrenches
Installation procedure:
1. Fit the new U bracket supplied with the KIT and screw it in place after pushing it
towards the handwheel as far as permitted by the adjustment slots.
2. Fit back the motor & projector supporting bracket previously taken down. It must be
screwed in place keeping the base flush with the left hand shoulder of the U bracket.
3. Insert the new photodetector mechanical support. Warning: the new mechanical
support is normally supplied with the limit switch and the SK3 photodetector already
mounted inside it: handle it with care so as not to expose it to shocks.
4. Replace the blade guard present on the previously taken down motor assembly with
the new version supplied with the KIT.
5. Fit back the motor assembly. WARNING: the photodetector mechanical support must
be pushed all the way towards the basket to make room for the passage of the motor
assembly.
6. Secure the photodetector mechanical support at a distance of 205 mm from the
support that links it to the projector motor supporting bracket. Make sure that the
support is vertical relative to the mechanical parts of the basket.
7. Adjust the connecting support of the photodetector mechanical parts, with the motor
supporting bracket, so that between the connecting support and the base of the latter
there is a gap of ca 10mm.
8. Fasten the motor assembly so that its supporting ring remains at a distance of 60 mm
from the base of the projector motor supporting bracket.
9. Adjust the entire assembly installed on the U bracket, by moving the U bracket within
the relative ad hoc slots; this adjustment must be performed so that the back of the
photodetector will remain at a distance of a few mm (3/5) from the lower support of the
basket rods.
10.Rotate the basket in all directions and make sure that in any opening condition the
bottom end of the rods remains at all times ca 10 mm above the upper end of the
photodetector mechanical support; if it does not, adjust the height of the photodetector
and its mechanical parts accordingly, by changing the distance specified at step 8.
11.For an upgrade with SK3 box version, fit back the box supporting bracket.
The mechanical parts now are ready for the installation of the SK3 upgrade kit

SK3 NEEDLE PATH DETECTOR
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Images illustrating the completion kit installation procedure:
1) Install the U bracket towards the handwheel 2) Fit back the projector/motor supporting bracket
3) Insert the new photodetector mechanical parts 4) Replace the blade guard with the new guard supplied
5) Fit back the engine assembly 6) Fasten the photodetector mechanical parts at a distance of 205mm
205m

SK3 NEEDLE PATH DETECTOR
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7) Adjust the photodetector support at a distance of 10mm from the base 8) and the motor assembly at a
distance of 60 mm from the support
9) Adjust the photodetector at a distance of a few mm from the basket and 10) Make sure that the rods do not
touch it
11) If necessary, fit back the box support
10m 60m

SK3 NEEDLE PATH DETECTOR
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Installing an SK3 kit:
The following procedure must be performed in parallel with the installation of a completion kit
and must be used in the case of an initial installation onto a line or an upgrade installation.
Materials needed:
•Small sized screwdriver for the terminals.
•2.5, 4 and 6 mm sized Allen wrenches
•8 mm long socket wrench
•8 and 13 mm wrenches
Procedure:
1. Insert wire of the SK3 photodetector + the limit switch wire in the tube connecting the
photodetector mechanical parts with the rest of the machine.
2. Insert the limit switch wire into the connection box fastened to the bracket using the PG
located in the portion facing the basket opening handwheel. In the PG located on the
opposite side, insert the limit switch connecting wire from the panel.
3. Insert the projector into its ad hoc support and arrange it so that the lenses of the
photodetector and the projector will face one another, at the same level and parallel to
one another. The distance between them should be approx 20mm. If this cannot be
achieved, you can work on the adjustments of the U bracket and the mechanical parts
of the photodetector.
4. Make sure that the blade and blade guard do not touch in the mechanical parts and the
limit switch rod can move freely.
5. For versions with the control assembly in a box, fasten the box to the relative support.
6. Fit the wires of the projector and the photodetector (3 wires in all), connecting them to
the box aboard the basket of the panel. In the case of panel installation, the limit switch
connection box can be replaced with a bigger one having four PG’s on the input and as
many on the output, and use it to make a connection between the wires from the panel
to the project and receiver wires, so as to simplify the harnessing scheme.
For correct photodetector operation, it is now necessary to proceed with the calibration and
alignment of the projector with the microcamera.

SK3 NEEDLE PATH DETECTOR
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Images illustrating the installation procedure of an SK3 kit:
1) Insert the photodetector+limit switch wires into the ad hoc tube
2) Connect the limit switch to the wire from the electric panel by means of the ad hoc box
3) Mount the projector, which must be at a distance of 20mm approx from the photodetector
4) Make sure that the blade and blade guard do not touch at any point and the limit switch rod can
move freely.
5) If necessary, the box be replaced Image at end of installation
20mm

SK3 NEEDLE PATH DETECTOR
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Calibration and alignment of the projector with the microcamera:
This process is indispensable for correct system operation, it must be performed in the event
of first installation and must be checked and, if necessary, repeated in the event of
malfunctioning (e.g. after a shock to the projector or the microcamera support).
The projector is aligned with the receiver by adjusting the position of the projector and, if
necessary, the position of the photodetector mechanical parts.
The supporting mechanical parts should always be vertical, i.e. parallel to the basket.
The calibration process can be performed in three ways, that can be used regardless of the
equipment available.
1. Calibration by means of an oscilloscope
2. Calibration by means of VDTEX programme
3. Calibration by means of a tester.
Calibration by means of an oscilloscope:
This is the method offering the best results. In view of the nature of the signals, we
recommend using a digital oscilloscope. However, an analog unit can also be used.

SK3 NEEDLE PATH DETECTOR
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RE: Calibrating the TGL SK3 by means of an oscilloscope.
1) Turn off the machine
2) Set switch SW2-1 on “ON”
3) Connect probe no. 1 (CH1) to board C352 terminal M5-5, connect 0V (potential) of probe no.1
to TP1 on board C318. On the first channel you can see the level of the direct light signal,
maintain this signal at the highest possible level, ca +10vdc.
4) Connect probe no.2 (CH2) on board C336 to test point TP5, connect 0V (potential) of probe
no.2 to TP4 on board C336. On the second channel you can see the analog signal of the
camera sensor, adjust the trigger or the oscilloscope for CH2.
5) Power the machine, make sure that the reflex / transparency (working mode) selector is set on
transparency and the red 7-segment display is on “0.” (On board C336), you can see this image.
Analog signal
from the camera
Direct light level
Probe CH2
(TP5 on
board C336)
Probe CH2
(TP4 on
board C336)
Probe CH1
(TP1 on
board C318)
Probe CH1
(M5.5 on
board C352)

SK3 NEEDLE PATH DETECTOR
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6) zoom ...
7) zoom in further ...
Adjust the camera up/down, left/right to obtain...
A) The analog signal from the camera will be similar to the previous image.
B) The direct light signal level will be ca +10Vdc.
8) Having adjusted the mechanical position of the camera without any fabric interposed between
the camera and the projector, interpose fabric (or a finger, or a screwdriver)...
In the next image, the fabric is represented as parallel lines, the needle path is represented as a line
of varying amplitude. ...
... now in the centre ...
Direct light signal
Reflex signal
Needle path
Direct light signal

SK3 NEEDLE PATH DETECTOR
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... now on the right ...
... now on the left ...
9) Check the level of the direct line signal (without any obstacles between the camera and the direct
light projector); in the next image you can see the signal reaching the highest level, ca +10Vdc.

SK3 NEEDLE PATH DETECTOR
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9) If you obscure the signal by interposing an obstacle between the camera and the projector you
will see the signal drop to ca –10Vdc.
Calibration by means of VDTEX SW:
This is perhaps the easiest method as it requires no specific equipment other than a portable
PC where to run the VDTEX program.
Material necessary:
•PC with VDTEX96 program installed
•4 mm Allen wrench
Minimum requirements for PC used for upgrade:
•Any PC DOS 6.22 or compatible operating system.
•The PC should be equipped with a standard receptacle type 9 pin RS232 serial connector
(DB9S).
The VDTEX96 SW version installed on the PC should be 3.0m or higher.
Obstacle
Signal
dropped to
the minimum
level
Direct light signal
dropped to the
minimum level
-10Vdc.

SK3 NEEDLE PATH DETECTOR
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Procedure:
•On C352 board: open, if closed, selector S7 (two-way selector, leave both ways free). If
S7 was closed previously, memorise point of connection to be able to reset it later.
•On C336 board: insert 10-way connector of flat cable into JP3 housing, insert receptacle
type connector of upgrade cable into serial communication port of PC.
•On the PC: run the VDTEX96 program. If the PC has been configured correctly, the
screen will display the following page.
•On the PC: press key F3 to view the calibration page.
•Make sure that the lenses of projector and receiver are perfectly clean. WARNING, do not
use abrasive substances or cloths, as this is no ordinary glass but optical glass and the
photodetector might mistake an incisions or score for a needle path.
•If necessary, adjust the photodetector mechanic support so that it is perfectly vertical and
so that the viewer lens is parallel to the plane of the projector.
•Rotate the projector so that it is parallel to the photodetector, then adjust it for height so
that the transparency light reference is as low as possible.
•Adjust the projector finely and, if necessary, the photodetector so that the transparency
signal is as symmetrical and as similar as possible to the photo, with the uppermost part in
the centre. During this process, make sure the transparency light reference does not move
too far up.
•If possible, during the adjustment process, make sure that the transparency centre
position is as close as possible to zero; if this occurs during system operation in the
absence of fabric and with the machine in automatic mode, the basket will be kept
stationary regardless of alarm threshold sensitivity setting.
•Check the quality of the signal by means of the expanded screen of the transparency
chart, which can be viewed by pressing key F7 in the main page.
•On C336 C352: reset the original position of S7.

SK3 NEEDLE PATH DETECTOR
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Images of VDTEX screens described in previous procedure:
Trasparence
centre
position
Trasparence
light
reference
Trasparence signal:The signal
should appear as flat as possible,the
part which is highest on average
should be around the centre.
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