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.

Technical Data and installation
SMART 200 TPG - 2.3 -

Concerning all electrical systems, it is a suggested rule to ensure that the ground cable
(GND) is connected to the sensor support

Technical Data and installation
- 2.4 - SMART 200 TPG

To correctly install the SMART 200 TPG system and sensors, it is necessary to
use a certain number of connecting cables provided by BTSR; their length and
type depend on the specific requirements and application types.
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.

FE10/200 Length 200 cm
FE10/500 Length 500 cm
 !"#
MA10/12CR Ready for 12 sensors with pitch of 10 cm
MA10/16CR Ready for 16 sensors with pitch of 10 cm
MA12/24CR Ready for 24 sensors with pitch of 10 cm
MA12/32CR Ready for 32 sensors with pitch of 10 cm
MA15/3CR Ready for 3 sensors with pitch of 15 cm
MA15/5CR Ready for 5 sensors with pitch of 15 cm
MA15/6CR Ready for 6 sensors with pitch of 15 cm
MA15/8CR Ready for 8 sensors with pitch of 15 cm
$%"&'%&()*

MA50/FEC Length 50 cm
MA100/FEC Length 100 cm
MA200/FEC Length 200 cm
#"#+
MA35/CR Length 35 cm
MA50/CR Length 50 cm
MA100/CR Length 100 cm
MA150/CR Length 150 cm
'%&(+**"
,-)-
 !
FE100/FEC Length 100 cm
FE200/FEC Length 200 cm
FE300/FEC Length 300 cm
FE400/FEC Length 400 cm

Technical Data and installation
SMART 200 TPG - 2.5 -
'%&(+*.*"
)- !

FE100 Length 100 cm
FE200 Length 200 cm
FE300 Length 300 cm
FE400 Length 400 cm
+*#

FE35/CR Length 35 cm
FE125/CR Length 125 cm
FE200/CR Length 200 cm
/ "*
MA2FE
/ "*0+)1)1
) ) 1 $22& &
##3#+&
MA2FE3
'!4"* *
MA4FE
 114"
TRF1524/100VA Output 15/24 Vac 100VA(can be used with up to 40 sensors)
TRF24/300VA Output 24 Vac/300VA (can be used with more than 40 sensors)
) 114+'5) 1 &-6&7
  
PSU 10A Required with more than 40 sensors

Technical Data and installation
- 2.6 - SMART 200 TPG
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Operating
SMART 200 TPG - 3.1 -


As in all SMART BTSR systems,the operation of SMART 200 TPG 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.
On the top left hand side of each button there is a red LED, which indicates that the
button is pressed down.
The display screen includes two separate zones used respectively for displaying
messages to the operator during the system programming and administration
phases and for signalling the operating status and levels in which the system is
working .
The following picture shows the location of the buttons and display zones that
constitute the control panel of the SMART 200 TPG system.

Operating
- 3.2 - SMART 200 TPG
 
It allows to activate the function selected from the menu (indicated by the symbol
>), to move to the programming of the displayed function or to confirm the setting
value displayed on the messages screen.
 
It allows return to the previous level of the menu (next upper level), without
continuing with the currently selected function, or without confirming the value of
a setting entered by mistake.
 
During navigation within the menus this button allows selection of next option
in the same menu level; this button has a cyclical function in the sense that
when the last choice from the menu has been selected, it returns to the first
option of the same menu.
When alphanumeric data are entered (for instance the Article Name or Keycode
access), this button allows the increase of characters displayed where the cursor
is located, according to the following cyclic sequence:
When entering numeric data (for example the number of sensors) it allows the
increase of numeric value of the field. If it is held down continuously the
numeric field increments more rapidly.
 !!"
During parameter programming, it allows changing the position of the cursor.
# 
During navigation within the menus selection of the previous choice is allowed
while remaining inside the same menu level. This button has a cyclical function
in the sense that when the first choice of menu is selected it returns to the last
option of the same menu.
When alphanumeric data are entered (for instance the Article Name or Keycode
access), this button allows the decrease of the characters displayed where the
cursor is positioned, according to the following cyclic sequence:
When entering numeric data (for example the number of sensors) it allows the
decrease of numeric value of the field. If it is held down continuously the
numeric field decrements more rapidly.

Operating
SMART 200 TPG - 3.3 -
$ !%&'(
The menu choices, or settings for the selected function during programming or
setup phase of the system as well as service messages are displayed with large size
fonts (1,5 x 0,8 cm), easy to read even from a distance, when the system is running
normally. In other words, it shows all the necessary information to guide the
operator step by step through the programming phase and interactive management
of the system.
When the displayed lines refer to the menu items, the selected one is indicated with
the symbol >. The presence of a flashing cursor (---) indicates the position where
the operator can enter an alphanumeric character or variable setting which will
replace the value currently displayed.
) !%'''
To enable a more direct and evident interpretation of the operating context in
which you are working, on the right hand side and bottom side of the operator
message area, 16 rectangular boxes (labels) are implemented. They display the
operating status of the system, and the hierarchic level of the menu at which you
are operating.
More specifically, the PROGRAM label indicates that you are operating in one of
the following modes: configuration, programming or data transmission to the
sensors. The CONTROL label indicates that the system is operating normally with
all monitor functions enabled, and according to the settings currently set in the
system. In this phase the message display indicates CONTROL OK. The ERROR
label indicates that an error has been detected during normal operation of the
system. In this case the message display shows the type of error detected (for
further information please refer to Operations Sequences).
The labels P1 .. P5 indicate the hierarchic level of the menu in which you are
operating. P1 is the highest level, P5 is the lowest hierarchical level. To move
from the upper to the lower level you must normally press down the ENTER
button, while to do the opposite, i.e. going from the lower to the upper level you
must press the RESET button.
The indication of level P1 .. P5 can be particularly useful during the initial phase
when one is not yet familiar with the use of the programming functions. For
example, if the system indicates P1 it is useless to press the RESET button, as the
system is already in the main menu and it is not possible to select a higher level of
the menu.
*
The IS3.. electronic sensors are capable of detecting, due to a patented and
advanced control technology, the image variation of a moving yarn under control;
it can show with absolute certainty the actual movement or stop condition of the
yarn. The technique based on image variation makes the IS3.. sensor exempt from
the influence of environment/yarn conditions: i.e. in humidity, conductivity and
machine vibrations. It does not require any physical contact with the yarn under
control and therefore allows perfect monitoring without affecting the tension
features of the yarn itself in any way. The IS3.. devices are the most reliable and
advanced solution for yarn control in textile machines. IS3.. is an unique electronic
sensor for yarn control; when combined with the SMART series controllers, thanks
to a patented innovating technique (Image Smart Scanning Sensor), it does not
require complex cabling and long installation time; the new multi-connector cable
allows in fact to control up to 200 yarn sensors. IS3.. is full programmable for an
easy fitting to the control of any type of yarn/application.
SMART
200 TPG

Operating
- 3.4 - SMART 200 TPG
+%,*
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.
I S 3
No characters = Standard Model
= Sealed Model
SL
{
No characters = Standard Model
= Self Startin
g
(Automatic Restartin
g
)
S
{
= Standard Model
T
{
{
= Hi
g
h Sensitivity Model
T2
= Wide Version - 25 x 15 mm
W
= Narrow Version - 15 x 5 mm
N
ma
g
e
S
S
S
I
mart
cannin
g
ensor
Example: IS3NT2S means: Narrow model sensor with high sensitivity and
automatic restart.
-,.*
The IS3.. sensors allow every single position of the machine to be stopped
immediately or to activate solenoid-valves, cutters, or other control devices,
automatically signalling which sensor, among those connected, was the first which
intervened to stop the position.
The IS3.. sensors of the last generation have two signalling lights (upper green
LED, lower red LED) and a “Touch Light” button.
The “Touch Light” button allows fast and precise sensor off/on operation. The
sensors equipped with the automatic restart feature will carry out an automatic
switch on, when the yarn restarts.
During the automatic numbering of the sensors (flashing green LED) it assigns the
displayed number in the devices configuration screen to the sensor.
The IS3.. Sensors of the previous generation (perfectly compatible with those of the
last generation) also have the two signalling lights (upper green LED, lower red
LED) and a membrane mechanical button located on the side of the sensor.
Touch Light

Operating
SMART 200 TPG - 3.5 -

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 200 TPG or to the power
supply PSU 10A. To install the sensors operate as follows:
Prepare the adequate multi-connector cable.
Open the rear cover of the sensor.
Plug the male connector of the cable into the Female connector of the sensor
(the reference key on the male connector must be positioned on the upper side
of the connector).
Close the rear cover and secure the sensor using a M3 screw.
Check that the yarn rooms in the centre of the area shown in the following
pictures.
*%,.'''.-/.
Green LED ON Normal operation, the yarn is running inside the sensor;
No technical fault detected by the sensor.
Red LED ON Yarn stopped.
Green LED FLASHING The system is in automatic numbering phase.
Red LED FLASHING During machine operation the sensor has detected a fault
(broken yarn)
.
Green LED ON
Red LED ON Stopped sensor. Switch off, then power on the system. If the condition is permanent, replace the sensor.
Green LED OFF
Red LED OFF Disabled sensor
(the “Touch Light” button has been
touched or PUSH has been pressed down).
To enable
again the sensor, start the yarn or press the PUSH button.
Green LED FLASHING
Red LED FLASHING Indicates a technical fault in the sensor
(e.g. a loss of
stored data).
Try to reprogram the sensor.
If the fault remains, replace the sensor.

Operating
- 3.6 - SMART 200 TPG
'.,,-./-,
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:
Normal yarn running condition
Yarn stopped or broken condition
The functioning of the sensor is based on the principle of variation of the image
relative to the shape of the yarn, detected by the tiny “camera”, which is
implemented inside the sensor. Such a variation of image normally occurs only if
the yarn is in actual movement inside the detection area, i.e. only if the yarn is
running.
Nevertheless, in certain cases, there may be some variation of image even though
the yarn is not running normally, this is the case of a broken yarn oscillating inside
the detection area.
Finally there are other factors that can affect the detection activity of the sensors,
like the size and type of yarn (silk, wool, acrylic, Lycra®, single filament nylon), as
the variation of the image depends on these factors as well.
That’s why the microcomputer embedded in the sensor, processes the images
provided by the “camera” by means of the sensor memory, which takes into
account also these other influencing factors.
The variables of this program are represented by the settings connected to the
article, which is being worked, i.e. the settings that can be defined, changed and
loaded in the sensors with the SMART 200 TPG system:
Start Frequency (F_START)
Stop Frequency(F_STOP)
Sensitivity (SENS)
Reaction Time (DELAY)
0-+
This setting indicates the minimum frequency of image variation, beyond which
the sensor signals that the yarn runs normally (green LED ON).
It can be programmed to a value between 1and 10.
%0-+
This setting indicates the minimum frequency of image variation, below which the
sensor signals that the yarn runs normally (red LED ON).
It can be programmed to a value between 1and 10.