btsr TS5 Series User manual

SMART 200 TSS & TS5
YARN CONTROL SYSTEM
Operating Manual
Rev. 2.0 – July 2003 ENGLISH

SMART 200 TSS – Rev. 2.0 – July 2003
Copyright 2003 - BTSR – All rights reserved.
This manual is intended for the users of the SMART 200 TSS 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 Contnents
SMART 200 TSS - i -
TABLE OF CONTNENTS
TABLE OF CONTNENTSTABLE OF CONTNENTS
TABLE OF CONTNENTS
INTRODUCTION
How to use this manual.............................................................................................................................................. I.1
Symbols used .............................................................................................................................................................. I.2
Chapter 1 - OVERVIEW
System components ....................................................................................................................................................1.1
System’s Operation Principles ..................................................................................................................................1.1
Special Features of SMART 200 TSS 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 200 TSS ..........................................................................................................2.2
Connection Example for Generic Applications on Rewinding, Doubling Cone Winder Machines, etc. (TSS)...2.3
Connection Example for Generic Applications on Warping Machines, Quilting, Embroidery Machines (TSQ) 2.4
Connection Cables and Power Supply Devices....................................................................................................2.5
Chapter 3 – OPERATION
SMART 200 TSS Terminal Features........................................................................................................................3.1
TS5.. Sensor Features.................................................................................................................................................3.4
Function of the TS5.. Sensors....................................................................................................................................3.4
TS5.. Sensor Types .....................................................................................................................................................3.5
Eyelet models ..............................................................................................................................................................3.5
Technical Characteristics of TS5.. sensor ................................................................................................................3.6
Electrical Connections ...............................................................................................................................................3.7
Mounting positions.....................................................................................................................................................3.7
Interface specification................................................................................................................................................3.8
Interpretation of the signaling lights located on the sensors ..................................................................................3.9
Parameters that affect the sensor detection features ............................................................................................3.10
Other factors that may affect the control...............................................................................................................3.12
Preliminary operations for using the SMART 200 TSS terminal ........................................................................3.14
Operating Sequences................................................................................................................................................3.15
Preliminary Instructions for the Correct Use of TS5.. Sensors........................................................................3.15
Enabling the SETUP Menu Functions (CONFIG)................................................................................................3.16
Enabling the SETUP Menu Functions (NEW, MODIFY, ERASE).....................................................................3.17
Enabling the WORK Menu Function.....................................................................................................................3.17
Enabling the GRAPH Menu Function ...................................................................................................................3.18
CONTROL Function (with SIDE option disabled) ...............................................................................................3.19
DEVICE Parameters setting for Initial installation .............................................................................3.20
SIDE Machine Sides Definition ........................................................................................................3.22
TSS - Q Application Type Configuration – TSS/TSQ ........................................................................3.23
MO-CTR Configuring the system operation in either MONITOR mode or CONTROL mode........3.24

Indice Generale
- ii - SMART 200 TSS
lk-ULK Enabling/Disabling the Touch Light button operation ........................................................3.26
ST-NCO Configuring the level of STOP signal as Normally Closed or Normally Open ..................3.27
EN-NCO Configuring the level of ENABLE signal as Normally Closed or Normally Open o .........3.28
D_CNTR Configuration of Sensor delay time before entering the Control status .............................3.29
OFFSET Offset Configuration ...............................................................................................................3.30
ABS / RELABS Configuring the Sensor Operating Mode ..............................................................................3.31
KEY-ST Password to access SETUP and WORK menus....................................................................3.32
KEY-LR Password to access LEARN function.....................................................................................3.33
CLOCK Reading/Setting the Printer Clock-Calendar (rtc)................................................................3.34
SENSOR TEST Sensors Test..............................................................................................................................3.35
COM TEST Testing the Efficiency Rate over the Communications Line between the SMART 200 TSS
Terminal and Sensors..............................................................................................................3.36
VERS – UPG Test of software version and Sensor’s version Updating .....................................................3.37
NEW Creating a New Article............................................................................................................3.39
TENS Creating a New Article Reference Nominal Tension............................................................3.41
TENS H Creating a New Article Characteristics of “Max Tension Threshold Exceeded” failure..3.42
TENS L Creating a New Article Characteristics of “Min Tension Threshold Exceeded” failure ..3.43
PEAK H Creating a New Article Characteristics of “Max Tension Peak Exceeded” failure...........3.44
PEAK L Creating a New Article Characteristics of “Min Tension Peak Exceeded” failure ...........3.45
NOYARN Creating a New Article Characteristics of the Yarn Missing Failure .................................3.46
MODIFY Modifying an existing Article .................................................................................................3.47
ERASE Erasing an existing Article......................................................................................................3.47
SCAN Displaying Articles currently loaded in the sensors..............................................................3.48
LOAD Loading an article to sensor memory.....................................................................................3.49
UNLOAD Unloading articles from the sensor memory .........................................................................3.51
BAR GRAPH Graphic visualization of the Tension Detected by each TS5.. device ..................................3.52
ISTOG GRAPH Graphic visualization (comparison) of the Tensions detected by multiple TS5.. devices...3.53
LEARN Procedure for TSQ Operating Mode .....................................................................................3.55
PRINT REPORT Production Report Printing....................................................................................................3.57
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

Introduction
SMART 200 TSS - I.1 -
INTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
Congratulations for choosing a BTSR product.
With our SMART 200 TTS yarn control system, you got an innovative, unique
solution, able to offer you multiple advantages concerning quality control of your
production.
The SMART 200 TSS system has been designed to meet two different application
typologies showing different requirements, even if both typologies are based on the
yarn Tension control which is entrusted to the TS5.. series BTSR tension sensors.
To manage the above mentioned application typologies, the system provided two
application modes:
TSS = On textile machines dedicated to the preparation of yarn (rewinding, texturing,
doubling cone winder machines, etc.) which during the entire productive cycle
utilize a specified number of yarns on several positions, in continuous mode. In this
kind of this applications it is necessary to immediately detect a possible failure on
yarn Tension, stop the position where the failure occurred and signal the failure
itself.
In this case, the SMART 200 TSS terminal acts basically as an article’s Data Base
with the possibility to load the tension control parameters (related to the article
under processing) into the installed TS5.. sensors as well as the possibility to
perform statistical analysis about the detected failures, including the printout of
production reports. The actual control function, including the stop of position that
detected the failure is performed by the individual TS5.. sensors.
TSQ = On textile machines such as beam warping machines, quilting machines,
embroidery machines etc. which, from time to time, may use a number of yarns not
necessarily equal to the number of installed TS5.. sensors.
In this case, besides the article’s Data Base function, the SMART 200 TSS
terminal performs a real time control function on the number of yarns used by the
machine during the normal production, by comparison with respect a sample
learning cycle. At the end of the learning cycle, the system will indicate the number
of “learnt” sensors and it will enable only those learnt sensors, disabling all the
other sensors. In this working mode too, the controller item will be the yarn tension
concerning the enabled sensors, however it will be the SMART 200 TSS terminal,
rather than the individual sensors to decide if and when the textile machine must be
stopped in case of failures not ranging within the tolerance.
How to use this manual
This Operation 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 solving
the main technical faults of the system.
Appendix A – Quick reference summarizes 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 200 TSS
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.
TS5.. The TS5.. BTSR sensor family includes some variants indicated by the
letters following the TS5.. term, and identifying the reference weight in
grams, the type of eyelet used etc. For your convenience, within this
manual we will always use the generic term TS5..
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.
Within the operating procedures section, this symbol indicates that, to
activate the desired function you must press and hold down for 3 seconds
the button.
Within the Appendix A “Quick Reference” the push-buttons of SMART control
panel are shown as follows:

Introduction
SMART 200 TSS - I.3 -
Meaning of the Capital/Small Letters on Display
Within the functions that provide two programmable alternative options, i.e.:
!"System Working Mode (either TSS or TSQ)
!"Normally Open or Normally Closed Contact
!"Enabled/Disabled Condition
!"Pulse/Continuous Signalling, etc.
The letters shown on display as capital letters indicate the currently active choice,
while the small letters refer to the possible alternative choice.
Example:
Item Function Current Programming
TSS-q TSS-q= TSS mode
TSs-Q
System Working Mode selection
(either TSS or TSQ) TSs-Q= TSQ mode
ST-NCo NCo = normally closed
ST-NcO
Stop Output programmable as
Normally Closed (NC) or Normally
Open (NO) contact NcO = normally open
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
Alternative items:
Within the description of configuration/programming procedures the alternative
screen shots are shown with this bracket symbol.

Introduction
- I.4 - SMART 200 TSS
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Overview
SMART 200 TSS - 1.1 -
1
11
1 -
--
- OVERVIEW
OVERVIEWOVERVIEW
OVERVIEW
System components
The SMART 200 TSS system consists of a control/programming terminal and a
variable number of TS5.. type sensors (up to 200) connected to the terminal using
specific interface cables.
System’s Operation Principles
The TS5.. sensors (Tension Smart Scanning Sensor) allow accurate measurement
and analysis of the Tension applied to the yarn within the textile machine.
The normal yarn working tensions (TENS), the minimum (TENS L) and maximum
(TENS H) tension thresholds,the minimum (PEAK L) and maximum (PEAK H)
peak tension beyond which the position (in case of TSS operating mode) or the
whole machine (in case of TSQ operating mode ) shall be stopped, as well as the
yarn missing (NOYARN) condition, are all characteristics that depends on the type
of yarn (article) being processed an that shall be controlled by each TS5.. sensor.
These features must be programmed on each sensor and can be changed according
to the article which is being processed.
The SMART 200 TSS terminal has in fact the function of programming and,
changing if needed the sensors’ features, according to the quality control
requirements; in addiction, it has the function of displaying either globally or
selectively the counters that record the different types of defects detected by the
sensors.
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.
Special Features of SMART 200 TSS system
The SMART 200 TSS system has a set of unique features which make it a true
microcomputer dedicated to the yarn quality control.
SMART 200 TSS is a fully parametric system; this means that for each type of
defect the user 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 control
parameters related to the name of the article to a sensor or to a specific set of
sensors within the textile machine controlled by the sensors themselves.
The main advantages of this solution can be summarized 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.

Overview
- 1.2 - SMART 200 TSS
!"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.
!"Visualization at a glance:
The system allows displaying all the technical features concerning the involved
position (actual tension, minimum and maximum threshold tension, minimum
and maximum peak value, etc.). In addition it is possible to simultaneously
control the values of 8/12/16 TS5.. sensors in graphic mode.
General Features of SMART systems
!"TS5.. Sensors (Tension Smart Scanning Sensor…) (BTSR Patents)
The TS5.. sensors are connected to the SMART control terminal using specific
single connector and doubler 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. Parameters can be programmed
either globally to all connected sensors or individually to each sensor.
!" Multi-sensor System
The system allows connecting up to 200 yarn quality control sensors of the
TS5.. series.
!" Easy Monitoring
Besides the information shown on graphical display of SMART 200 TSS, each
TS5.. sensor has a red LED that, when flashing, indicates the type of fault
detected, thus making the operator task easier.
!" Sensor Diagnostics
Each TS5.. sensor signals its operational status by means of two LEDs.

Technical data and installation
SMART 200 TSS - 2.1 -
2
22
2 –
––
– TECHNICAL DATA AND INSTALLATION
TECHNICAL DATA AND INSTALLATIONTECHNICAL DATA AND INSTALLATION
TECHNICAL DATA AND INSTALLATION
Technical Features
SMART 200 TSS 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
TS5.. 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)
Analogue Output 0 – 5 Vdc
"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
Signalling With integrated LED’s
Dimensions 50 x 25 x 12,5 mm
Temperature range 10° - 60 °C
Installation
The installation of the SMART 200 TSS 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 supplies.

Technical data and installation
- 2.2 - SMART 200 TSS
Interface Connectors on SMART 200 TSS
Concerning all electrical systems, it is a recommended rule to ensure that the ground cable
(GND) is connected to the sensor support.

Technical data and installation
SMART 200 TSS - 2.3 -
Connection Example for Generic Applications on Rewinding, Doubling Cone Winder Machines, etc. (TSS)
Concerning all electrical systems, it is a recommended rule to ensure that the ground cable
(GND) is connected to the sensor support.

Technical data and installation
- 2.4 - SMART 200 TSS
Connection Example for Generic Applications on Warping Machines, Quilting, Embroidery Machines (TSQ)
Concerning all electrical systems, it is a recommended rule to ensure that the ground cable
(GND) is connected to the sensor support.

Technical data and installation
SMART 200 TSS - 2.5 -
Connection Cables and Power Supply Devices
To correctly install the SMART 200 TSS system and sensors, it is necessary to use
a certain number of connecting cables provided by BTSR; their length and type
depend on the specific requirements and application types.
The following table lists at glance the types and lengths of the main connection
cables, which BTSR may provide. For further details and queries about the cables
and accessories available, please contact your local BTSR dealer.
SMART Power Cables (I/O Connectors)
FE10/200 Length 200 cm
FE10/500 Length 500 cm
Cables 4 x 0.35 mm with Female to Female Connector for connections
between SMART 200 TSS /PSU 10A and MA2FE8 Doubler Cable
FE100/FEC Length 100 cm
FE200/FEC Length 200 cm
FE300/FEC Length 300 cm
FE400/FEC Length 400 cm
Doubler Cable from one Male to two Female with Independent Stop
and Ground outputs to Connect a Solenoid-valve, Cutter, Alarm
Signalling Light, etc.
MA2FE8
Extension Cable 4x0.35 mm with Male and Female connector.
MA50/FEC Length 50 cm
MA100/FEC Length 100 cm
MA200/FEC Length 200 cm
Transformers for SMART 200 TSS
TRF1524/100 Output 15/24 Vac 100VA (can be used with up to 40 sensors)
TRF24/300VA Output 24 Vac/300VA (can be used with more than 40 sensors)
Stabilised Power Supply with 24 Vdc output, 10A Peak, 6A
continuous
PSU 10A Required with more than 40 sensors (up to a maximum of 100
sensors for each PSU 10A)
Printer for SMART 200 TSS
PRNT 01 Printer with clock-calendar feature for production report, including
CV485/232 conversion interface cable.

Technical data and installation
- 2.6 - SMART 200 TSS
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Operation
SMART 200 TSS -3.1 -
3
33
3 –
––
– OPERATION
OPERATIONOPERATION
OPERATION
SMART 200 TSS Terminal Features
As in all SMART BTSR systems,the operation of SMART 200 TSS 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 SMART 200 TSS system.

Operation
- 3.2 - SMART 200 TSS
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.
!"When alphanumeric data are entered (for instance the Article Name or Keycode
access), this button allows you to increase the character displayed where the
cursor is located, 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 Article Name or Keycode
access), this button allows you to decrease the character displayed where the
cursor is positioned, 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.

Operation
SMART 200 TSS -3.3 -
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.
When you select the GRAPH function from Main Menu, this area is used to
graphically represent the tension detected by a specific sensor, or to compare by
means of a histogram the readings of multiple sensors (8, 12, 16).
7. Operating Status Signalling 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 OK.
The ERROR label indicates that an error has been detected during normal
operation of the system. In this case the Message area shows the type of error
detected (for further information please refer to Operations Sequences in this
chapter and to chapter 4 – Troubleshooting and Maintenance).
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.
SMART
200 TSS

Operation
- 3.4 - SMART 200 TSS
TS5.. Sensor Features
The TS5.. devices are intelligent sensors able to detect, due to sophisticated control
technique, the tension applied to the yarn being controlled, signalling possible
anomalies about the tension itself.
The tension exerted by the yarn on sensor’s loafing cell ((depending on the feeding
tension of the yarn itself), is detected by the electronics of the sensor and converted
by the built-in DSP (Digital Signal Processor) into a digital signal that can be
interpreted both by the TS5.. sensor and by the SMART 200 TSS terminal.
TS5.. devices can be used for yarn quality control (under both static and dynamic
conditions) which, thanks to an innovative patented technique (Tension Smart
Scanning Sensor) combined to the advanced yarn control terminal SMART 200
TSS don't need complex wirings and long installation times, allowing you to
manage up to 200 positions.
The TS5.. devices are fully programmable for an easy implementation of quality
control of any kind of yarn/application.
As the TS5.. are parametric devices, it is possible to set freely error percentages on
tension and the duration of anomalies. The TS5.. devices are very easy to use as
they are ready to accommodate a large variety of accessories that make them
suitable to the quality control of any type of yarn.
Function of the TS5.. Sensors
The TS5.. sensors provide the real time control of the yarn running inside the
eyelet and, in case of defect, they either immediately stop the machine position or
activate solenoid-valves, cutters, or other control devices, automatically signalling
which is the first sensor, (among those connected), that stopped the position.
The TS5.. sensors have two signaling lights (green LED, red LED) and a “Touch
Light” button.
The “Touch Light” button is used to carry out the automatic sensor numbering and
error reset operations.
During the automatic numbering of the sensors (flashing green LED), by skimming
the touch light you assign the sensor the number shown on Device Config. Screen
of SMART 200 TSS terminal.
During on alarm condition (flashing red LED), by skimming the touch light, you
will reset the position.