btsr MATRIX CUBE User manual

MATRIX CUBE
Operating Manual
ENGLISH
Rev. 4.2 – April 2014

MATRIX CUBE - Rev. 4.2 - April 2014
Copyright – BTSR International SpA - All rights reserved.
This manual is entrusted to the users of MATRIX CUBE system used to control/monitor the application
tension of elastic yarns on automatic diapers production lines. You are kindly recommended to thoroughly
read the instructions provided by this manual prior to connect and use the system.
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 center. 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, EMC
Directive 2004/108/EC and Low Voltage Directive 2006/95/EC.
All BTSR products are covered by patents and adopt exclusive, profitable and high tech solutions.
PROFIBUS

is a registered trademark of Profibus International.
BTSR® is a registered trademark “Best Technology Study & Research” of BTSR International S.p.A.

Introduction
i

Introduction
MATRIX CUBE - i -
Introduction
The MATRIX CUBE has been developed by BTSR International S.p.A. to optimize the elastic yarn
application on automatic diapers production lines.
Since, for space reason it is impossible to install feeding devices (such as BTSR ULTRAFEEDER 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 adjustment 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 CUBE terminal; this too can communicate with the SM-DIN/DUOLOOP Board via
RS485 serial line.
The SM-DIN/DUOLOOP Board may also be integrated (as an alternative solution) with the
production line management system, via industrial field bus (PROFIBUS). In this case, the
programming of TS55 and DIAPER FEEDER control parameters can be directly carried out by the
line control system.
Application Principle Layout
Example of creel with 4 positions (4 TS55 sensors and 4 DIAPER FEEDER devices)

Introduction
MATRIX CUBE - ii -
The control/adjustment parameters (minimum/maximum tension, control activation delay, etc. on TS55
sensors, feeding tension, exit tension with machine stationary, etc., on DIAPER FEEDER devices) must be
programmed taking into account the possible variables (yarn elasticity, distance between TS55 sensors and
DIAPER FEEDER devices, friction generated by the various yarn sliding wheels, etc.), in such a way as to
find the most suitable values for each specific application.
Creel Structure
Considering the high operating speed of diapers production lines, notwithstanding the use of large capacity
yarn spools, an additional feature has been implemented to allow the junction of multiple spools on each
position (up to 4 spools), i.e. by connecting the tail of a spool with the head of the next spool, thus obtaining
a long operation capacity, without having to stop the machine to replace the empty spools.
The passing from a run out spool to the next spool is detected by yarn running sensors which inform the
operator about the occurred spool change through a message displayed both on SMART MATRIX CUBE
terminal and on the display of DIAPER FEEDER device that controls the involved position. This allows the
operator to replace the run-out spool, while the machine continues to operate with the new spool.
The MATRIX CUBE system may control up to 10 positions (10 elastic yarns).
The creels consist of stackable modules.
Each module controls an individual position and it comprises:
- a DIAPER FEEDER device
- a feeding spool unit (up to 4) (A)
- a “spool change” sensor (B)
Typically, the creels can be composed of 3 or 4 stacked modules.
Examples: 2 creels, each one with 3 modules, to feed 6 elastic yarns
only 1 creel with 4 modules, to feed 4 elastic yarns
A
B

Introduction
MATRIX CUBE - iii -
In particular cases, up to 6 modules can be stacked, adopting particular precautions to ensure creel stability
and operator safety during cleaning, spool replacement, maintenance operations, etc .
For more information, please refer to Section 1.
Manual Objectives
This manual has been written to provide the users of MATRIX CUBE system with the essential information
required to:
•Correctly install and connect the various system components (creel items, SMART MATRIX CUBE
terminal, SM-DIN/DUOLOOP control Board, DIAPER FEEDER devices, TS55 sensors, etc.)
•Configure the system according to the application needs and setup the various operation
parameters.
•Detect and interpret the error signaling and system efficiency data
•Use the diagnostics maintenance and utility functions offered by the system (system component
test, firmware upgrading, etc.).
How to Use this Manual
The manual is subdivided into 5 sections plus an appendix:
Section 1 – includes the connection diagrams and the electrical interface of the various system
components as well as the instructions for a correct assembly and loading of creels.
Section 2 – provides the operating instructions for a correct use of the SMART MATRIX CUBE terminal
as well as the parameter configuration/programming instructions
Section 3 – lists the possible error messages.
Section 4 – provides detailed information about the DIAPER FEEDER device.
Section 5 – provides the information needed for a correct preventive maintenance of the system.
Appendix A – provides an example of preliminary control procedure (Sign OFF) to be carried out at system
reception time.
Symbols Used
This symbol indicates a safety prescription that must be absolutely adopted to avoid possible
risks of injury.
This symbol is used to point-out notes, warnings and other important information.
In the SMART MATRIX CUBE terminal function descriptions, this symbol
indicates the function (e.g. IDENTIFY) within the menu item (SETUP).
SETUP →IDENTIFY

Introduction
MATRIX CUBE - iv -
Prescription for a Safe Use of the System
The parts of MATRIX CUBE system which may cause an exposure to the hazards listed on Harmonized
Standard EN ISO 14121-1:2007 Machinery Safety – Principle of Risk Assessment are the following:
- The electrical box on board of the creel, due to the presence of harmful voltages (380/480 VAC three-
phase)
- The DIAPER FEEDER devices due to the rotation of elastic yarn feeding motor
- The creel stability according to configuration (creel stacking possibility, frame mounted on wheel, etc.)
The protective measures to be adopted by the users are then the following:
The access to the inside of electrical box shall be allowed exclusively to skilled and
authorized maintenance staff.
During the system operation, the Plexiglas sliding protections of DIAPER FEEDER devices,
must be kept closed.
After any electrical maintenance work, make sure that the electrical box and the creel frame
are correctly connected to the protection earth system (PE clamp and stranded wires to
connect the various creel elements).
Whenever a creel cleaning or maintenance operation is to be carried out at a height
exceeding 2 meters, use exclusively a footboard, a self-stable ladder or a suitable lifting
device.
Never lean a ladder to the creel and never try to use the creel frame to reach the top side of
the creel itself. →Falling risk due to the movable creel, that leans on wheels
Prior to open the electrical box, always turn off the main switch or disconnect the power
cord
In case of creels composed of 5 or 6 stacked modules, the wheels must be replaced by
fixed supports anchored to ground or (as an alternative) 8 angle brackets must be fastened
to the 4 edges of the bedframe and to the ground (see example on picture A below).
Moreover, make sure that all the creel modules are tightly interconnected by means of the
stranded wires shown on the picture of Paragraph 1.3 “System power supply”.
The stranded wires must be applied at least on 2 opposed creel side, as shown on picture
B below
Picture A Picture B

Introduction
MATRIX CUBE - v -
Warranty and Manufacturer Liability
The creel Equipment and components supplied by BTSR are designed exclusively for diaper process
applications.
BTSR hereby expressly disclaims any liability in case of goods not used in compliance with their intended
use.
The users are fully responsible for the practical work.
They shall make sure that the equipment is used in compliance with the local law and regulation
prescriptions, in particular for what concerns the safety of employees and, more generically, for any and all
provisions relating to health, labor, safety and accident prevention.
Any claim shall be notified without delay, upon discovery of any defect.
In case, after carefully assessment, the claim is proven to be well-founded, BTSR shall, at its sole option,
either replace or repair the defective goods.
Other warranty terms
BTSR guarantees quality and reliability of the Equipment which has been designed and manufactured to
provide the best production performance.
Warranty does not include possible damages or indirect costs due to machinery stop, productivity decrease
or defective production caused by a non-correct operation of BTSR equipment/devices.
It is the responsibility of the customer to carry out periodical cleaning, device calibration/offset and overall
performance check aimed at keeping the equipment operation within the expected performance range.
Warranty does not apply in case of faults or damages caused by electrical connection of equipment/devices
to a supply voltage different from the specified voltage or by a sudden overvoltage / undervoltage
occurrence.
Warranty does not apply in case of flood, fire, electrostatic/inductive discharge as well as discharges caused
by lighting or other phenomena external to BTSR equipment.
Warranty does not include damages to operators or other equipment/devices connected to BTSR equipment.
The customer is fully responsible for correct use and maintenance of the equipment, according to the
instructions provided by this Operating Manual.
In addition, he shall keep in stock the recommended BTSR spare parts kit.

Introduction
MATRIX CUBE - vi -
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Table of Contents
MATRIX CUBE - vii -
Table of Contents
1 – Installation and Connections
1.1 Creel Assembly..........................................................................................................................................1
1.2 TS55 Sensor Assembly .............................................................................................................................2
1.3 System Power Supply ...............................................................................................................................3
1.4 Connection to MASTER CUBE Box ..........................................................................................................5
1.5 TS55 Sensor Connection ..........................................................................................................................5
1.6 SMART MATRIX CUBE Interface .............................................................................................................6
1.7 SM-DIN/DUOLOOP Interface....................................................................................................................8
1.8 DIAPER FEEDER Interface.......................................................................................................................10
1.9 Configuration of SM-DIN/DUOLOOP Board..............................................................................................13
1.10 Configuration of DIAPER FEEDER Devices ...........................................................................................15
1.11 Configuration of TS55 Sensors ...............................................................................................................15
1.12 Creel Loading ..........................................................................................................................................16
1.13 Creel Threading.......................................................................................................................................21
2 – Operating Instructions
2.1 SMART MATRIX CUBE Operation............................................................................................................27
2.2 Navigation throughout the Display Windows.............................................................................................28
2.3 Immediate Function Activation through the SMART MATRIX CUBE Buttons ..........................................33
2.4 Interpretation of Operating Screens ..........................................................................................................34
2.5 SMART MATRIX CUBE Menu Structure...................................................................................................35
Device Configuration and Numbering .......................................................................................................36
WEB-UP function ......................................................................................................................................39
BUS NODE function..................................................................................................................................40
CUBE TYPE function ................................................................................................................................41
Configuration of I/O Signals on SM-DIN and SMART MATRIX CUBE.....................................................42
Setting the motor rotation direction ..........................................................................................................43
DUO LOOP enabling/disabling .................................................................................................................44
FIELD BUS enabling/disabling..................................................................................................................45
Efficiency Calculation Mode ......................................................................................................................46
Keycode Setting ........................................................................................................................................47
Communication Test .................................................................................................................................49
Offset on TS55 and/or DIAPER FEEDER Devices...................................................................................50
Checking the I/O Signals of SMART MATRIX CUBE Terminal ................................................................52
SMDIN Software Upgrade.........................................................................................................................53
SMDIN information....................................................................................................................................54
DIAPER FEEDER upgrade .......................................................................................................................55
MATRIX CUBE LCD Display Adjustment .................................................................................................56
Information about MATRIX CUBE ............................................................................................................57
Style Programming....................................................................................................................................58
Style Loading ............................................................................................................................................65
Graphics Display .......................................................................................................................................67
Efficiency Data ..........................................................................................................................................68
Alarm Counter Display ..............................................................................................................................69
Choice of Visualization Mode....................................................................................................................70

Table of Contents
MATRIX CUBE - viii -
3 – Error Messages
SMART MATRIX CUBE Error Messages ........................................................................................................71
4 – DIAPER FEEDER Device
Elastic Yarn Feeding Device: DIAPER FEEDER ............................................................................................73
5 – Maintenance of MATRIX CUBE System
5.1 Preventive ordinary maintenance..............................................................................................................97
5.1.1 Periodic cleaning of the various components...............................................................................97
5.1.2 Calibration of tension sensors ......................................................................................................98
5.1.3 Coil separator adjustment ........................................................................................................ 100
Annex A
A.1. Sign Off procedure at system reception............................................................................................... 101

Installation and
Connections
1

Installation and Connections
MATRIX CUBE - 1 -
1.1 Creel Assembly
The following figure shows the details for a correct assembly of the creel modules.
No. Description Code
1 MATRIX CUBE creel module MCC/MCC/001
2 Separating panel ST.4.048
3 Centering pin ST.2.374
4 Bed frame with casters MCC/BCS/001
5 MASTER CUBE electrical box MCC/MCB/001
6 SMART MATRIX CUBE terminal MCC/SMC/001
7 MATRIX CUBE wheel assembly MCC/MCW7001
1
2
2
2
2
1
1
3
4
5
6
7
3
A
B
C
A
B
C

Installation and Connections
MATRIX CUBE - 2 -
1.2 TS55 Sensor Assembly
The TS55 sensor assembly must be installed as close as possible to the elastic yarn application point.
A = Sensor cable junction board (see paragraph 1.4 – TS55 Sensor Connection)
B = TS55 Sensors
A
A
B
B

Installation and Connections
MATRIX CUBE - 3 -
1.3 System Power Supply
The electrical equipment of MATRIX CUBE system is enclosed in a box (A) located on the low rear side of
the creel and it complies with the prescriptions of the Harmonized Standard EN 60204-1:2006.
The electrical box is fitted with an ON/OFF switch with “Door Locking” feature, and it provides a protection
degree IP54.
The electrical supply, provided by a three phase line (380/480V
± 15%) + ground is connected (through
suitable protection fuses) to the switching power supply unit (W1) which delivers a 24 VDC output voltage
used to power all system components (SM-DIN/DUOLOOP, (W2), DIAPER FEEDER devices, etc.).
The following figures show the electrical box location, the correct ground connection of creel elements, the
topographic view of the electrical box, as well as the interconnection diagram of all system components.
The TS55 sensor connectors and DIAPER FEEDER connectors feature a protection degree IP67.
Location of electrical box Ground connection of creel elements
Make sure that the creel metallic frame and the electrical box itself are correctly connected to ground
(PE clamp inside the electrical box and stranded wires to connect the various creel elements).
A
Stranded wire for
ground connection

Installation and Connections
MATRIX CUBE - 4 -
Topographic View of MASTER CUBE Box
MASTER CUBE Interconnection Diagram
SERIAL
INTERFACE
MACHINE
INTERFACE
THREE PHASE
POWER SUPPLY
+ GROUND
PROTECTION
FUSES
MAIN SWITCH
START/STOP
RELAY

Installation and Connections
MATRIX CUBE - 5 -
1.4 TS55 Sensor Connection
1.5 Connection to MASTER CUBE Box
Connection of
MATRIX CUBE
creel modules
TS55 connection (A)
Start / Stop / Alarm,
etc signal cable
380/480 Vac power
cable
SMART MATRIX
CUBE connection
From MASTER CUBE Box (A)
TS55 Sensor
TS55
Sensor
PIN COLOR SIGNAL
1 Brown Vdc
2 White Rx Tx +
3 Yellow GND+sch
4 Green Rx Tx -
TS55 Sensor
TS55 CONNECTOR
FRONT VIEW

Installation and Connections
MATRIX CUBE - 6 -
1.5.1 Connection Cable Pat to Electrical Box
Lead the DIAPER FEEDER interface cable (shown with green lines) and of SMART MATRIX CUBE terminal
(shown with blue line) inside the creel module cable ducts, until reaching the electrical box and connect them
to the corresponding connectors, as shown on the following figure.