btsr SMART WARP User manual

SMART MATRIX WARP
Operating Manual
ENGLISH
Rev. 3.0 - December 2011

SMART MATRIX WARP - Rev. 3.0 - December 2011
Copyright - BTSR – All rights reserved.
This manual is entrusted to the users of SMART MATRIX WARP system developed for control/monitoring
activities of textile machinery equipped with either quality control (IS3)or tension control (TS5/TS7)sensors.
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 Machinery Directive 2006/42/EC and
EMC Directive 2004/108/EC.
All BTSR products are covered by patents and adopt exclusive, profitable and high tech solutions.
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BTSR® is a registered trademark “Best Technology Study & Research” of BTSR International S.p.A.

Introduction
i

Introduction
SMART MATRIX - i -
Introduction
Congratulations for choosing a BTSR product.
With our SMART MATRIX WARP yarn control system, you got an innovative, unique solution, which offers
you multiple advantages concerning the quality control of your production.
SMART MATRIX WARP has been designed for applications on large warping machines that use in
continuous mode a large number of yarns (thousands) during the entire working cycle.
SMART MATRIX WARP, combined with either IS3 yarn control sensors or TS5/TS7 tension sensor,
represents a complete and effective machine control system.
The SMART MATRIX WARP system has been developed by BTSR International S.p.A. to make easier and
optimize:
•The sensor programming,
•The system configuration,
•The production monitoring.
The system is capable of self-learning the yarn sequence used by the textile machine during a sample cycle
(LEARN) and to indicate any type of error detected during the subsequent production cycles (broken or
missing yarns, uncut yarns, threading or pick-up errors, excessive or insufficient yarn tension, etc.).
The availability of a “User Friendly” graphic interface allows you to quickly and intuitively program all the
operating parameters of IS3/TS5/TS7 sensors; in addition, it provides a real time monitoring of sensors
behavior and production efficiency.
Manual Objectives
This manual has been written to provide the users of SMART MATRIX WARP system with the essential
information required to:
•Correctly install and connect the various system components (SMART MATRIX terminal, SM-DIN
WARP Boards, IS3 or TS5/TS7 sensors, ACT/D lamp interface modules, 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.).

Introduction
SMART MATRIX - ii -
How to Use this Manual
The manual is subdivided into 3 sections:
Section 1 – includes the connection diagrams and the electrical interface of the various system
components.
Section 2 – provides the operating instructions for a correct use of the SMART MATRIX WARP terminal
as well as the parameter configuration/programming instructions and data/errors display
facilities.
Section 3 – describes the main characteristics and performances of the various system components (IS3
sensors, TS5/TS7 sensors, SM-DIN WARP modules, etc.). Furthermore, it provides some
details to better understand the operating principles upon which the SMART MATRIX WARP
system is based (Row/Column/Bar Priority, SLOW-FAST Control Parameters, etc.).
Symbols Used
This symbol is used to point-out notes, warnings and other important information.
IS3 Within this manual, the IS3F-485 sensors used for SMART MATRIX WARP application will be
indicated with the generic wording IS3.
TS5/TS7 Within this manual, the TS5/Dttt... or TS7/Dttt… sensors as well as the last generation TS55/Dttt...
/ TS77/Dttt… sensors used for SMART MATRIX WARP application will be indicated with the
generic wording TS5/TS7.
In the program function descriptions, this symbol indicates the function
(e.g. DEVICE) within the menu item (SETUP).
The graphic symbol of either IS3 sensor or TS5/TS7 sensor, shown on the page header, indicates
that the relevant function applies exclusively to the indicated sensor type.
SETUP →DEVICE

Table of Contents
SMART MATRIX - iii -
Table of Contents
1 – Connections and Electrical Interface
PC ↔SMART MATRIX ↔SM-DIN Connection.......................................................................................... 1-1
SMART MATRIX ↔SM-DIN ↔IS3 + ACT/D Connection .......................................................................... 1-2
SMART MATRIX ↔SM-DIN ↔TS5 + ACT/D Connection ......................................................................... 1-3
SMART MATRIX ↔SM-DIN ↔TS7 + ACT/D Connection ......................................................................... 1-4
SM-DIN ↔Machine Interface ...................................................................................................................... 1-5
Sensors (ACT/Ds) Interface ......................................................................................................................... 1-6
SM-DIN ↔ACT/Ds ↔Machine Interface .................................................................................................... 1-7
SMART MATRIX ↔SM-DIN/PC/DISPLAY Interface .................................................................................. 1-8
SMART MATRIX WARP Generic Application Diagram (IS3)....................................................................... 1-9
SMART MATRIX WARP Generic Application Diagram (TS5)...................................................................... 1-10
2 – Operating Instructions
SMART MATRIX WARP Operation.............................................................................................................. 2-1
Navigation throughout the Display Windows................................................................................................ 2-2
SMART MATRIX WARP Menu Structure..................................................................................................... 2-9
Choice of Device Type (IS3 or TS5/TS7) ..................................................................................................... 2-10
Creel Mapping (STD or ADV) ....................................................................................................................... 2-11
Sensor Configuration and Numbering .......................................................................................................... 2-12
Lamps (ACT/D) Configuration and Numbering ............................................................................................ 2-17
Smart Matrix Code........................................................................................................................................ 2-20
Board Mode .................................................................................................................................................. 2-21
Options ......................................................................................................................................................... 2-22
Input/Output Configuration on SM-DIN/Smart Matrix ................................................................................... 2-23
Efficiency Calculation Mode ......................................................................................................................... 2-25
Keycode Setting............................................................................................................................................ 2-26
Communication Test..................................................................................................................................... 2-28
Sensors Test................................................................................................................................................. 2-29
Lamps Test ................................................................................................................................................... 2-30
Offset TS5/TS7 ............................................................................................................................................. 2-31
Sensors Firmware Upgrade.......................................................................................................................... 2-33
ACT/D Upgrade ............................................................................................................................................ 2-33
MATRIX LCD Adjustment............................................................................................................................. 2-37
LED Display setup ........................................................................................................................................ 2-38
Information about SMART MATRIX WARP.................................................................................................. 2-39
Style Parameters Programming (TS5/TS7).................................................................................................. 2-40
Style Parameters Programming (IS3F) ........................................................................................................ 2-42
Style Loading ................................................................................................................................................ 2-44
Sensors Histogram ....................................................................................................................................... 2-45
Efficiency Data.............................................................................................................................................. 2-47
Error Counter Display (TS5/TS7) ................................................................................................................. 2-48
Error Counter Display (IS3) .......................................................................................................................... 2-50
LEARN.......................................................................................................................................................... 2-52
SMART MATRIX Error Message.................................................................................................................. 2-53
Errors shown on Display of SM-DIN Boards ................................................................................................ 2-56

Table of Contents
SMART MATRIX - iv -
3 – System Components and Configuration
IS3 Sensor Features..................................................................................................................................... 3-1
TS5/TS7 Sensor Features............................................................................................................................ 3-4
Differences between TS5 and TS7 Sensors ................................................................................................ 3-13
SM-DIN WARP ............................................................................................................................................. 3-14
ID and Transmission Speed Configuration on Each SM-DIN Board ............................................................ 3-15
Machine Configuration (Levels, Creels, Rows, Columns, Bar) .................................................................... 3-16
SLOW-FAST Control Parameters ................................................................................................................ 3-21

Connections and
Electrical Interface
1

PC ↔SMART MATRIX ↔SM-DIN Connection
SMART MATRIX - 1-1 -
PC ↔SMART MATRIX ↔SM-DIN Connection
The following diagram shows the interconnections among: SMART MATRIX Terminal, SM-DIN Sensor
Interface Boards and PC.
The PC is mainly used for firmware update operations on SMART MATRIX Terminal, SM-DIN
Boards and Sensors (**).
(*) To connect the sensors, please refer to the following sections:
SMART MATRIX
↔ SM-DIN ↔ IS3/TS5/TS7 Sensors + ACT/Ds Connection.
(**) To update the firmware on SM-DIN Boards and Sensors, you must:
-Disconnect cable {from Smart Matrix PC-IN connector
-Disconnect cable |from 1st SM-DIN Board SM/IN }connector
-Connect cable {to connector }of 1st SM-DIN Board
Prior to operate the SMART MATRIX terminal, make sure you have programmed the communication
speed on all the SM-DIN WARP Boards as well as on CV232/485/9 module.
For more details, please refer to paragraph SMART MATRIX
↔ SM-DIN/PC Interface on Section 1
and to paragraph ID and Transmission Speed Configuration on Each SM-DIN Board on Section 3.
As alternative
Sensors Sensors Sensors

SMART MATRIX ↔SM-DIN ↔IS3 + ACT/D Connection
SMART MATRIX - 1-2 -
SMART MATRIX ↔SM-DIN ↔IS3 + ACT/D Connection
The following diagram shows the connection of IS3 Sensors and Lamp Interface Modules (ACT/D) to SM-
DIN Boards, as well as the connection between SM-DIN Boards and SMART MATRIX.
MAX 100
BOARDS
SM-DIN

SMART MATRIX ↔SM-DIN ↔TS5 + ACT/D Connection
SMART MATRIX - 1-3 -
SMART MATRIX ↔SM-DIN ↔TS5 + ACT/D Connection
The following diagram shows the connection of TS5 Sensors and Lamp Interface Modules (ACT/D) to SM-
DIN Boards, as well as the connection between SM-DIN Boards and SMART MATRIX.
MAX 100
BOARDS
SM-DIN

SMART MATRIX ↔SM-DIN ↔TS7 + ACT/D Connection
SMART MATRIX - 1-4 -
SM-DIN ↔SMART MATRIX ↔TS7 + ACT/D Connection
The following diagram shows the connection of TS7 Sensors and Lamp Interface Modules (ACT/D) to SM-
DIN Boards, as well as the connection between SM-DIN Boards and SMART MATRIX.
MAX 100
BOARDS
SM-DIN

SM-DIN ↔Machine Interface
SMART MATRIX - 1-5 -
SM-DIN ↔Machine Interface
The following diagram shows the electrical interface (pin assignment) of SM-DIN Warp Board.
The sensor interface is shown on the following page.
(*) Recommended power supply: 24 Vdc.
If the ATC POWER unit is used, the power supply on PINs 1 and 2 of Power connector must not be
provided, because the entire system is already supplied (through the ATC POWER module itself) by
the PSU 10ASM unit (please refer to diagrams on pages 1-9 and 1-10).
Machine Interface
(INPUT)
Machine Interface
(OUTPUT)
Power Supply (*)

Sensors (ACT/Ds) Interface
SMART MATRIX - 1-6 -
Sensors (ACT/Ds) Interface
The following diagram shows the electrical interface (pin assignment) of SM-DIN to sensors connection.
As you may note, 4 identical connectors are available, allowing you to connect up to 4 sensors and/or
ACT/Ds chains.
The SM-DIN/WARP Board can directly supply up to 30 IS3 sensors or 20 TS5/TS7 sensors (Imax=1A).
The ATC POWER unit must be used to supply a higher number of sensors. The unit is supplied by an
external power supplier (e.g. PSU 100ASM), as shown on the examples on pages 1-9 and 1-10.
Sensors (ACT/Ds)
Sensors (ACT/Ds)
Sensors (ACT/Ds)
Sensors (ACT/Ds)
Max 100 IS3 or
64 TS5/TS7 sensors
+
100 ACT/Ds modules
SM-DIN nn Module – (Identified by means of Edt function directly on the SM-DIN
module)

SM-DIN ↔ACT/Ds ↔Machine Interface
SMART MATRIX - 1-7 -
SM-DIN ↔ACT/Ds ↔Machine Interface
The following diagram shows the electrical interface (pin assignment) of ACT/D modules.
P = Numbering button
Lv = Green Led (normally flashing)
Lr = Red Led (on = communication with SM-DIN in progress)
Lr1 = Red Led (on = out 1 active)
Lr2 = Red Led (on = out 2 active)
IN X = Inputs not used for Warp application
The outputs of ACT/D modules will always be indicated (for simplification)
as “Lamps”.
(1) Lamp direct connection example (Imax = 100 mA) as NO contact.
(2) Lamp connection example by means of external relay (I> 100 mA).
- Lamp/Cutter, etc. - - Lamp/Cutter, etc. -
(1)
(2)

SMART MATRIX ↔SM-DIN/PC Interface
SMART MATRIX - 1-8 -
SMART MATRIX ↔SM-DIN/PC/DISPLAY Interface
The following figure shows the electrical interface (pin assignment) of Smart Matrix terminal.
(*) Press the Pbutton to setup the communication speed on CV232/485/9:
- LED LV with single flashing = 57.6 Kbps
- LED LV with double flashing = 115 Kbps
(**) Not necessary for Warp application
SMART MATRIX Terminal Technical Characteristics
Power supply voltage 24 VDC ± 10%
Current absorption 100 mA Max
Protection fuse (SMART MATRIX) 1.5 A
Protection fuse (Sensor power supply) 1.5 A
0 – 24 VDC
VIL Max 1.2 VDC
Inputs
VIH Min 5 VDC
Operating temperature range +10° / +60° C
Storage temperature -25° / +85° C
Overall dimensions 140x80x31 mm
(*)
(**)
Supply voltage from SM-DIN
Supply voltage from SM-DIN

SMART MATRIX WARP Generic Application Diagram (IS3)
SMART MATRIX - 1-9 -
SMART MATRIX WARP Generic Application Diagram (IS3)
On the example shown, the power supply of the entire system is provided by the PSU 10 ASM power
supplier, by means of the ATC POWER unit, whereby it does not have to be provided on PINs 1 and 2
of SM-DIN WARP unit Power connector.
SM-DIN

SMART MATRIX WARP Generic Application Diagram (TS5)
SMART MATRIX - 1-10 -
SMART MATRIX WARP Generic Application Diagram (TS5)
On the example shown, the power supply of the entire system is provided by the PSU 10 ASM power
supplier, by means of the ATC POWER unit, whereby it does not have to be provided on PINs 1 and 2
of SM-DIN WARP unit Power connector.
SM-DIN