btsr SMART WARP User manual

SMART WARP & IS3F-485
YARN CONTROL SYSTEM
Operating Manual
Rev. 1.0 – January 2006 ENGLISH

SMART KNIT – Rev. 1.0 – January 2006
Copyright 2006 - BTSR - All rights reserved.
This manual is intended for the users of SMART WARP yarn control systems. You are kindly
recommended to carefully read the instructions reported in this manual before making the connections 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 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 of “Best Technology Study & Research” of BTSR International S.p.A.
Lycra® is a registered trademark of DuPont

Table of Contents
SMART WARP - 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 Operation Principle....................................................................................................................................1.1
Special Features of SMART WARP System............................................................................................................1.1
General Features of SMART BTSR systems ...........................................................................................................1.2
Chapter 2 – TECHNICAL DATA AND INSTALLATION
Technical Features .....................................................................................................................................................2.1
SM-DIN - Sensor Connection....................................................................................................................................2.2
SM-DIN Modules Interconnection............................................................................................................................2.3
Electrical Interface.....................................................................................................................................................2.4
Chapter 3 – OPERATION
SMART WARP Terminal Features .........................................................................................................................3.1
SM-DIN Module Configuration................................................................................................................................3.4
Operating Signaling/Anomalies .................................................................................................................................3.5
Signaling LEDS...........................................................................................................................................................3.5
IS3 Sensors Features ..................................................................................................................................................3.6
Optical interface of IS3 sensors.................................................................................................................................3.6
Interpretation of the sensor signaling lights ............................................................................................................3.6
Settings that affect the sensor detection features.....................................................................................................3.7
Programming examples for F_START/F_STOP and relevant sensor delays.......................................................3.8
Automatic adaptation of control parameters to the machine speed ......................................................................3.9
Preliminary operations for using the SMART WARP Terminal ........................................................................3.10
Operating Sequences................................................................................................................................................3.11
Functions available from SETUP menu (CONFIG) .............................................................................................3.12
Functions available from SETUP menu (P_SLOW / P_FAST) ...........................................................................3.12
A1 - BOARDS - Number of Connected SM-DIN Modules (Boards) ...................................................................3.13
A2 - MAP - Sensors Distribution Map .................................................................................................................3.13
A3 - DEVICE - Sensors Numbering .......................................................................................................................3.14
A4 - INPUT - Configuration of Input Signals........................................................................................................3.15
A5 - OUTPUT - Configuration of Output Signals.................................................................................................3.15
A6 - KEYCOD - Access Password to Programming Menus (KSETUP) .............................................................3.16
A6 - KEYCOD - Access Password to LEARN function (KLEARN) ...................................................................3.16
A7 - TEST-COM - Test of Communication Line Between SMART WARP Terminal and SM-DIN Modules3.17

Table of Contents
- ii - SMART WARP
A7 - TEST-SENSOR - Test of Individual Sensors ................................................................................................ 3.18
B1 - P_SLOW - Configuration of Detection Parameters with Slow Ext Input Active....................................... 3.19
B2 - P_FAST - Configuration of Detection Parameters with Fast Ext Input Active ......................................... 3.20
Learning Cycle (LEARN) ........................................................................................................................................ 3.21
Display Signalings during the Control Process ..................................................................................................... 3.22
Chapter 4 – TROUBLESHOOTING AND MAINTENANCE
Troubleshooting ......................................................................................................................................................... 4.1
Machine Test .............................................................................................................................................................. 4.4
Ordinary Maintenance .............................................................................................................................................. 4.4
Repairs........................................................................................................................................................................ 4.4
Updating the Software Version on SMART Terminals.......................................................................................... 4.5

Introduction
SMART WARP - I.1 -
INTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
Congratulations for choosing a BTSR product.
With our SMART WARP yarn control system, you got an innovative, unique
solution, which offers you multiple advantages concerning the quality control of
your production.
SMART WARP has been designed for applications on large warping machines
that use in continuous mode a large number of yarns (up to 2000) during the entire
working cycle.
The system is capable of self-learning the number of yarns used by the textile
machine during a sample cycle, indicating any type of errors detected during the
subsequent production cycles (broken or missing yarns, uncut or not correctly used
yarns, threading or pick-up errors, etc.).
SMART WARP, combined with yarn control sensors IS3F-485, represents a
complete and effective machine control system.
How to use this manual
This Operation Manual is divided into 4 Chapters
Chapter 1 – Overview describes the main features, components and the operation
principle of the system.
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.
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.
IS3 Within this manual, the IS3F-485 sensors used on SMART WARP application,
will be generically indicated as IS3.
SM-DIN Within this manual, the SM-DIN/WARP interface modules, will be generically
indicated as SM-DIN.

Introduction
- I.2 - SMART WARP
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Overview
SMART WARP - 1.1 -
1
11
1 -
--
- OVERVIEW
OVERVIEWOVERVIEW
OVERVIEW
System Components
The SMART WARP system includes a control/programming terminal and a
variable number of IS3 sensors connected to the terminal by means of interface
modules (up to 20).
Each interface module (SM-DIN)can manage up to 100 IS3 sensors.
The maximum theoretical number of sensors connectable to the system is then
(20 x 100) = 2000.
System’s Operation Principle
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 article which is being processed.
The terminal has in fact the function of programming and, if necessary, changing
the sensors’ features, according to the production requirements.
The main task of SMART WARP is to provide a continuous production
monitoring as well as an automatic count of the yarns used (CONTROL function)
comparing each individual production cycle with the sample cycle previously self-
learned (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 WARP System
The SMART WARP 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 of quickly changing the sensors’ program, 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 sensors according to
the type of yarn to be processed, guarantees a perfect symbiosis between sensor
and yarn.
! Automatic adaptation of parameters to the machine speed:
the possibility of configuring 2 different sets of parameters, associated with two
different machine speeds (P_SLOW and P_FAST)allows you to control in the
best possible way the yarn running status, both during the ramp stages
(P_SLOW)and during the normal rate stage (P_FAST).

Overview
- 1.2 - SMART WARP
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 are connected to the SM-DIN modules in “daisy-chain” mode, thus
making extremely easy the wiring operation.
! 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, either in global or selective way, the sensor
detection features (Sensor Image Variation Frequency, Sensitivity, Reaction
Time, Tolerance, etc.).
! Easy Monitoring and Fault Detection
Besides the information provided on the graphical display of the SMART
WARP terminal, each IS3 sensor has a red LED that, when flashing, indicates
the location of the technical fault of the yarn, making the operator work easier.
! Sensor Diagnostic
Each IS3 sensor signals the operational status by means of two LEDs.
(For further information please refer to “Interpretation of the sensor signaling
lights").

Technical Data and Installation
SMART WARP - 2.1 -
2
22
2 –
––
– TECHNICAL DATA AND INSTALLATION
TECHNICAL DATA AND INSTALLATIONTECHNICAL DATA AND INSTALLATION
TECHNICAL DATA AND INSTALLATION
Technical Features
SMART WARP Terminal
Power supply voltage 15 Vac or 24 Vdc ± 10%
Maximum absorption 150 mA
Dimensions 135 x 95 x 40 mm
Operating Temperature range 0° - 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
IS3 Sensors
Power supply voltage 24 Vdc ± 20%
Absorption Typical 12,5 mA (max 20 mA)
Reaction Delay Programmable from 5 to 1000 msec
Sensitivity Programmable (10 levels)
Signaling With integrated LEDs (red – green)
Sensor identification Through “Touch Light”
Dimensions 25 x 35 x 10 mm
Temperature range 0° - 60 °C
SM-DIN/WARP Modules
Power supply voltage 15 .. 24 Vac or 24 Vdc ± 10%
Absorption Typical 0.2 A - Max 6 A
2 STOP Outputs (Stop1 - Stop2) NO/NC relay contacts: 0-24 Vac
3 Inputs (Slow Ext - Fast Ext -
Reset Ext)
NO/NC relay contacts: (0-24 Vdc)
Integrated Touch-pad 3 push buttons
Signaling 3 digit display + 8 signaling LEDs
Dimensions 138 x 125 x 35 mm
Operating Temperature range 10° - 70 °C
Mounting type Inside the cabinet: on DIN rail, or fastening
screws.
On panel: with cover plates
Protection Self-restoring fuse, 5A
Power Supply
Power supply voltage (*) 15..24 Vac ± 10% (by transformer)
(*) The supply voltage to SMART WARP terminal is provided by the connection
cable between terminal and SM-DIN interface module.

Technical Data and Installation
- 2.2 - SMART WARP
SM-DIN - Sensor Connection
As described on chapter 1, the SMART WARP system can manage up to 2000
IS3 sensors, connected through SM-DIN interface modules (up to 20). Each
module can manage up to 100 sensors distributed along 4 backbone lines.
The SM-DIN modules communicate with SMART WARP terminal via RS485 serial
lines.
Concerning all electrical systems, it is a suggested rule to ensure that the ground cable
(GND) is connected to the device support.
SM-DIN
Modules
Sensors
connection

Technical Data and Installation
SMART WARP - 2.3 -
SM-DIN Modules Interconnection

Technical Data and Installation
- 2.4 - SMART WARP
Electrical Interface
Machine Interface
(INPUTS)
Machine Interface
(OUTPUTS)
Chain 1 - Sensors
Chain 2 - Sensors
Chain 3 - Sensors
Chain 4 - Sensors
Max 100 sensors
identified by means of
Device function
(Setup →Config menu)
SM-DIN module nn – (identified by means of Edt function directly on SM-DIN module)
Transformer

Operation
SMART WARP - 3.1 -
3
33
3 –
––
– OPERATION
OPERATIONOPERATION
OPERATION
SMART WARP Terminal Features
As for all SMART BTSR systems,the operation of SMART WARP 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 signaling 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 system.
1. ENTER button
It allows you 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.
2. RESET button
It allows you to 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.
3. NEXT CY button
! During navigation within the menus this button allows you to select the next
option within 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.

Operation
- 3.2 - SMART WARP
! When alphanumeric data are entered (for instance the access Keycode), this
button allows the increase of characters pointed by the cursor, according to the
following cyclic sequence:
! When entering numeric data (for example the number of sensors) it allows you
to increase the numeric value of the field. If it is held down continuously the
numeric field increments more rapidly.
4. CONTROL Button
During parameter programming, it allows changing the position of the cursor.
5. REPEAT button
! During navigation within the menus this button allows you to select the
previous option within 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 access Keycode), this
button allows the decrease of characters pointed by the cursor, according to the
following cyclic sequence:
! When entering numeric data (for example the number of sensors) it allows you
to decrease the numeric value of the field. If it is held down continuously the
numeric field decrements more rapidly.
6. Operator’s Message Area:
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.
SMART
WARP

Operation
SMART WARP - 3.3 -
7. Operating Status Signaling Area
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 parameters currently set in the
system. In this phase the message display indicates CONTROL nnnn.
The ERROR label indicates that an error has been detected during normal
operation of the system. In this case the display shows the type of error detected
(for more information please refer to the operating sequences within this chapter
and to chapter 4 – Troubleshooting).
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 an upper to a lower level you must normally press down the ENTER button,
while to do the opposite, i.e. going from a lower to an upper level you must press
the RESET button.
The level indication 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.

Operation
- 3.4 - SMART WARP
SM-DIN Module Configuration
The SM-DIN sensor interface modules require the programming of 2 parameters
only:
- Identification number of SM-DIN modules within the system (1 to 20)
- Communication speed (Baudrate) between SMART WARP and SM-DIN
(115,2 or 57,6 Kbps)
Procedure
During the normal machine operation
Parameter 01 (SM-DIN module identification number)
To increase the value (max. 20)
To decrease the value (min. 1)
Parameter P02 (Baudrate)
(*) Always set 115.2 Kbps
3 sec.
To select 57.6 Kbps or 115.2 Kbps
(Default = 115.2 Kbps) (*)

Operation
SMART WARP - 3.5 -
Operating Signaling/Anomalies
During the normal machine operation, the display of SM-DIN modules may show
the following operating/failure signalings.
Normal operation condition.
Learn in progress.
Sensor numbering (identification) in progress.
Fault/error signaling
Signaling LEDS
The lighting of respective red leds indicates:
FAST input inactive.
SLOW input inactive.
RESET input active.
SM-DIN module in CONTROL status.
Communication in progress between SM-DIN and SMART WARP.
STOP output (AL2) active (led flashing).
STOP output (AL1) active (led flashing).
SM-DIN module powered

Operation
- 3.6 - SMART WARP
IS3 Sensors Features
The IS3 electronic sensors are capable of detecting, thanks 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 (Image Smart Scanning Sensor),
makes the IS3 sensor exempt from the influence of environment/yarn conditions:
i.e. humidity, conductivity and machine vibrations. It does not require any physical
contact with the yarn under control and therefore it allows a 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 on
textile machines.
IS3 is fully programmable for an easy adaptation to the control of any type of
yarn/application.
Optical interface of IS3 sensors
The IS3 sensors have two signaling lights (green LED, red LED) and a “Touch
Light” optical button.
During the automatic numbering of the sensors (flashing green LED), touch the
optical button to give the sensor the number shown in the devices configuration
screen.
Interpretation of the sensor signaling lights
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.
(BROKE: broken yarn - UNCUT: uncutted yarn).
Green LED ON
Red LED ON
Stopped sensor. Switch off, then switch on the system. If
the condition is permanent, replace the sensor.
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.
Green led
Touch
light
Red led

Operation
SMART WARP - 3.7 -
Settings that affect the sensor detection features
The IS3 sensors do not simply detect the presence of the yarn, but they work 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 missing or broken condition
The functioning of the sensor is based on the principle of image variation related to
the shape of the yarn, detected by the small “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 type
of yarn used and to the specific application.
! Non-control time (D_CNTR)
! Signaling tolerance for broken yarn (BROKE)
! Signaling tolerance for uncut yarn (UNCUT)
! Sensitivity (SENS)
! Reaction Time (DELAY)
! Start Frequency (F_START)
! Stop Frequency (F_STOP)
Non-control time
(D_CNTR)
This parameter allows you to delay the beginning of the actual control process
after the activation of SLOW EXT and FAST EXT inputs. It can be programmed
to a value ranging between 100 ms and 20 s.
Signaling tolerance for broken yarn
(BROKE)
This parameter allows you to establish the minimum duration of “broken or
missing yarn” anomaly, to signal the (BROKE) condition. Such duration is tightly
related to the actual machine operating speed. It can be programmed to a value
ranging between 10 ms and 2 s, or it can be disabled (OFF).
Signaling tolerance for uncut yarn
(UNCUT)
This parameter allows you to establish the minimum duration of “uncut yarn”
anomaly, to signal the (UNCUT) condition. Such duration is tightly related to the
actual machine operating speed. It can be programmed to a value ranging between
10 ms and 2 s, or it can be disabled (OFF).
Sensitivity
(SENS)
The SENS parameter allows the control of the sensor sensitivity level, depending
on the article to be processed.
It can be programmed to a value ranging between 1and 10. The default value is 4.

Operation
- 3.8 - SMART WARP
The suggested values for different yarns are as hereafter indicated:
Very thick yarns 1
Thick yarns 3
Medium yarns 5
Fine yarns (single filament yarn) 6-8
Very fine yarns (Lycra®) 9-10
Reaction time (DELAY)
The DELAY parameter allows the adjustment of the sensor to the characteristics of
yarn to be processed (e.g. elasticity), by defining the Reaction Time of the sensor
before signaling a defect. It is possible to program 8 pre-set values:
5 ms - 10 ms - 20 ms - 50 ms - 100 ms - 200 ms - 500 ms - 1000 ms
# 50 ms is the suggested value for very high running speed of the yarn.
# 200 ms is the suggested value for normal yarns.
# 500 ms is the suggested value for elastic yarns.
Start Frequency
(F_START)
This parameter indicates the minimum frequency of image variation, beyond
which the sensor signals that the yarn is running normally (green LED ON).
It can be programmed to a value ranging between 1and 10.
Stop Frequency
(F_STOP)
This parameter 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 ranging between 1and 10.
Programming examples for F_START/F_STOP and relevant sensor delays
As the diagram shows, if the F_START and F_STOP value is set low (e.g. = 2),
then the sensor could detect the condition of “running yarn” even though the yarn
is actually still or broken, and is undergoing a light oscillation (Aand B areas of
the diagram). Otherwise, if a higher value is set (e.g. = 5) then the image variation
of Aand Bareas is not considered sufficient to detect the condition of “running
yarn”. It must be observed, however, that if the yarn detected by the sensor has a
very regular profile (e.g. Lycra® or single filament yarn), the frequency of the
image variation is lower; therefore if a value too high is programmed, the sensor
could not detect the “running yarn” condition (or it would detect it with excessive
delay). This is why the F_START and F_STOP values can be “calibrated”
according to the article to be processed, in order to obtain the condition of optimal
detection for that particular article.
!
In the presence of frequent errors detected by the sensors, it is suggested to
gradually change such values until an optimal condition is achieved.