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KTF/100HPS

(Constant Tension Feeder - High Performance)

YARN CONTROL SYSTEM

Operating Manual

ENGLISH

Rev. 1.0 – April 2005

Summary of Contents for KTF/100HPS

Page 1: ...KTF 100HPS Constant Tension Feeder High Performance YARN CONTROL SYSTEM Operating Manual ENGLISH Rev 1 0 April 2005 ...

Page 2: ...chnical 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...

Page 3: ...le of a Complete System including KTF 100HPS Devices KTF PW4 Power Supply and Notebook with PC LINK KTF Studio Analysis Monitoring Software 2 6 Connecting Cables and Power Supply devices 2 7 Connecting Cables and Accessories in case of Installation with KTF PW4 Power Supply 2 7 Installation of KTF 100HPS with flat cable KTF FLAT 2 8 Connection Cables and Accessories in case of Installation with Fl...

Page 4: ...0 3 19 Mode 01 3 20 Mode 02 3 21 Mode 03 3 21 Mode 04 3 22 Specific Operation Characteristics for Mode 04 3 23 Error Reset 3 23 Activation of Open Collector Outputs to Drive the Solenoid Valve 3 23 Chapter 4 KTF 100HPS TROUBLESHOOTING AND MAINTENANCE Indications Provided by the Red Leds on KTF 100HPS device 4 1 Troubleshooting on KTF 100HPS Devices 4 2 Useful Hints when using the KTF 100HPS device...

Page 5: ...stated above The KTF 100HPS Constant Tension Feeder High Performance devices are in fact high precision measurement and control instruments providing a real time display of the exact yarn tension and guaranteeing through an accurate adjustment a constant yarn tension in every working condition This occurs independently of the speed at which the textile machine is running either high or low speed a...

Page 6: ...shooting and Maintenance provides a quick guide to solving the main failures of KTF 100HPS devices 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 TENSION ERROR All the items concerning the device programming menus withi...

Page 7: ... in C by pressing the Reset button An excessive increase of the temperature could infact indicate a wrong use of the device for this reason the software on board of device performs a continuous monitoring of the internal temperature If such temperature exceeds 110 C an alarm message ERROR C appears in the graphic area of LCD and the stop output is activated Thanks to a configurable safety code all...

Page 8: ...t Accurate yarn feeding speed measurement 1 to 1500 m min LFA m min Length of Absorbed Yarn Optimisation of yarn consumption and less difficulties to keep the correct size of manufactured products Drastic reduction of yarn consumption 8 to 15 for bare elastomers 2 5 for covered elastomers Better quality of manufactured product defect free and drastic drop of second choice production Constant keepi...

Page 9: ...during a sample cycle and then check that such amount is kept constant during the subsequent cycles within the tolerance limits and in case of deviation from these limits the textile machine will be stopped For more details please refer to the SMART KTF 2000 operating manual Further Advantages obtained by using a PC or Notebook Connected to the KTF 100HPS Device via Serial Line Using the PC LINK K...

Page 10: ...Overview 1 4 KTF 100HPS Page intentionally left blank ...

Page 11: ...d 3 push buttons 2 STOP red LEDs 1 on the front side 1 on the rear side Signalling With LCD graphic display Dimensions 125 x 60 x 40 mm Operating Temperature range 10 60 C Power supply KTF PW4 6 6 outputs Power supply voltage 24 Vac 20 Output voltage 2 x 24 Vdc 5 standard 2 x 32 Vdc 5 boost Max output current 2 x 20A peak 2 x 10A continuous Dimensions 115 x 135 x 55 mm Operating Temperature range ...

Page 12: ...s besides the INC DEC and STOP interface signals This is the solution typically used for hosiery machines etc Connection of KTF 100HPS Devices with KTF PW4 Power Supply to the Textile Machine and Related Functions 1 Connect EXC terminals to the machine Stop lamp to exclude the KTF alarms when the machine is not running the EXC function also allows to automatically reset possible alarm signaling by...

Page 13: ... yarn processing time then deactivate the programmable INC DEC outputs simultaneously with the thread guide of yarn 8 Set the jumper to position to operate in normal configuration recommended Yarn feeding speed up to 1500 m min Set the jumper to position in case of particular needs requiring higher speed up to 2500 m min Operating with the jumper set to BOOST configuration the operating temperatur...

Page 14: ...Technical data and installation 2 4 KTF 100HPS NPN Programmable Outputs Machine Connections PNP Programmable Outputs Machine Connections Electrical Interface of KTF 100HPS Devices ...

Page 15: ... Connection Example of a Complete System including KTF 100HPS Devices KTF PW4 Power Supply and SMART KTF 2000 Terminal Concerning all electrical systems it is a suggested rule to ensure that the ground cable GND is connected to the device support ...

Page 16: ...omplete System including KTF 100HPS Devices KTF PW4 Power Supply and Notebook with PC LINK KTF Studio Analysis Monitoring Software as alternative Concerning all electrical systems it is a suggested rule to ensure that the ground cable GND is connected to the device support ...

Page 17: ... please contact your local BTSR dealer Connecting Cables and Accessories in case of Installation with KTF PW4 Power Supply 8 way connection cable between KTF 100HPS and KTF PW4 KTF 400 FE Length 400 cm Female to female cable for connection between SMART KTF 2000 and KTF PW4 FE 50 FEC Length 50 cm FE 100 FEC Length 100 cm FE 200 FEC Length 200 cm FE 400 FEC Length 400 cm 24Vac transformers for KTF ...

Page 18: ...ch are secured to the back side of KTF devices The KTF FIX bracket is equipped with contact pins that penetrate the insulation layer and establish the electrical connection with the individual wires of flat cable thanks to the pressure provided by a contrast screw The electrical connection between KTF FIX clamping bracket and KTF 100HPS device is provided by the KTF10 FIX cable The following figur...

Page 19: ...e a height of 25 mm Connection cables and accessories in case of installation with flat cable KTF FLAT Flat cable KTF FLAT for KTF FIX KTF FLAT Variable length Flat cable KTF FLAT for KTF FIX with connectors for KTF PW4 connection 500 FLAT PW4 Length 500 cm with connector for KTF PW4 Connection cable between KTF 100HPS and KTF FIX KTF 10 FIX Length 10 cm Quick multi connection clamping of KTF 100H...

Page 20: ...plete System Including KTF 100HPS Devices External Power Supply Flat Cable KTF FLAT and SMART KTF 2000 Terminal Concerning all electrical systems it is a suggested rule to ensure that the ground cable GND is connected to the device support KTF 10 FIX FE 100FEC KTF FLAT KTF FIX ...

Page 21: ...luding KTF 100HPS Devices Flat Cable KTF FLAT and Notebook with PC LINK KTF Studio Analysis Monitoring Software as alternative Concerning all electrical systems it is a suggested rule to ensure that the ground cable GND is connected to the device support KTF FLAT KTF FIX KTF 10 FIX FE 100FEC ...

Page 22: ... the roller passing over the separation device When using nylon or cotton yarn with discontinuous processing and high stitch feeding variation due to patterns or sudden yarn feeding changes make just 1 coil around the roller After having wound the desired number of coils around the roller pull out the yarn from the bottom routing it over the loading cell tension sensor For a correct separation of ...

Page 23: ...ssing and holding down this push button for about 3 seconds on particular parameters you will have the possibility to enable disable the corresponding function 3 PUSH BUTTON RESET Press this push button to cancel possible error signalling on KTF display red LED flashing During the Programming phase press it to decrease the value of displayed parameter During the Control phase without an alarm cond...

Page 24: ...the set Target has been reached INC DEC Indicates with 1 flashing the increment of main tension Indicates with 1 flashing the decrement of main tension P1 P2 In Control environment indicates that the operating tension is the one defined in P1 MAIN TENSION In Control environment indicates that the operating tension is the one defined in P2 EXIT TENSION B Message Area It shows in the selected langua...

Page 25: ... by the device s motor 1 OFFSET Execution and or Error Reset When a KTF 100HPS device detects an Error condition E2 Tension Error etc the device stops and the LFA nnnn indication on display is replaced by the error message To re activate the device after having removed the cause that generated the error the operator shall simply turn in manual mode 2 revolutions the device roller The system detect...

Page 26: ...s the error performs the offset operation providing that the yarn is kept far from the loading cell and restores the normal operating conditions LFA nnnn shown on the display In this case the front red LED shows 2 sequences of close flashings 1 st flashing sequence Error Reset Offset 2 nd flashing sequence ...

Page 27: ... shown on display indicates that the device is currently excluded Re inclusion To re activate the device press and hold down for 3 seconds to confirm to cancel the operation In order to temporarily de activate a KTF 100HPS device simply press The condition of device temporarily de activated is signalled by the two red Leds front and rear on the device and by the Stop Led on KTF PW4 device 3 Contro...

Page 28: ...e Firmware version will temporarily appear on the display To switch from SIMPLE to ADVANCED and viceversa press and hold down for 3 seconds the ENTER button To avoid undesired changes of operating parameters after the installation of KTF 100HPS devices and after having setup and checked all the working parameters in ADVANCED programming environment it is advisable to activate the SIMPLE programmin...

Page 29: ...ed access to the device programmable functions KTF CODE Possibility to visualise and or directly set the device identification code LANGUAGE Possibility to choose the language used to show the message on the device display Setting of these parameters is already done by BTSR during manufacturing default values however it can be easily changed by the textile machine operator to meet specific require...

Page 30: ...agram of P1 P4 Advanced Programming Levels and Default Settings NOTES The values shown refer to the default parameters set by BTSR A LFA Length of Absorbed Yarn in m min B The selectable languages are Italian English French Spanish German Japanese ...

Page 31: ... which the KTF device must operate to create the desired article INC DEC active Allowed values 0 2 100 0 grams During programming phase you cannot set a tension value lower than the ERROR TENSION value or greater than the difference between the device full scale value 100 0 g and the ERROR TENSION value Choose the desired value using to increase the value or to decrease the value to confirm P1 2 E...

Page 32: ...KTF 100HPS Operation 3 10 KTF 100HPS Example 1 Main Tension 2 0 g Error Tension 0 5 g Example 2 Main Tension 5 0 g Error Tension 2 0 g Example 3 Main Tension 5 0 g Error Tension 6 g ...

Page 33: ...decrease the value to confirm Example Main Tension 2 0 g Error Tension 0 5 g Time Alarm 2 0 sec P1 4 INC DEC TENSION Increment decrement resolution of the tension graduated by INC DEC external pulses At every INC DEC pulse the main tension will be either increased or decreased by the amount indicated by this parameter with respect to the value set in MAIN TENSION 1st variable of P1 Allowed values ...

Page 34: ...ns that the function has been disabled In this case the EXIT TENSION parameter will assume the same value set on MAIN TENSION parameter within the P1 programming level To re enable this function press and hold down for 3 seconds the Enter button The OFF indication will disappear and it will be replaced by a modifiable numeric value Choose the desired value using to increase the value or to decreas...

Page 35: ...ivate the RELAX TENSION function When the yarn feeding speed becomes lower than the value set with this parameter the RELAX TENSION function will be automatically activated Allowed values 01 10 where 01 means activation speed 1 mt min 02 means activation speed 5 mt min 03 means activation speed 10 mt min 04 means activation speed 15 mt min 09 means activation speed 40 mt min 10 means activation sp...

Page 36: ... device operates with the tension set in MAIN TENSION A after a speed change and or a thread guide exit condition the feeding speed decreases following a deceleration ramp and when it reaches the value programmed in RELAX SPEED 03 10 m min in the example above the operating tension of KTF automatically toggles from MAIN TENSION value A 2 g to RELAX TENSION value B 0 8 g Deceleration Ramp Speed cha...

Page 37: ...T value resulting from the clamping position of the KTF 100HPS While lifting the yarn above the load cell press to check whether the stored OFFSET value corresponds to the actual OFFSET value If the two values are different press to align them to select the next parameter Keeping pressed for 3 seconds enables the Automatic Offset function and the display shows OFFSET AUTO For more details about th...

Page 38: ...s soon as the tension value will return within the programmed limits Mode 03 Function selection without INC DEC commands with or without KTF PW4 power supply By selecting Mode 03 the KTF 100HPS will be able to work without INC DEC commands but using the KTF PW4 power supply In such condition the device will use the tension value programmed in EXIT TENSION P2 as well as in ERROR TENSION and TIME AL...

Page 39: ...cret key code decreases the value of secret key code Press to save the key code and move to the next parameter P3 4 KTF CODE This function allows you to visualise and or set the numeric code corresponding to the identification address of the KTF 100HPS device Set the desired identification code using to increase the value or to decrease the value Usually the setting of device identification code i...

Page 40: ...t to select the P4 level to continue P4 1 LANGUAGE SELECTION This function allows you to select the language used to display messages and errors or to scroll forward backward the list of available languages ITALIANO ENGLISH FRANCAIS ESPANOL DEUTSCH JAPANESE to confirm the language indicated on display and return to the beginning of P4 menu to return to CONTROL status ...

Page 41: ...ension Alarm depend on the selected working mode MODE 00 The typical characteristics of Mode 00 are the following Immediate graduation reset as soon as the INC DEC signals are simultaneously de activated Error Tension Alarm active only when KTF 100HPS operates with P1 Tension MAIN TENSION P1 MAIN TENSION 2 0 gr EXIT TENSION 4 0 gr INC DEC TENSION 0 1 gr The time between two INC DEC commands must b...

Page 42: ...vation deactivation Error Tension Alarm active only when KTF 100HPS operates with P1 tension The A and B pulses must not necessarily have the same duration however it is important that their duration is not less than 60 msec If the two pulses A and B occur in a time less than 1 second the programmed tension will be restored to the original value always 1 second after the time S Graduations Reset ...

Page 43: ... only when KTF 100HPS operates with P1 tension MAIN TENSION Main Tension 2 0 g Error Tension 0 5 g Time Alarm 2 0 sec MODE 03 The typical characteristics of Mode 03 are the following INC DEC commands usable like for Mode 00 The KTF 100HPS device generates the Error Tension Alarm when the tension goes out of the programmed tolerance band and automatically resets the alarm as soon as the tension ret...

Page 44: ...ENSION Motor rotation direction reversed for yarn recovery during particular working steps with activation of a solenoid valve Such solenoid valve activates an air blow that directs the yarn inside a recovery chamber The solenoid valve can be driven either by the textile machine or directly by the KTF through the CHA and CHB output signals see paragraph Electrical Interface of KTF 100HPS Devices p...

Page 45: ... Modes 02 and 03 as soon as the tension value drops again within the programmed tolerance band ACTIVATION OF OPEN COLLECTOR OUTPUTS TO DRIVE THE SOLENOID VALVE When the KTF operates in Mode 04 and activates the yarn recovery function by reversing the motor rotation direction is activates the two CHA and CHB outputs on KTF s connector 2 see Electrical Interface of KTF 100HPS devices page 2 4 These ...

Page 46: ...KTF 100HPS Operation 3 24 KTF 100HPS Page intentionally left blank ...

Page 47: ...ON BLINKING ON Manual roller rotation with Auto Offset de activated Reset of Pending Alarms Single pulse sequence OFF Manual roller rotation with Auto Offset activated Offset execution Reset of Pending Alarms Double pulse sequence OFF This condition is obtained with INC DEC disabled i e when you are working with the tension defined in P2 If you work with the tension defined in P1 even if you press...

Page 48: ...te the cause of failure please contact your BTSR reseller it could be necessary to send the device to the BTSR repair centre Current Error displayed on KTF display 1 The current absorbed by the device exceeded the maximum allowed value 1 Check the usage conditions of the systems If you cannot locate the cause of failure please contact your BTSR reseller it could be necessary to send the device to ...

Page 49: ...ter P3 4 is correct if necessary carry out the numbering procedure using the SMART KTF 2000 terminal or set directly the identification code on KTF device parameter P3 4 2 Check the correct operation of SMART KTF 2000 terminal using the numbering procedure described in the SMART KTF 2000 manual 3 Check the wiring starting from SMART IN connector on KTF PW4 power supply and on SMART KTF 2000 termin...

Page 50: ...achine stop phase will be eliminated Even if the torque of motor driving the roller rotation is very low and does not involve hazards for the operator safety it s always advisable to lock the motor prior to operate on KTF 100HPS devices yarn threading tilt adjustment of coil separation device etc in order to avoid unexpected motor start up events To lock the motor just press the button on KTF and ...

Page 51: ...BTSR International S p A Via S Rita 21057 OLGIATE OLONA VA Tel 0331 323202 Fax 0331 323282 Internet www btsr com REV 1 0 04 05 DISTRIBUTOR ...

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