btsr DIAPERFEEDER IP54 DUOLOOP User manual

DIAPERFEEDER IP54
(DUOLOOP VERSION)
YARN CONTROL SYSTEM
Operating Manual
ENGLISH
Rev. 1.4 – February 2016

DIAPERFEEDER IP54 DUOLOOP VERSION)– Rev. 1.4 – February 2016
Copyright - BTSR - All rights reserved.
This manual is intended for the users of DIAPERFEEDER IP54 devices used to control/monitor the
application tension of elastic yarns on automatic diapers production lines. It is suggested to carefully
read the instruction reported on this manual before making the connections and use the devices.
BTSR reserves the right to change at 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. 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 Machine Directive 2006/42/EC and
EMC 2004/108/EC.
All BTSR products are covered by patents and adopt exclusive, profitable and high tech.
Solutions.
PROFIBUS®is a registered trademark of PNO (PROFIBUS Network Organization)
BTSR® is a registered trademark “Best Technology Study & Research” of BTSR International S.p.A

Table of Contents
DIAPERFEEDER IP54 - i -
TABLE OF CONTENTS
INTRODUCTION
The ideal solution to maintain the elastic yarn tension constant..........................................................I.1
How to use this manual..............................................................................................................................I.3
Symbols used..............................................................................................................................................I.3
Reference Documentation .........................................................................................................................I.3
Chapter 1 - OVERVIEW’
Management and programming of DIAPERFEEDER IP54 Devices ......................................................1.1
Main Characteristics of DIAPERFEEDER IP54 Devices .........................................................................1.1
Advantages obtained by using the SMART MATRIX FEEDER Terminal combined with
DIAPERFEEDER IP54 Devices..................................................................................................................1.2
Chapter 2 – TECHNICAL DATA AND INSTALLATION
Technical Features.....................................................................................................................................2.1
Electrical Interface of DIAPERFEEDER IP54 Devices. ...........................................................................2.2
Example of application (Board SM-DIN/DUOLOOP)...............................................................................2.3
Example of application – 4 positions –Ethernet IP network (Board SM-DIN/DUOLOOP/ETH) ..........2.4
Example of application – 4 positions – Profinet IP network (Board SM-DIN/DUOLOOP/PFN) ..........2.5
Example of application – 4 positions – Profinet IP network (Board SM-DIN/DUOLOOP/PFN) ..........2.5
Component Identification..........................................................................................................................2.6
SM-DIN/DUOLOOP Interface .....................................................................................................................2.7
Interface SM-DIN/DUOLOOP/ETH - SM-DIN/DUOLOOP/PFN .................................................................2.9
Configuration of SM-DIN/DUOLOOP Board...........................................................................................2.11
Configuration of SM-DIN/DUOLOOP/ETH and SM-DIN/DUOLOOP/PFN Boards ...............................2.13
DIAPERFEEDER IP54 overall dimensions (in mm)...............................................................................2.13
Instructions for Correct Yarn Threading ...............................................................................................2.15
Chapter 3 – OPERATION
Operating Characteristics of DIAPERFEEDER IP54 Devices ................................................................3.1
Symbols shown on LCD............................................................................................................................3.2
Functions Directly Available to the Textile Machine Operator..............................................................3.3
1) Alarm Reset..........................................................................................................................................3.3
2) Current Yarn Type and Application Reading .......................................................................................3.3
3) Exclusion and Re-inclusion of a DIAPERFEEDER IP54 Device ........................................................3.4
4) Control of Temperature and Current Absorbed by DIAPERFEEDER IP54.........................................3.4
Programming the DIAPERFEEDER IP54 Devices...................................................................................3.5
General Diagram of Simple Programming Environment..........................................................................3.5
Advanced Programming of DIAPERFEEDER IP54 Devices...................................................................3.6
General Diagram of P1÷P4 Advanced Programming Levels and Default Settings ................................3.8
P1 Programming Level ..............................................................................................................................3.9
P2 Programming Level ............................................................................................................................3.12
P3 Programming Level ............................................................................................................................3.15
P4 Programming Level ............................................................................................................................3.17

Table of Contents
- ii - DIAPERFEEDER IP54
Chapter 4 – DIAPERFEEDER IP54 TROUBLESHOOTING AND MAINTENANCE
Indications Provided by the Red LEDs on DIAPERFEEDER IP54 Device ............................................4.1
Troubleshooting Table ..............................................................................................................................4.2
Errors detected on the SM-DIN/DUOLOOP boards ................................................................................4.5
Errors detected on the Board SM-DIN/DUOLOOP/ETH and SM-DIN/DUOLOOP/PFN.........................4.6
Calibration of Tension sensors ................................................................................................................4.8
Coil separator adjustment.........................................................................................................................4.9
Periodic cleaning of the components....................................................................................................4.10

Introduction
DIAPERFEEDER IP54 - I.1 -
INTRODUCTION
Congratulations for choosing a BTSR product.
With our DIAPERFEEDER IP54 yarn feeding devices, you got an innovative,
unique solution able to offer you multiple advantages concerning quality of your
production.
The ideal solution to maintain the elastic yarn tension constant
The DIAPERFEEDER IP54 device comes from the experience built-up by BTSR in
the field of yarn feeling at constant tension.
The DIAPERFEEDER IP54 devices are in fact high precision measurement and
control instruments providing a real time display of the exact yarn tension and
guaranteeing, through an accurate adjustment, a constant tension feeding of the
yarn itself in every working condition.
Thanks to the IP54 protection degree, the device is able to work with critical
environmental conditions, like humidity, dustiness, etc.
The DIAPERFEEDER IP54 devices are fully programmable and can easily be
adapted to any kind of yarn or tension adjustment and to any operating speed of
the textile machine on which they are installed. Furthermore these devices are
manufactured using very high quality and precision electronic components which
guarantee an exact display of the yarn tension as well as an accurate real-time
control of the tension itself, exclusive characteristics of BTSR systems.
Thanks to its modularity characteristics, the DIAPERFEEDER IP54 device is
capable of managing not only the TS44.. tension sensor, but also the IS3F.. image
scanning sensor, thus allowing the user to obtain a complete quality control for
what concerns both the yarn tension and the correct yarn running condition.
DUOLOOP solution for automatic diaper production lines
Since, for space reason it is not always possible to install DIAPERFEEDER IP54
feeding devices on the exact application point of the elastic yarns along the
production line, an innovative solution based upon two independent (yet
interactive) tension control/adjustment systems has been developed:
•A first yarn tension control system at the application point, consisting of
TS55 sensors (BTSR Patent).
•A second yarn feeding tension control/adjustment system consisting of one
or more creels located at a certain distance from the actual elastic yarn
application point and based upon DIAPER FEEDER motor-driven devices
(BTSR Patent).
The two control systems are controlled and coordinated by a CPU consisting of a
SM-DIN/DUOLOOP/** Board capable of communicating both with the TS55..
sensors and with the DIAPER FEEDER devices via RS485 serial lines.
The control/adjustment parameters of TS55.. sensors and of DIAPER FEEDER
devices can be programmed through a SMART MATRIX BTSR terminal; or they
can be directly programmed from the production line control system by means of
field bus interface (PROFIBUS), through the SM-DIN/DUOLOOP control board.

Introduction
- I.2 - DIAPERFEEDER IP54
DUOLOOP solution Summary diagram
SERIAL LINE
SERIAL LINE
ELASTIC YARNS
PRODUCTION LINE
PROFIBUS
SERIAL LINE
SERIAL LINE
ELASTIC YARNS
PRODUCTION LINE
PROFIBUS

Introduction
DIAPERFEEDER IP54 - I.3 -
How to use this manual
This Operation Manual is divided into 4 Chapters.
Chapter 1 – Overview describes the main features, components and the operation
principle of DIAPERFEEDER IP54 devices.
Chapter 2 – Technical Data and Installation gives the necessary instructions to
install the devices.
Chapter 3 – Operation gives a detailed description of the necessary operations to
setup and program the DIAPERFEEDER IP54 devices according to the application
needs.
Chapter 4 – Troubleshooting and Maintenance provides a quick guide to solving
the main failures of DIAPERFEEDER IP54 devices.
Symbols used
Highlights notes, warnings and subjects to which the attention of the reader
should be directed.
Indicates a particularly sensitive situation which could have an effect on the
safety or proper operation of the system.
TENSION ERROR
All the items concerning the device programming menus, within this
manual, are always show in CAPITAL LETTERS.
TS44..
TS55..
IS3F..
To make the description easier, the interface Boards:
SM-DIN/DUOLOOP
SM-DIN/DUOLOOP/ETH
SM-DIN/DUOLOOP/PFN
will generically be indicated as SM-DIN/DUOLOOP/**
Reference Documentation
For operating details about the programming/analysis and monitoring system
available for DIAPERFEEDER IP54 device management, please refer to the
SMART MATRIX WINDINGFEEDER manual – Rev. 1.1 – Ed. 02/2010
P1.2
To make the description easier, the tension and yarn running
sensors are mentioned with the family name only, without further
specifications such as grams, protection degrees etc.

Introduction
- I.4 - DIAPERFEEDER IP54
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Overview
DIAPERFEEDER IP54 - 1.1 -
1 - OVERVIEW
Management and programming of DIAPERFEEDER IP54 devices
The DIAPERFEEDER IP54 devices can be programmed and used either in
individual and autonomous way by the user through the integrated operator interface
(LCD display + 3 buttons) or via PROFIBUS standard interface through the SMDIN
DUOLOOP/** BTSR board, or again they can be connected to a
control/programming SMART MATRIX (BTSR patent)terminal, still using the SM-
DIN/DUOLOOP/** board, thus obtaining a complete system providing further
levels of analysis, adjustment, control and speed-up of production cycles, as well
as statistical data processing, particularly useful to reach the quality and saving
goals stated in the Introduction of this manual.
Main Characteristics of DIAPERFEEDER IP54 Devices
Full Digital Technology
The DIAPERFEEDER IP54 device is a fully high-tech digital instrument that allows
setting of the exact tension value at which you want to operate. The data setting is
done through a small three-button key-pad and a graphic LCD display.
In normal operating conditions the LCD provides a real time display of the exact
yarn tension (in grams) during the manufacturing process, the yarn consumption
speed (LFA) (in m/min) and, in graphical form, both the average and peak values of
the yarn tension.
The DIAPERFEEDER IP54 devices are controlled by two DSPs (Digital Signal
Processor) and by ASIC components (BTSR Patent) which provide great versatility
(parameters may be programmed depending on the various yarn processing
conditions)
The Full Digital Technology also allows performing a number of extremely accurate
controls on the device motor (absorbed current, speed, motor angular position,
etc.).
Temperature control
In addition, the operator may display at any time the internal temperature (in °C) of
both control board and motor, by pressing the Reset button.
An excessive increase of the temperature could infact indicate a wrong use of the
device; for this reason, the software on board of the DIAPERFEEDER IP54 device
performs a continuous monitoring of the internal temperature.
If such temperature exceeds 100°C, an alarm message (ERROR °C) appears in
the graphic area of LCD, and the Stop output is activated.
Safety
Thanks to a configurable safety code, all parameters can only be changed by
authorized staff knowing such safety code.
Flexibility
The use of DIAPERFEEDER IP54 devices offers a lot of application.
Constant yarn tension both when the machine speed changes and when the
yarn packages gradually get empty.
Best efficiency by eliminating the yarn breakage (tears and extratensions), and
possibility of working at the highest speed offered by the machine.

Overview
- 1.2 - DIAPERFEEDER IP54
Accurate yarn feeding speed measurement (1 to 2,500 m/min) – (LFA m/min =
Length of Absorbed Yarn).
Possibility of using the yarn up to the complete package emptying.
Better machine efficiency.
Possibility of finding the best application conditions of DIAPERFEEDER IP54
device: (No of coils to be wound around the roller, ideal programming values for
parameters etc), thanks to the continuous visualization, in graphic form, of both
average and peak values of yarn tension.
IP54 Protection Degree
The DIAPERFEEDER IP54 version is able to work with critical environmental
conditions, like humidity, dustiness, etc.
Usable with any type of yarn
The DIAPERFEEDER IP54 device considerably reduces the preparation tasks,
thanks to a single self-threading ceramic eyelet that makes the operator job easier.
The tension value displayed on LCD indicates the actual tension with which the
device is working. This guarantees a constant and accurate monitoring of the
working process.
Advantages obtained by using the SMART MATRIX WINDINGFEEDER
Terminal combined with DIAPERFEEDER IP54 Devices
Using the SMART MATRIX BTSR terminal connected to DIAPERFEEDER IP54
devices you have the possibility of developing a wide range of functions which
facilitate the practical use of the installed DIAPERFEEDER IP54s (immediate
download and upload of data), as well as displaying fundamental data, such as yarn
consumed and yarn tension.
Possibility of creating up to 99 “articles”, saving them to the Data Base for an easy
subsequent recall. Without the need of setting up new parameters, these will simply
be called from the Data Base and subsequently transferred to the DIAPERFEEDER
IP54 devices installed on textile machine.
Possibility of using the TARGET function (meter count) and the Stop output, when
reaching the amount of meters setup, with possible automatic bobbin change enabling
(autodoffing).
Possibility of controlling and quickly correcting the tension adjustments, thus eliminating
the defects due to irregular tensions, tears and wrong yarn unwinding.
Possibility of identifying the connected DIAPERFEEDER IP54s using an automatic
numbering procedure (BTSR Patent).

Technical Data and Installation
DIAPERFEEDER IP54 - 2.1 -
2 – TECHNICAL DATA AND INSTALLATION
Technical Features
DIAPERFEEDER IP54 Device
Power supply voltage 24 VDC ± 10%
0.2 A (during normal operation);
1 A (under stress);
Maximum absorption
3 A (at start-up)
STOP Outputs: relay contacts (NO) 0.3 A 125 VAC
1 A 30 VDC
Opto-insulated Inputs 0-24 VDC
VIL Max 1,2 VDC
VIH Min 5 VDC
Programmable yarn tension (100g
version
0.5 ÷ 100 gr. (resolution 0.1 gr.)
Programmable yarn tension (1000g
version
5 ÷ 1000 gr. (resolution 1 gr.)
Programmable alarms 0.1 ÷ 25 sec.
Dimensions 220 x 86 x 98 mm
Operating temperature range 10° - 60 °C
Storage temperature -25° - +85° C
Tension range 0 / full scale
IP degree IP54
IS3F..
Power supply voltage 12 .. 24 Vdc ± 20%
Absorption 15 mA (max 20 mA)
STOP output NPN
STOP output protection Protection against over-voltages/short-
circuits
Maximum Current of STOP output 200 mA continuous; 500 mA peack
Reaction Delay Programmable from 5 to 1,000 msec
Sensitivity Programmable (10 levels)
Signaling With integrated LEDs
Dimensions (mm) 15 x 15 x 36,5 (Narrow) - 25 x 15 x 36.5 (Wide)
Operating temperature range 10° - 60 °C
Storage temperature -25° - +85° C
TS44..
Power supply voltage 12 .. 24 Vdc ± 10%
Absorption 20 mA (max)
Analogue Output 500 mV - 10V
Analogue output resistance 1K Ohm
Operating temperature range 10° - 50 °C
Storage temperature -25° - +85° C
Tension range 0 – full scale
Useful tension range 0% - 95% full scale
Max applicable tension 10 times full scale
Drift error (a) 0.05% / °C
Repeatability error (b) 0.5%
Max linearity error (c) 2% (0 - full scale )
Dimensions 50 x 25 x 12.5 mm

Technical Data and Installation
- 2.2 - DIAPERFEEDER IP54
Electrical Interface of DIAPERFEEDER IP54 Devices
TS44 Connector for TS44/1000RW/IP tension sensor connection
POWER Connector power connection
IS3 Connector for IS3F yarn image sensor connection
IS3F
TS44
POWER
TS44 POWER
IS3F

Technical Data and Installation
DIAPERFEEDER IP54 - 2.3 -
Example of application (Board SM-DIN/DUOLOOP)
The following figure shows an application example comprising 4 DIAPERFEEDER IP 54 devices, 1 SM-
DIN/DUOLOOP board, 1 PSU 10AS switching power supply and 4 TS55.. tension control sensors.
Concerning all electrical systems, it is a suggested rule to ensure that the ground cable
(GND) is connected to the device support.

Technical Data and Installation
- 2.4 - DIAPERFEEDER IP54
Example of application – 4 positions –Ethernet IP network
(Board SM-DIN/DUOLOOP/ETH)

Technical Data and Installation
DIAPERFEEDER IP54 - 2.5 -
Example of application – 4 positions – Profinet network
(Board SM-DIN/DUOLOOP/PFN)

Technical Data and Installation
- 2.6 - DIAPERFEEDER IP54
Component Identification
The following table lists the codes and functions of the various components indicated on the application
example shown on the previous page
CODE DESCRIPTION
DIAPERFEEDER/IP DIAPER FEEDER unit with rotary separator
WFI.SP.005 Inlet bracket with horizontal wheel for WF
TS44/1000ERW/IP 1000 gr. tension sensor- BC.0.063 - RW with IP67 connector
WFO.SP.001 RWO base bracket assembly
RWO.SP.006 Ceramic wheel with RW-OUT bearing
IFE/400/IMA/001 400 cm power chord-machine interface- IP67
CN.X8.002-M5M12 Socket with connection cable and 5 poles connectors - IP67 M12
CNS.003 Socket outlet protection cap
FE30/VSL Profibus adapter cable
SMDIN/DUOLOOP System management board + profibus converter
SMDIN/DUOLOOP/ETH System management board + profibus converter
SMDIN/DUOLOOP/PFN System management board + profibus converter
SMPRFB/2000/IP SMDINPRFBUS- CN.X8.001 socket connection cable
CN.X8.001 Distribution socket - IP67 – 8 positions FE 4 ways
TS55/D1000E/IP 1000 gr. digital tension sensor BC.0.063 with IP67 connector
CNS.001 Socket outlet protection cap
FEC100 100cm 4 wires cable
F8M12/200 200cm extension cable – 5 poles connector - IP67 M12

Technical Data and Installation
DIAPERFEEDER IP54 - 2.7 -
SM-DIN/DUOLOOP Interface
Machine Interface
(INPUT)
Machine Interface
(OUTPUT)
DIAPERFEEDER IP54
chain
DIAPERFEEDER IP54
chain
TS55.. chain
TS55.. chain
Max 10 DIAPERFEEDER IP54
devices and 10 TS55.. sensors
PROFIBUS Interface
PSU 20AS

Technical Data and Installation
- 2.8 - DIAPERFEEDER IP54
SM-DIN/DUOLOOP Control Unit Technical Characteristics
Power supply voltage 24 VDC
Maximum absorption 200 mA Max
Protection fuse (Board protection) 5 A
Protection fuse (sensors supply) 3 A
0.3 A 125 VAC
STOP output (normally open contacts) 1 A 30 VDC
0 – 24 VDC
VIL Max 1.2 VDC
Inputs
VIH Min 5 VDC
Operating temperature range +10° / +60° C
Storage temperature -25° / +85° C
Dimensions 138.5x124x35 mm

Technical Data and Installation
DIAPERFEEDER IP54 - 2.9 -
Interface SM-DIN/DUOLOOP/ETH - SM-DIN/DUOLOOP/PFN
Machine Interface
(INPUT)
Machine Interface
(OUTPUT)
DIAPER FEEDER
Chain
TS55 Chain
Max 10 DIAPER FEEDER
devices and
10 TS55 sensors
PROFIBUS Interface (*)
PSU 20AS
(*) option
ETHERNET interface

Technical Data and Installation
- 2.10 - DIAPERFEEDER IP54
Technical Characteristics
Power supply voltage 12-15VAC - 24 VDC
Maximum absorption 200 mA Max
Protection fuse (Board protection) 3 A
Protection fuse (sensors supply) 3 A
0.3 A 125 VAC
STOP output (normally open contacts) 1 A 30 VDC
0 – 24 VDC
VIL Max 1.2 VDC
Inputs
VIH Min 5 VDC
Operating temperature range +10° / +60° C
Storage temperature -25° / +85° C
Dimensions 138.5x124x35 mm