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
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1 -
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- 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
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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 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