btsr SMART 3000TW User manual

SMART 3000TW & IS3..
YARN CONTROL SYSTEM
Operating Manual
ENGLISH

Copyright 2001 - BTSR - All rights reserved.
This manual is intended for the users of the SMART 3000TW 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 3000TW - i -
TABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTS
INTRODUCTION
How to use this Manual..............................................................................................................................................I.1
Symbols used ...............................................................................................................................................................I.2
Chapter 1 - OVERVIEW
System Components................................................................................................................................................... 1.1
System’s Operating Principles.................................................................................................................................. 1.1
Special Features of SMART 3000TW System......................................................................................................... 1.1
General Features of SMART BTSR systems........................................................................................................... 1.2
Chapter 2 – TECHNICAL DATA AND INSTALLATION
Technical Features..................................................................................................................................................... 2.1
Installation.................................................................................................................................................................. 2.1
SMART 200 INT-TW 485 Sensor Interface Boards (BOARD).......................................................................... 2.2
Connection Example for General Purpose Application ....................................................................................... 2.3
Connecting cables and Power supply devices...................................................................................................... 2.4
External RESET Connection (RST - EXT)........................................................................................................... 2.5
Chapter 3 – OPERATING
SMART 3000TW Terminal Features....................................................................................................................... 3.1
Meaning of Red Leds inside the SMART 3000TW Terminal’s ............................................................................. 3.2
SMART 200 INT-TW 485 Interface Board Features ............................................................................................. 3.4
IS3.. Sensors Features................................................................................................................................................ 3.5
Types of IS3.. sensors for SMART 3000TW............................................................................................................ 3.5
Function of the IS3.. Sensors..................................................................................................................................... 3.5
Installation of the IS3.. Sensors ............................................................................................................................ 3.6
Interpretation of the signalling lights located on the sensors................................................................................. 3.6
Settings that affect the sensor detection features .................................................................................................... 3.7
Programming examples for F_START/F_STOP and relevant sensor delays ......................................................... 3.8
Interface Board Hardware Coding .......................................................................................................................... 3.9
Sensor Identification Modes ................................................................................................................................... 3.10
Physical Identification ......................................................................................................................................... 3.10
Logical Identification........................................................................................................................................... 3.10
Priority Example...................................................................................................................................................... 3.12
Example of creel section physical wiring (Side) with 100 sensors (5 rows x 20 columns).................................. 3.14
Preliminary operations for using the SMART 3000TW terminal....................................................................... 3.15
Operating Sequences ............................................................................................................................................... 3.17
Learning Cycle (LEARN) ....................................................................................................................................... 3.18
Display Messages during the Control Phase.......................................................................................................... 3.19
Summary Diagram of SMART 3000TW Programming/Configuration Menu .................................................. 3.21
P1 Programming Level............................................................................................................................................ 3.22
SYNC: Proxy Pulse Divisor ................................................................................................................................ 3.22

Table of contents
- ii - SMART 3000TW
RESET: Characteristics of Reset signal.............................................................................................................3.23
D_LEARN: Delay time before starting the Learn and Control phases...........................................................3.23
NUMBER DEVICES: Numbering and Organisation of IS3.. Devices Connected to the System .................3.24
NUMBER BARS: Numbering of Bars (Optional).............................................................................................3.25
Individual sensor replacement example .............................................................................................................3.26
KEY_COD: Password to Access the Programming Menus .............................................................................3.27
K_LEARN: Password to Access the Learning Function ..................................................................................3.27
P2 Programming Level ............................................................................................................................................3.28
DEFINE SIDE: Defining the Number of Sections (Side)..................................................................................3.28
PRIOR xxx: Defining the Priority for Logical Sensor Identification ..............................................................3.28
EXAMPLE: System with 4 sections (Sides A, B, C, D) with Column Priority
(10 Columns and 8 Sensors for each column) ....................................................................................................3.30
P3 Programming Level ............................................................................................................................................3.33
BROKE G: Error Tolerance for Broken Yarn (global)....................................................................................3.33
UNCUT G: Error Tolerance for Uncut Yarn (global) ......................................................................................3.34
P4 Programming Level ............................................................................................................................................3.35
SENS G: Sensitivity (global)................................................................................................................................3.35
DELAY G: Reaction Time (global).....................................................................................................................3.36
TEST Functions........................................................................................................................................................3.37
TEST_SE: Sensors Test.......................................................................................................................................3.37
COM_B01: Testing the Efficiency Rate over the Communications Line between the
SMART 3000TW terminal and all sensors connected to the various Boards.................................................3.37
TEST_BA: Bars Test ...........................................................................................................................................3.38
BAR_B01: Testing the Efficiency Rate over the Communications Line between the
SMART 3000TW terminal and all Sensors connected to the various Boards ................................................3.39
PX Programming Level ...........................................................................................................................................3.40
F_START: START Frequency ...........................................................................................................................3.40
F_STOP: STOP Frequency.................................................................................................................................3.41
H_SPEED: Enabling/Disabling the Sensors reading Synchronism with PRX signal.....................................3.41
Reading/Resetting the BROKE and UNCUT Counters........................................................................................3.42
Chapter 4 – TROUBLESHOOTING AND MAINTENANCE
Troubleshooting .........................................................................................................................................................4.1
Initial Board Configuration ......................................................................................................................................4.3
Temporary Sensor Disabling.....................................................................................................................................4.4
Machine Test ..............................................................................................................................................................4.5
Ordinary Maintenance ..............................................................................................................................................4.5
Repairs ........................................................................................................................................................................4.5
Updating the Software Version on SMART Terminals ..........................................................................................4.6
Updating the Software Versione on SMART 200 INT-TW 485 Board .................................................................4.7
Parameters Summary Table .....................................................................................................................................4.8
Appendix A – Quick Reference...................................................................................................................................... A.1

Introduction
SMART 3000TW - I.1 -
INTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
Congratulations for choosing a BTSR product.
With our SMART 3000TW yarn control system, you get an innovative, unique
solution, able to offer you multiple advantages concerning quality control of your
production.
SMART 3000TW has been designed for applications on large warping machines
that use in continuous mode a large number of yarns (up to 1920) during the entire
working cycle.
The system is able to self-learn the yarn sequence picked-up by the textile machine
during a sample cycle and to indicate any type of error detected during the
subsequent production cycles (broken or missing yarns, uncut or wrong sliding
yarns, wrong threading or wrong picking-up errors, etc.).
This allows to eliminate up to 80% of waste and seconds quality that would
normally occur during production; in addition it dramatically reduces needle
breakages and machine stops, thus allowing a rapid pay-back of your investment.
SMART 3000TW, combined with IS3.. yarn smart control sensors, represents a
full and effective machine control system.
How to use this Manual
This Operating Manual is divided into 4 Chapters and 1 Appendix.
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 solve
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.

Introduction
- I.2 - SMART 3000TW
Symbols used
!Highlights notes, warnings and items 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 please refer to paragraph “Types of IS3.. sensors”.
In the operating sequences, this symbol indicates that, to activate the desired
function, you must press and hold for 3 seconds the button.
Within the Appendix A “Quick Reference” the push-buttons of SMART control
panel are shown as follows:
=Button
=Button
=Button
=Button
=Button
Alternative Items
Within the description of configuration/programming procedures the possible
alternative screen shots are shown with this bracket symbol.

Overview
SMART 3000TW - 1.1 -
1 - OVERVIEW
1 - OVERVIEW1 - OVERVIEW
1 - OVERVIEW
System Components
The SMART 3000TW system includes a control/programming terminal and a
variable number of IS3.. type sensors connected to the terminal by means of 1 to 8
SMART 200 INT-TW 485 Interface Boards.
Each Interface Board can handle up to 240 IS3.. Sensors. The maximum number of
sensors the system may handle is therefore (8 x 240) = 1920.
System’s Operating Principles
The sensors’ detection features (Start Frequency !F_START, Stop Frequency !
F_STOP, Sensitivity !SENS, Reaction Time !DELAY)can be programmed
according to the type of yarn being processed.
These features must be programmed on each sensor and can be changed according
to the application.
The terminal has in fact the function of programming and, changing (if needed) the
sensors’ features, according to the production requirements.
The main task of SMART 3000TW is to provide a continuous production
monitoring and an automatic computation of the yarns used (CONTROL function),
by comparing each production cycle with a sample cycle previously self-learnt
(LEARN function) under “ideal” conditions, thus detecting possible deviations with
respect to the above mentioned sample cycle and stopping the textile machine
when the detected errors exceed the set tolerance.
Special Features of SMART 3000TW System
The SMART 3000TW 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.
During the production monitoring phase the system stores all the technical faults
each sensor founds, 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 sensors’ program, according to
the application.
!Maximum simplicity:
concerning the installation as well as programming and administration of the
system.
!Maximum precision:
the possibility of programming the technical features of sensors according to the
type of yarn to be processed, guarantees a perfect symbiosis between sensor and
yarn.

Overview
- 1.2 - SMART 3000TW
General Features of SMART BTSR systems
!Self Learning Technique (BTSR Patents)
The system automatically learns the sequence of yarns used by the textile
machine.
!IS3.. Sensors (Image Smart Scanning Sensor) (BTSR Patents)
The sensors of the IS3.. series are connected to the SMART control terminal by
means of simple multi-connector cables, thus making quite easy the system
installation task.
!Automatically assigned numbers (BTSR Patents)
The identification of sensors is performed by the system by means of an
automatic numbering procedure resulting in a simple and fast system
configuration.
!Programmable Functions
The systems allows programming the sensor detection features (Sensor Image
Variation Frequency, Sensitivity, Reaction Time, Tolerance, etc.).
!Production Data
The system records, during production, the machine stops detected by each
sensor and by error type.
!Easy Monitoring
Besides the information provided on the graphical display of SMART 3000TW
terminal, each IS3.. series sensor has a red LED that, when flashing, indicates
the location of the yarn technical fault, making the operator intervention easier.
!Sensor Diagnostic
Each IS3.. sensor signals the operational status by means of two LEDs.
(For further information please refer to “Interpretation of the signalling lights
located in the sensors").

Technical Data and Installation
SMART 3000TW - 2.1 -
2 – TECHNICAL DATA AND INSTALLATION
2 – TECHNICAL DATA AND INSTALLATION2 – TECHNICAL DATA AND INSTALLATION
2 – TECHNICAL DATA AND INSTALLATION
Technical Features
SMART 3000TW Terminal
Power supply voltage 15 Vac or 24 Vdc ± 10%
Maximum Absorption 150 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
IS3.. Sensors
Power supply voltage 12 .. 24 Vdc ± 20%
Absorption Typical 12.5 mA (max 15 mA)
Reaction Delay Programmable from 5 to 1000 msec
Sensitivity Programmable (10 levels)
Signalling With integrated LEDs (red – green)
Dimensions 15 x 15 x 36,5 (narrow) - 25 x 15 x 36,5 (wide)
Temperature range 0° - 60 °C
SMART 200 INT-TW 485 Boards
Power supply voltage 15 Vac or 24 Vdc ± 10%
Maximum Absorption 150 mA
Dimensions 140 x 110 x 30 mm
Temperature range 0° - 60 °C
Signalling LEDs 8 [STOP/ALARM – NEXT CYCLE – COM. PORT
RS485 – CONTROL – LEARN – IDENTIFY –
SYNCRONISM – TIME OUT]
Protection 1 fuse 5 x 20 – 1A
PSU 10A Power Supply
Power supply voltage 24 Vac/dc ± 10%
Number of output channels 8 (4+4)
Output voltage 24 Vdc ± 5%
Max output current 10A peak / 6A continuous
Dimensions 115 x 135 x 55 mm
Temperature range 0° - 60°C
Signalling 1 power on LED for each channel
Protection 1 fuse 5 x 20 – 1A
Installation
The installation of the SMART 3000TW system depends on the type of target
application, on the number of SMART 200 INT-TW 485 Interface Board, on the
number of machine sections (Side) and on the type of priority used (i.e. Rows /
Columns / Bars Priority).
Depending on such characteristics, it will be necessary to use a given number of
PSU 10A Power Supplies, each one capable of supplying up to 8 independent
backbone lines to which it is possible to connect the same amount of sensor chains
(up to 60 sensors for each line).

Technical Data and Installation
- 2.2 - SMART 3000TW
SMART 200 INT-TW 485 Sensor Interface Boards
As described on chapter 1, the SMART 3000TW can manage up to 1920 IS3.. sensors connected through
Interface Boards (Board 1 ÷ 8). The Boards communicate with SMART 3000TW Terminal using a RS485
Serial Line.
From the physical point of view, the Boards may be installed tens of metres far from the SMART Terminal
and they may be included within a special box (Bx5040FSST). Each box is equipped with a safety switch
and cooling fans and it may host up to 4 boards.