btsr SMART CLEARER User manual

SMART CLEARER & ISSC.
YARN CONTROL SYSTEM
Operating Manual
Rev. 3.0 – July 2003 ENGLISH

SMART CLEARER – Rev. 3.0 – July 2003
Copyright 2003 - BTSR – All rights reserved.
This manual is intended for the users of the SMART CLEARER system. It is suggested to carefully read
the instructions described 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.
BTSR® is a registered trademark “Best Technology Study & Research” of BTSR International S.p.A.
Lycra® is a trademark byDuPont

Table of contents
SMART CLEARER - i -
TABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTS
INTRODUCTION
How to use this manual.............................................................................................................................................. I.1
Symbols used .............................................................................................................................................................. I.1
Chapter 1 - OVERVIEW
System components ....................................................................................................................................................1.1
System’s Operation Principles ..................................................................................................................................1.1
Special Features of SMART CLEARER system .....................................................................................................1.1
General Features of SMART systems ......................................................................................................................1.2
Chapter 2 –TECHNICAL DATA AND INSTALLATION
Technical Features .....................................................................................................................................................2.1
Installation ..................................................................................................................................................................2.1
Interface Connectors on SMART CLEARER.....................................................................................................2.2
Connection Cables and Power Supply Devices....................................................................................................2.3
Example of Generic Application Connection.......................................................................................................2.4
Chapter 3 – OPERATION
SMART CLEARER Terminal Features ..................................................................................................................3.1
ISSC.. Sensor Features ..............................................................................................................................................3.4
Function of the ISSC.. Sensors..................................................................................................................................3.4
Interface specification ...............................................................................................................................................3.5
Interpretation of the signalling lights located on the sensors .................................................................................3.6
Parameters that affect the sensor detection features ..............................................................................................3.7
Preliminary operations for using the SMART CLEARER terminal...................................................................3.11
Operating Sequences .............................................................................................................................................3.12
Machine Start Procedure.........................................................................................................................................3.13
Preliminary Instructions for the Correct Use of ISSC.. Sensors......................................................................3.13
Restart after an Alarm Condition on a Single Position ....................................................................................3.13
Enabling the SETUP Menu Functions (CONFIG)................................................................................................3.14
Enabling the SETUP Menu Functions (NEW, MODIFY, ERASE).....................................................................3.15
Enabling the WORK Menu Function.....................................................................................................................3.16
Enabling the READ Menu Function ......................................................................................................................3.16
CONTROL Function ..............................................................................................................................3.17
DEVICE Parameters setting for Initial installation ........................................................................3.18
DCNTR Configuration of Sensor delay time before entering the Control status........................3.19
lk-ULK Enabling/Disabling the Touch Light button operation...................................................3.20
MO-CTR Configuring the system operation in either MONITOR mode
or CONTROL mode ..........................................................................................................3.21
EN-NCO Configuring the level of ENABLE signal as Normally Closed or Normally Open.......3.23
ST-NCO Configuring the level of STOP signal as Normally Closed or Normally Open.............3.24

Table of contents
- ii - SMART CLEARER
ST-CP Stop signal Configuration as Continuous or Pulse Signal ..............................................3.24
CAL-AM Configuration of Sensor Automatic/Manual Calibration...............................................3.26
ABS/REL Configuring the Sensor Operating Mode.........................................................................3.27
KEYCODE Password to access SETUP and WORK menus ..............................................................3.28
CLOCK Reading/setting the printer Clock-Calendar (rtc)...........................................................3.29
SENSOR TEST Sensors Test ........................................................................................................................3.30
COM TEST Testing the Efficiency Rate over the Communications Line between the
SMART CLEARER Terminal and Sensors ....................................................................3.31
VERS-UPG Software Version Test and Update...................................................................................3.32
NEW Creating a New Article ......................................................................................................3.33
SPEED - Creating a New Article - Machine collection speed ........................................3.35
NEP - Creating a New Article - Characteristics of the Nep defect ................................3.36
SLUB (-)..............................................................................................................................3.37
SLUB (+) Creating a New Article - Characteristics of the Slub/Tangle defect............3.38
YARN(-) - Creating a New Article - Characteristics of the Missing Ply defect............3.39
YARN(+) - Creating a New Article - Characteristics of the Added Ply defect............3.40
NOYARN - Creating a New Article - Characteristics of the Yarn Missing Defect......3.41
MODIFY Modifying an existing Article............................................................................................3.42
ERASE Erasing an existing Article ................................................................................................3.42
SCAN Displaying Articles currently loaded in the sensors........................................................3.43
LOAD Loading an article in sensor memory...............................................................................3.44
UNLOAD Unloading articles from the sensor memory....................................................................3.45
READ Real time reading of the Title detected by Sensor XXX .................................................3.46
ZEROSET Manual Activation of ZEROSET Procedure...................................................................3.46
PRINT REPORT......................................................................................................................................................3.47
Chapter 4 – TROUBLESHOOTING AND MAINTENANCE
Troubleshooting..........................................................................................................................................................4.1
Ordinary Maintenance ..............................................................................................................................................4.2
Repairs ........................................................................................................................................................................4.2
Updating the Software Version on SMART Terminals ..........................................................................................4.3
Product Summary Tables..........................................................................................................................................4.4
Appendix A - QUICK REFERENCE ............................................................................................................................ A.1
Appendix B - INSTALLATION EXAMPLE ................................................................................................................. B.1

Introduction
SMART CLEARER - I.1 -
INTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
Congratulations for choosing a BTSR product.
With our SMART CLEARER yarn control system, you got an innovative, unique
solution, able to offer you multiple advantages concerning quality control of your
production. SMART CLEARER has been designed for application on textile
machines dedicated to the preparation of yarn (cone winder, doubling, twisting
frame, interlacing machines, etc.), which during the entire productive cycle utilise
a specified number of yarns on several sections, in continuous mode. 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
ISSC.. series BTSR sensors is to detect these technical failures.
How to use this manual
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 include a connection diagram showing the
use of the SMART CLEARER system and ISSC.. sensors in a general purpose
application environment.
Symbols used
Highlights notes, warnings and subjects to which the attention of the reader
should be directed.
Indicates a particularly sensitive situation which could have an effect
on the safety or proper operation of the system.
ISSC.. The ISSC.. BTSR sensor family includes some variants indicated by the
letters following the ISSC term. (e.g. ISSC-A). Within this manual we will
always use the generic term ISSC..
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 function itself.

Introduction
- I.2 - SMART CLEARER
Within the Appendix A “Quick Reference” the push-buttons of SMART control
panel are shown as follows:
Meaning of the Capital/Small Letters on Display
Within the functions that provide two programmable alternative options, i.e.:
Normally Open or Normally Closed Contact
Enabled/Disabled Condition
Pulse/Continuous Signalling, etc.
The letters shown on display as capital letters indicate 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
ST-Cp Cp = continous signal
ST-cP
Stop output programmable as
Continous Signal (C) or Pulse Signal
(P) cP = pulse signal
LK-ulk LK = “touch light” disabled
lk-UKL
Enabling (ULK) or disabling (LK) the
“touch light” button. ULK = “touch light” enabled
EN-NCo NCo = normally closed
EN-NcO
Enable signal programmable as
Normally Closed (NC) or Normally
Open (NO) contact NcO = normally open
MO-ctr MO = Monitor
mo-CTR
Monitor (MO) or Control (CTR)
CTR = Control
CAL-aM aM = Manual
CAL-Am
Manual (M) or Automatic (A)
calibration mode Am = Automatic
Alternative items:
Within the description of configuration/programming procedures the alternative
screen shots are shown with this bracket symbol.

Overview
SMART CLEARER - 1.1 -
1
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1 -
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- OVERVIEW
OVERVIEWOVERVIEW
OVERVIEW
System components
The SMART CLEARER system consists of a control/programming terminal and
a variable number of ISSC.. type sensors (up to 200) connected to the terminal
using specific interface cables.
System’s Operation Principles
The sensors’ detection features: Nep (NEP), yarn reduction (SLUB-), Yarn
Slub/Tangle (SLUB-), Missing ply (YARN -), Added ply (YARN +), Yarn broken
(NOYARN), Yarn running speed (SPEED), Control Activation delay (D-CONTR)
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 quality control requirements, as
well as the function of displaying either globally or selectively the counters that
record the different types of defects by the sensors.
Special Features of SMART CLEARER system
The SMART CLEARER system has a set of unique features which make it a true
microcomputer dedicated to the yarn quality control.
SMART CLEARER is a fully parametric system; this means that for each type of
defect the use can freely define the desired parametric values. When these values
are exceeded, the system signals a fault condition.
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 the
sensor(s) will have to detect.
The main advantages of this solution can be summarised as follows:
Absolute flexibility:
thanks to the possibility of quickly changing the sensors’ program, according
to the article to be processed.
Maximum simplicity:
concerning the installation as well as system programming and administration.
Maximum accuracy:
the possibility of programming the detection capability of the sensors
according to the type of yarn to be processed guarantees a perfect symbiosis
between sensor and yarn.
Furthermore, the possibility to print a report containing the summary of failures
detected by the sensors (Production Report) offers a valuable support for
keeping and improving the quality level of production.

Overview
- 1.2 - SMART CLEARER
General Features of SMART systems
ISS.. Sensors (Image Smart Scanning…) (BTSR Patents)
The ISS.. sensors are connected to the SMART control terminal using just one
multi-connector cable, or specific single-connector cables.
Automatic numbering (BTSR Patents)
The identification of sensors is performed by the system by means of an
automatic numbering procedure.
Programmable Functions
The system allows programming and saving all the quality control
characteristics associated with various articles.
Multi-sensor System
The system allows connecting up to 200 yarn quality control sensors of the
ISSC.. series.
Easy Monitoring
Besides the information shown on graphical display of SMART CLEARER,
each ISSC.. sensor has a red LED that, when flashing, indicates the type of
fault detected.
Sensor Diagnostics
Each ISSC.. sensor signals its operational status by means of two LEDs.

Technical data and installation
SMART CLEARER - 2.1 -
2
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2 –
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– TECHNICAL DATA AND INSTALLATION
TECHNICAL DATA AND INSTALLATIONTECHNICAL DATA AND INSTALLATION
TECHNICAL DATA AND INSTALLATION
Technical Features
SMART CLEARER Terminal
Power supply voltage 24 Vdc ± 10%
Maximum Absorption 100 mA
Dimensions 135 x 95 x 40 mm
Temperature range 10° - 60 °C
LCD graphic Display 80 x 40 mm
Integrated Touch-pad 5 membrane buttons with integrated red LED
Protection 2 fuses 5 x 20 – 1A
ISSC.. Sensors
Power supply voltage 12 .. 24 Vdc ± 20%
Absorption 30 mA (max 50 mA)
ENABLE input logic Programmable (NO - NC)
STOP output NPN open collector
STOP output logic Programmable (NO - NC) (cont. – pulse, 2sec.)
"Auto-calibration" function Auto-calibration of sensor
STOP output protection Protection against over-voltages and short-circuits
STOP output max current 200 mA continuous; 500 mA peak
Activation delay Programmable from 1 to 250 sec
Signaling With integrated LED
Dimensions 15 x 15 x 36,5
Temperature range 10° - 50 °C
Installation
The installation of the SMART CLEARER system depends on the type of
application and on the number of sensors to be connected. When the number of
sensors is limited, it is possible to connect them directly to the SMART terminal,
otherwise it is necessary to use a stabilized power supply PSU 10A. This is
capable of supplying up to 8 independent backbone lines to which it is possible to
connect several sensor chains (up to a maximum of 100 sensors). The number of
sensors may be extended to 200, using two PSU 10A power supply.

Technical data and installation
- 2.2 - SMART CLEARER
Interface Connectors on SMART CLEARER
Concerning all electrical systems, it is a recommended rule to ensure that the ground cable
(GND) is connected to the sensor support.