btsr IS3 User manual

SMART 200-TPG & IS3..
YARN CONTROL SYSTEM
Operating Manual
ENGLISH

Copyright 1999 - BTSR – All rights reserved.
This manual is intended for the users of the SMART 200 TPG system. It is suggested to carefully read the
instruction reported in this manual before making the connections and use the system.
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. 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 89/336/EEC EMC Directive and
73/23/EEC Low Voltage Directive.
All BTSR products are covered by patents and adopt exclusive, profitable and high tech. Solutions .
Lycra® is a trademark byDuPont

Table of contents
SMART 200 TPG - i -

INTRODUCTION
How to use this manual.............................................................................................................................................. I.1
Symbols used .............................................................................................................................................................. I.1
Chapter 1 - OVERVIEW
System components....................................................................................................................................................1.1
System’s Operating Principles..................................................................................................................................1.1
Special Features of SMART 200 TPG system .........................................................................................................1.1
General Features of SMART system........................................................................................................................1.2
Chapter 2 –TECHNICAL DATA AND INSTALLATION
Technical Features.....................................................................................................................................................2.1
Installation..................................................................................................................................................................2.1
Electrical connections ............................................................................................................................................2.1
Example of Generic Application Connection when the number of sensors
is less than 40.......................................................................................................................................................2.2
Example of Generic Application Connection when the number of sensors
is greater than 40..................................................................................................................................................2.3
Connecting cables and Power supply devices......................................................................................................2.4
Chapter 3 – OPERATING
SMART 200 TPG Terminal Features ......................................................................................................................3.1
IS3.. Sensors Features................................................................................................................................................3.3
Types of IS3.. sensors.................................................................................................................................................3.3
Function of the IS3.. Sensors.....................................................................................................................................3.4
Interpretation of the signalling lights located on the sensors.................................................................................3.5
Settings that affect the sensor detection features.....................................................................................................3.6
Setting the affect the general operation features of the sensor...............................................................................3.7
Preliminary operations for using the SMART 200 TPG terminal.........................................................................3.9
Operating Sequences................................................................................................................................................3.10
Enabling the SETUP Menu Function.....................................................................................................................3.11
CONTROL function................................................................................................................................................3.12
Enabling the WORK Menu Function.....................................................................................................................3.12
DEVICE - Parameters setting for Initial installation ..........................................................................................3.13
ST-NCO - Setting the Stop Output as Normally Open (NO) or Normally Closed (NC)....................................3.14
ST-pCN - Setting the Stop Output as Continous (CN) or Pulsing (P).................................................................3.15
ST-Fyn - Enabling/Disabling the Flashing red LED on the 1st Sensor detecting the Defect..............................3.16
lk-ULK - Enabling/Disabling the "Touch Light" Operation...............................................................................3.17
KEYCODE - Password to access SETUP and WORK menus.............................................................................3.18
SENSOR TEST - Sensors Test ...............................................................................................................................3.19

Table of contents
- ii - SMART 200 TPG
COM TEST - Testing the Efficiency Rate over the Communication Line between the
SMART 200 TPG terminal and Sensors ...............................................................................................................3.20
MODIFY - Modifying settings of a stored article or Creating a new article .....................................................3.21
ERASE - Deleting a article .....................................................................................................................................3.23
PROGRAM - Sensors Programming ....................................................................................................................3.24
READ - Viewing parameters programmed in the sensors ..................................................................................3.26
LOAD - Loading an article in sensor memory .....................................................................................................3.28
UNLOAD - Unloading articles from the sensors memory ...................................................................................3.30
SCAN - Displaying Products currently loaded in the sensors .............................................................................3.31
Chapter 4 – TROUBLESHOOTING AND MAINTENANCE
Troubleshooting .........................................................................................................................................................4.1
Ordinary Maintenance..............................................................................................................................................4.2
Repairs........................................................................................................................................................................4.2
Product Summary Tables..........................................................................................................................................4.3
Appendix A - QUICK REFERENCE............................................................................................................................A.1
Appendix B - INSTALLATION EXAMPLES...............................................................................................................A.2

Introduction
SMART 200 TPG - I.1 -

Congratulations for choosing a BTSR article.
With our SMART 200 TPG yarn control system, you get an innovative, unique
solution, able to offer you multiple advantages concerning quality control of your
production. SMART 200 TPG has been designed for application on textile
machines dedicated to the preparation of yarn (cone winder, doubling, texturizing
machines, etc.), which during the entire productive cycle utilize a specified number
of yarns on several sections and without stopping. In this kind of application it is
necessary to immediately detect a possible technical fault along the yarn, stop the
position where the fault occurred and signal the fault. The task of the IS3.. series
BTSR sensors is to detect these technical failures.

This Operation Manual is divided into 4 Chapters and 2 Appendices.
Chapter 1 – Overview describes the main features, components and how the
system works.
Chapter 2 – Technical Data and Installation gives the necessary instructions to
install the system correctly.
Chapter 3 – Operation gives a detailed description of the necessary operations to
setup and program the system according to the application needs.
Chapter 4 – Troubleshooting and Maintenance provides a quick guide to solving
the main technical faults of the system.
Appendix A – Quick reference summarises the sequence of operations that staff
who have had sufficient experience in handling the system, have to carry out in
order to setup and program the system.
Appendix B – Electrical Connections describe some electrical diagrams showing
the use of the SMART 200 TPG system and IS3.. sensors in the most common
application environments.

Highlights notes, warnings and points 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.
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. For further details refer to paragraph “Types of IS3.. sensors”.
While scrolling through features that can be activated from the SETUP and WORK
menus, this symbol indicates the procedure that describes the specific feature. The
same symbol is reported at the beginning of the page, which describes in details the
same function.

Introduction
- I.2 - SMART 200 TPG
Within the Appendix A “Quick Reference” the push-buttons of SMART control
panel are shown as follows:

Within the functions that provide two programmable alternative options, i.e.:
Normally Open or Normally Closed Contact
Enabled/Disabled Condition
Pulse/Continuos Signalling, etc.
The letters shown on display as capital letters refer to the currently active choice,
while the small letters refer to the possible alternative choice.
Example:
Item Function Current Programming
ST-NCo NCo = normally closed
ST-NcO
Stop Output programmable as
Normally Closed (NC) or Normally
Open (NO) contact NcO = normally open
LK-ulk LK = “touch light” disabled
lk-UKL
Enabling (ULK) or disabling (LK) the
“touch light” button. ULK = “touch light” enabled
ST-PCn Pcn = pulsing output
ST-pCN
Stop output programmed as pulsing
(P) or continuos (CN) pCN = continous output
ST-FYn FYn = function enabled
ST-FyN
Enabling/disabling the red LED
flashing feature on the 1st sensor
which detected the fault. FyN = function disabled

Within the description of configuration/programming procedures the alternative
screen shots are shown with this bracket symbol.

Overview
SMART CLEARER - 1.1 -


The SMART 200 TPG system includes a control/programming terminal and a
variable number of IS3.. type sensors (up to 200) connected to the terminal using a
single multi-port interface cable.

The sensors’ detection features (Start Frequency →F_START, Stop Frequency →
F_STOP, Sensitivity →SENS, Reaction Time →DELAY)depend on the type of
yarn (article) being processed.
These features must be programmed on each sensor and can be changed according
to the article which is being processed.
The terminal has in fact the function of programming and, as conditions change, it
can vary the sensors’ features, according to the production requirements.
The terminal can be used in the following two different ways:
1) To program and reprogram the sensors, and therefore it can be used by the
production assistant only during these phases.
2) It can be permanently connected to the machine.
In the latter case, it can be used to give a continuos and precise activity of
production control.

The SMART 200 TPG system has a set of unique features which make it a true
microcomputer dedicated to programming/control of production and statistical
analysis of technical faults.
In particular it allows the definition in advance of up to 99 different articles, and it
is possible to associate its own sensor detection features to each of them.
At this stage, the programming (and reprogramming) phase of the sensors is
limited to an extremely quick and easy operation: it consists of communicating the
name of the article to the sensor or to a specific set of sensors on the machine,
which they will have to detect. The system is able to monitor up to 10 different
articles at a time. Furthermore, during the production monitoring phase the system
saves in memory all the technical faults each sensor found, allowing the machine
operator to analyse which and how many technical faults have been detected by
each individual sensor.
The main advantages of this solution can be summarised as follows:
Absolute flexibility:
thanks to the possibility to quickly change the program of the sensors,
according to the article to be processed.
Maximum simplicity:
concerning the installation as well as programming and administration of the
system.
Maximum precision:
the possibility of programming the technical features of the sensors
according to the type of yarn to be processed guarantees a perfect symbiosis
between sensor and yarn.

Overview
- 1.2 - SMART CLEARER

IS3.. Sensors (Image Smart Scanning Sensor) (BTSR Patents)
The sensors of the IS3.. series are connected to the SMART control computer with just
one multi-port cable.
Automatically assigned numbers (BTSR Patents)
The identification of sensors is performed by the system by means of an automatic
numbering procedure.
Programmable Functions
The systems allows programming and saving in memory of up to 99 articles for each
one of them, it is possible to define different values, regarding Sensor Image Variation
Frequency, Sensitivity and Delay of the Sensor.
Multisensor System
The system allows the connection of all types of sensors from the IS3.. series, which
check that the yarn runs properly; and there is the possibility to combine sensors of the
new generation (equipped with a “Touch Light” device) with sensors equipped with
the “PUSH” membrane button.
Production Data
The system records, during production, the machine stops stored by each sensor and
by error type.
Easy Monitoring
Besides the information on the graphical display of the Smart 200 TPG, each IS3..
series sensor has a red LED that, when flashing, indicates the location of the technical
fault of the yarn, making intervention for the operator easier.
Sensor Diagnostic
Each IS3.. sensor signals the operational status by means of two LEDs.

Technical Data and installation
SMART 200 TPG - 2.1 -



Power supply voltage 24 Vdc ± 10%
Maximum Absorption 100 mA
Dimensions 135 x 95 x 40 mm
Temperature range 0° - 60 °C
LCD Graphical Display 80 x 40 mm
Integrated Touchpad 5 membrane buttons with integrated red LED
Protection 2 fuses 5 x 20 – 1A

Power supply voltage 12 .. 24 Vdc ± 20%
Absorption 10 mA (max 15 mA / 20 mA*)
STOP output NPN open collector
STOP output protection Protection from over-voltages and short-circuits**
Maximum Current of STOP
output 200 mA continuous; 500 mA peack
Reaction Delay Programmable from 5 to 1000 msec
Sensitivity Programmable (10 levels)
Signalling With integrated LEDs
Dimensions 15 x 15 x 36,5 (narrow) - 25 x 15 x 36,5 (wide)
Temperature range 0° - 60 °C

The installation of the SMART 200 TPG system depends on the type of
application to which it is destined and on the number of sensors to be connected to
it. When there are less than 40 sensors, it is possible to connect them directly to the
SMART terminal, otherwise it is necessary to use a stabilised power supply PSU
10A. This is capable of supplying up to 8 independent backbone lines to which it is
possible to connect the same amount of sensor chains (up to a maximum of 200).

*Model with “PUSH”
button
** Only for model with
“Touch Light”

Technical Data and installation
- 2.2 - SMART 200 TPG

Concerning all electrical systems, it is a suggested rule to ensure that the ground cable
(GND) is connected to the sensor support.