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SMART MATRIX QUILT - Rev. 1.1 - January 2010 
Copyright - BTSR – All rights reserved. 

This manual is entrusted to the users of 

SMART MATRIX QUILT

 system developed for control/monitoring 

activities of quilting machines equipped with 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 

EMC 2004/108/CE 

and 

Low Voltage 

Directive 2006/95/CE

. 

 

All BTSR products are covered by patents and adopt exclusive, profitable and high tech solutions. 
 

Adobe Acrobat

 is a registered trademark of Adobe Systems Incorporate. 

BTSR

® is a registered trademark “Best Technology Study & Research” of BTSR International S.p.A. 

Summary of Contents for SMART MATRIX QUILT

Page 1: ...SMART MATRIX QUILT Operating Manual ENGLISH Rev 1 1 January 2010 ...

Page 2: ...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 EMC 2004 108 CE and Low Voltage Directive 2006 95 CE All BTSR products are covered by pa...

Page 3: ...Introduction i ...

Page 4: ......

Page 5: ... yarn sequence used by the quilting machine during a sample cycle LEARN and to indicate any type of error detected during the subsequent production cycles excessive or insufficient yarn tension The availability of a User Friendly graphic interface allows you to quickly and intuitively program all the operating parameters of TS5 TS7 sensors in addition it provides a real time monitoring of sensors ...

Page 6: ...nces of the various system components TS5 TS7 sensors SM DIN QUILT boards Furthermore it provides some details to better understand the operating principles upon which the SMART MATRIX QUILT system is based SLOW FAST Control Parameters menagement of PRXsignal etc Symbols Used This symbol is used to point out notes warnings and other important information TS5 TS7 Within this manual the TS5 Dttt or ...

Page 7: ...Mode 2 14 Keycode Setting 2 15 Communication Test 2 17 Sensor Test 2 18 TS5 TS7 Offset 2 19 Sensor Firmware Upgrade 2 21 SM DIN QUILT Board Firmware Upgrade 2 22 Information reading from SM DIN QUILT Boards 2 23 MATRIX LCD Adjustment 2 24 Information about SMART MATRIX QUILT 2 25 Style Programming TS5 TS7 2 26 Style Loading 2 29 Graphics 2 32 Efficiency Data 2 33 Alarm Counter Display TS5 TS7 2 34...

Page 8: ...Table of Contents SMART MATRIX QUILT iv Page left intentionally blank ...

Page 9: ...Connections and Electrical Interface 1 ...

Page 10: ......

Page 11: ...MART MATRIX SM DIN TS5 TS7 Sensors Prior to operate the SMART MATRIX terminal make sure you have programmed the communication speed on all the SM DIN QUILT 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 On all electrical system...

Page 12: ... DIN TS5 Connection SMART MATRIX QUILT 1 2 SMART MATRIX SM DIN TS5 Connection The following diagram shows the connection of TS5 Sensors to SM DIN Boards as well as the connection between SM DIN Boards and SMART MATRIX ...

Page 13: ...TRIX TS7 Connection SMART MATRIX QUILT 1 3 SM DIN SMART MATRIX TS7 Connection The following diagram shows the connection of TS7 Sensors to SM DIN Boards as well as the connection between SM DIN Boards and SMART MATRIX ...

Page 14: ...N 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 Machine Interface INPUT Machine Interface OUTPUT Power Supply ...

Page 15: ...nnection As you may note 4 identical connectors are available allowing you to connect up to 4 TSx xx The number of TS xx sensors actually connectable to the Board depends on the capacity of power supply system used Sensors Sensors Sensors Sensors Max 100 TS xx sensors SM DIN nn Module Identified by means of Edt function directly on the SM DIN module ...

Page 16: ...ss the small P button 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 1 As STOP output it is advisable to use the Relay ...

Page 17: ...RIX QUILT Generic Application Diagram SMART MATRIX QUILT 1 7 SMART MATRIX QUILT Generic Application Diagram The MACHINE STOP signal can be obtained either from the SM DIN Boards or from the SMART MATRIX terminal ...

Page 18: ...SMART MATRIX QUILT Generic Application Diagram SMART MATRIX QUILT 1 8 Page left intentionally blank ...

Page 19: ...Operating Instructions 2 ...

Page 20: ......

Page 21: ...sages etc graphic information sensors map etc B 6 buttons for immediate activation of particular functions increment decrement speed up shortcuts C Multi function Rotary Selector How to Use the Rotary Selector The selector provides both pointing and data entry functions Turn the selector to select a menu item function parameter within the configuration screens etc Rapid click to confirm the select...

Page 22: ...be carried out using exclusively the multi function Rotary Selector through a navigation technique based upon Pointing Selecting and Value Setting actions The following example explains this navigation technique The example refers to the I O Signals Confituration function on SM DIN QUILT Board which makes use of 2 windows IN and OUT 1 Name label of currently selected window foreground 2 Name label...

Page 23: ...pointed item The field name will be shown in reverse and the symbols appear to the right of the field value Example FAST INPUT field selected reverse Turn the selector either to Clockwise or to Counter clockwise direction to select the desired option NO Normally Open contact or NC Normally Closed contact Example New value of FAST INPUT N C Once you have set the desired value e g N C click to confi...

Page 24: ...hlighted Click to select the OUT window and enable the access to its parameters Select the desired parameter as explained on previous paragraph 1 Navigation inside the Selected Window IN 3 Parameters Saving Once you have setup all the desired parameters within a determined function press and hold down 3 seconds the rotary selector SAVE to save the settings BACK to return to previous screen without...

Page 25: ... of the various function will be provided on next paragraphs The following examples are only provided to summarize the Button Function association Within some configuration parameter setting functions the B1 B6 buttons may also perform a shortcut function which will be explained each time Immediate function activation buttons B1 Sensors Histogram B2 Efficiency Data B3 Alarms Counters B4 LEARN Acti...

Page 26: ... detected 004 4 active sensors System working in Stop status No errors detected 004 4 active sensors Tension High failure TENS H detected by sensor No 1 DEVICE01 mounted on needle bar 1 LEVEL1 Press to scroll the list of sensors in alarm Learn reservation P_LEARN Learn in progress LEARN 0004 number of sensors detected Alternating ...

Page 27: ...ollowing graphic symbols will be used Turn the selector to point the desired option Select the desired option and click to confirm Press and hold down the button 3 sec to return to previous menu and or to activate the data saving function Error Alternating Error details Main Menu Style Database management Style Loading System Configuration ...

Page 28: ...of SM DIN QUILT Boards used 1 10 Point the symbol of 1st Board Select the field indicating the number of sensors connected to Board 1 default 100 Set the number of sensors actually connected to Board 1 e g 12 and confirm Point the symbol of 2nd Board and so on for all the Boards used Once you have configured all the Boards For instance let suppose now to configure an application comprising 4 TS5 s...

Page 29: ...how The green led will flash on all sensors Shim the touch light of the sensor corresponding to LEVEL 01 DEVICE 01 The sensor s led changes from flashing green to red On SMART MATRIX display the DEVICE and LEVEL fields will automatically increase to select one by one the sensors to be numbered Shim the touch light of the relevant sensor and continue with the numbering of all sensors At the end of ...

Page 30: ...out all the operations described for sensor configuration and numbering until the start numbering screen appears Select the position of sensor to be re numbered LEVEL NN DEVICE NN Shim the touch light of the relevant sensor the sensor s led changes from flashing green to red To quit the identification procedure after the sensor re numbering EXIT to return to configuration menu ...

Page 31: ...nals The identification code is required for Upgrade operations Enter the SETUP menu Select MATRIX CODE Choose the SMART MATRIX identification code and activate the save function SAVE to save the choice BACK to return to the previous screen without saving EXIT to return to menu Since the SMART MATRIX QUILT application uses only one terminal always set 1 as identification code SETUP MATRIX CODE ...

Page 32: ...you to configure the output relay of SMART MATRIX terminal as normally open NO or normally closed NC contact Enter the SETUP menu Select I O CONFIG Select BOARDS Configure the input signals FAST SLOW RESET LEARN ZPX PRX within the IN window and the output signals STOP1 STOP2 within the OUT window as NO or NC To activate the save function SAVE to save the choice BACK to return to the previous scree...

Page 33: ...X terminal as NO or NC To activate the save function SAVE to save the choice BACK to return to the previous screen without saving EXIT to return to menu For more information about the meaning and function of FAST SLOW RESET LEARN PRX signals please refer to the STYLE EDIT function on next pages and to Section 3 System Information ...

Page 34: ...g EXIT to return to menu If you select the MANUAL option then after an alarm signaling you will have to press the RESET button or another button capable of providing the RESET signal according to the polarity previously set with the I O CONFIG function prior to restart the machine Is you select the AUTO option then you may restart the machine after an alarm signaling without supplying any manual R...

Page 35: ... list of accessible menus and options it also allows you to remove clear users and to change the list of accessible menus and options You cannot set two users with the same name or with the same password Enter the SETUP menu Select KEY CODE Add New User Press the indicated button to add a new user Set the new user name e g ALAN and password e g ALAN123 in the ACCOUNT windows Select the menus and o...

Page 36: ...ated button to edit change the access rights of selected user Change the configuration of menus and options available to the selected user SETUP MENU STYLE LOAD STYLE EDIT PATTERN LEARN ERROR COUNTERS When you try to access a password protected function the following prompt will appear Choose the user name and set the password to access the selected function ...

Page 37: ...ct TEST COM Select COMM EFF to check the efficiency level of communications Select GLOBAL or SINGLE single Board Number of sensors on which communication errors occurred DEV IN ERROR and total number of transmission repeated as result of detected errors TOTAL RETRY A maximum of 5 transmission are repeated for each sensor Global efficiency index Like for GLOBAL option but referred to the selected B...

Page 38: ...evious menu If the GLOBAL Test shows an error e g 001 005 which means that one sensor does not correctly communicate with the system then operate as follows 1 Run the SINGLE Test to locate the Board which the defective sensor is connected to 2 Select the Sensor Test and confirm the correct red Led blinking the sensor which does not show the red led blinking is the defective or disconnected one SET...

Page 39: ...ectable sensor range Prior to start the calibration procedure remove the yarn from the loading cell of the involved sensors Enter the SETUP menu Select SERVICE Select TS xx OFFSET Current offset reading Select the sensor on which you want to read the current offset LEVEL NN DEVICE NN Current value detected on sensor located at LEVEL 01 DEVICE 01 position 0 2 g To move to the sensor calibration fun...

Page 40: ...irm the operation OFFSET operation completed Offset on a sensor range OFFSET RANGE to calibrate the desired sensor range Select the desired sensor range e g from LEVEL 02 DEVICE 01 to LEVEL 02 DEVICE 02 To calibrate the selected sensors To confirm the calibration of selected sensors OFFSET operation completed ...

Page 41: ... the firmware of TS5 TS7 sensors Enter the SETUP menu Select SERVICE Select TS5 UPG Select the range of sensors on which you want to upgrade the FIRMWARE default All To continue UPGRADE to start the upgrading Automatic scanning of sensors to be upgraded Automatic upgrading in progress SETUP SERVICE TS xx UPG ...

Page 42: ... firmware of SM DIN QUILT Boards Enter the SETUP menu Select SERVICE Select BOARDS UPG Select the range of SM DIN QUILT Boards on which you want to upgrade the FIRMWARE default All To continue UPGRADE to start the upgrading Automatic upgrading in progress The display of Boards currently being upgraded will show SETUP SERVICE BOARDS UPG ...

Page 43: ...OARDS INFO SETUP SERVICE BOARDS INFO Firmware Release currently loaded on the Board Board Hardware Release Board BOOTLOADER Program Release Sensor Upgrading Release Number of TS xx sensors currently managed by the Board Contact configuration NO or NC of input signals Contact configuration NO or NC of output signals Reset Timeout time after which the STOP signal will be released following an alarm ...

Page 44: ...ay and to set the display auto off time 1 20 minutes or No Off if the auto off function is not required Enter the SETUP menu Select LCD DISPLAY Adjust CONTRAST BRIGHTNESS DISPLAY AUTO OFF To activate the save function SAVE to save the settings BACK to return to the previous screen without saving EXIT to return to the menu SETUP LCD DISPLAY ...

Page 45: ...ILT This function allows you to detect the Hardware Firmware OS and Boot Program versions These values shall be communicated to BTSR Service Department when requiring technical support to solve specific problems Enter the SETUP menu Select the INFO menu item To return to previous menu SETUP INFO ...

Page 46: ...ltiple groups the identification number of the first device belonging to the first group GROUP 1 will always be L1D1 Level 1 Device 1 and you will only have the possibility of setting the identification number of the last device belonging to the first group L1DN the first device of the second group will automatically be set as L2D1 Level 2 Device 1 and so on Exsample 4 TS5 TS7 devices grouped into...

Page 47: ...nimum tension value below which an alarm will be generated 1 100 of the setpoint value LOW ms running time with tension LOW after which an alarm will be generated 10 5 000 ms Tol Tolerance 1 250 HIGH maximum tension value above which an alarm will be generated 1 999 of the setpoint value HIGH ms running time with tension HIGH after which an alarm will be generated 10 5 000 ms Tol Tolerance 1 250 T...

Page 48: ...ist of styles contained in the database including the TS5 STYLEBB style To leave the function Programming a New Style EXIT to return to previous menu General Notes to speed up the parameter programming 1 The parameters set on one of the two windows either FAST or SLOW can be copied to the other window pressing the shortcut button when the built in lamp is lit A confirmation message Copy from XXXX ...

Page 49: ... name setting keyboard shows the name of the selected style to be modified TS5 STYLEAA Type the Name you want to assign to the modified style To save the new style If you change the style currently loaded on specific TS5 TS7 devices indicated by the diskette symbol the changes will be automatically loaded on the relevant TS5 TS7 devices Style Clearing This function allows you to remove a style fro...

Page 50: ...he sensors Style Loading Select the STYLE LOAD menu item Once you have activated the STYLE LOAD function from main menu choose the style you want to load e g TS5 STYLE1A and press LOAD A temporary LOAD Style Gr N window will appear At the end of the loading operation the style list will automatically re appear TS5 STYLE1A style loaded To leave the function EXIT to return to main menu STYLE LOAD ...

Page 51: ...om main menu choose the style you want to unload e g TS5 STYLE1A and press LOAD The symbol indicates that TS5 STYLE1A is the style currently loaded on the devices Confirm the style unloading operation The style TS5 STYLE1A will be unloaded from the TS5 TS7 devices The diskette symbol will disappear from the right side of the style name ...

Page 52: ...nsion stored during the inspection session Press the graphics direct access button Histogram To select the various positions to either increase or decrease the vertical axis scale tension to move to the bar graph option Bar Graph Select EXIT to return to the histogram display and then to CONTROL status Tension value of selected sensor dark bar Sensor position LEVEL NN DEVICE NN Selected device tur...

Page 53: ...ton to directly access the efficiency data By selecting the relevant window LEARN RESET STYLOAD you will see the data that summarize The work time The stop time The total time The efficiency rate respectively from the last LEARN operation from the last RESET operation from the last style loading operation STYLOAD To leave the function BACK to return to the previous display EXIT to return to the me...

Page 54: ...e counters The indicated values represent the sum of all errors TENS H TENS L referred to all devices Counter clearing on a range of devices To select the desired device interval To activate the clearing operation CRL ALL to clear the counters of selected devices During the clearing operation a CLEAR COUNTERS message will appear Counter clearing on a range of devices Displayng the counters of indi...

Page 55: ...the clearing operation a CLEAR COUNTERS message will appear Displaying the counters of individual devices To select desired device the value of counters TENS H and TENS L are referred to the selected device only in this example LEVEL 1 DEV 001 To leave the function EXIT to leave the function to CONTROL status ...

Page 56: ... the end of learning cycle after the time interval defined in Delay FAST the system automatically activates the Control mode and continuously controls the regular running of yarn inside all the nnnn sensors detected during the learning stage The LEARN function must be activated while the Quilting Machine is stationary Pressing the button the LEARN function is reserved P_LEARN shown on the screen a...

Page 57: ... Replace the SMART MATRIX QUILT terminal Errors detected on SM DIN Boards MESSAGE DESCRIPTION POSSIBILE SOLUTION ERR RAM SMDIN XX RAM memory error on SM DIN module with XX ID code Press Reset to clear the error ERR EEP SMDIN XX Eeprom memory error on SM DIN module XX ID code Press Reset to clear the error Then re program ID code and Baudrate on SM DIN module ERR PRG LEVEL XX Sensor programming err...

Page 58: ...EVICE YY Press Reset to clear the error then repeat the numbering procedure SHORT LEVEL XX Short circuit on sensor stop output DEVICE YY Confirm the correct connection of stop line TENS L LEVEL XX Low tension alarm DEVICE YY TENS H LEVEL XX High tension alarm DEVICE YY ERR COM LEVEL XX Communication error with sensor YY DEVICE YY Check the connection cables or repeat the numbering procedure ...

Page 59: ...rocess RAM Error Error detected on RAM memory contents the memory will be initialized with the default values EEPROM Error Error detected on EEPROM memory contents the memory will be initialized with the default values Input Signals Error The Board cannot determine the logical level of the external input signals EXT Communication Error The Board cannot communicate with one or more sensors Programm...

Page 60: ...Errors shown on Display of SM DIN Boards SMART MATRIX QUILT 2 40 Page left intentionally blank ...

Page 61: ...System Information 3 ...

Page 62: ......

Page 63: ... error percentages on tension and the duration of anomalies The TS5 TS7 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 TS7 Sensors The TS5 TS7 sensors provide the real time control of the yarn running inside the eyelet and in case of defect they either immediately st...

Page 64: ...le in various typologies to meet specific needs of individual installations applications The following diagram shows a detailed coding rule of the available sensors depending on possible variables Example TS5 D500DD TS5 sensor 500 grams weight with model D eyelet Diamond finishing Eyelet Models TSX D ...

Page 65: ...SMART MATRIX QUILT 3 3 Mechanical Characteristics of TS5 TS7 Sensors Sizes mm The cable with external connector identifies the TS5 version for more details please refer to the Differences between TS5 and TS7 Sensors paragraph ...

Page 66: ...TS5 TS7 Sensor Features SMART MATRIX QUILT 3 4 Usage The cable with external connector identifies the TS5 version for more details please refer to the Differences between TS5 and TS7 Sensors paragraph ...

Page 67: ...on TENS H Max Tension Threshold TENS L Min Tension Threshold TENS for QUILT application it is represented by Working Tens parameter within the EDIT Group N PARAMETERS screen This parameter indicates the nominal tension value i e the reference SETPOINT tension according to which the threshold minimum and maximum errors will be calculated TENS H for QUILT application it is represented by High parame...

Page 68: ...Parameters that Affect the TS5 TS7 Sensor Detection Features SMART MATRIX QUILT 3 6 Tension Control Example TENSION TIME Error TENS H Error TENS L ...

Page 69: ... 2 GND 3 RX TX 4 RX TX 5 STOP 6 GND 7 ANAL 8 ENABLE 1 VCC 2 GND 3 RX TX 4 RX TX Recommended Technical Characteristics TS5 TS7 Power supply voltage 12 24 VDC 10 24 VDC 10 Current absorption 45 mA Max 30 mA Max Analogic output only for TS5 8 pin 100 mV 5 V Analogic output resistance only for TS5 8 pin 1K Ohm Operating temperature range 10 50 10 50 Storage temperature range 25 85 25 85 Tension range ...

Page 70: ...2 essential parameters P01 Unique Board identification code 01 10 P02 Communication speed Baudrate For more details please refer to next page SM DIN QUILT Technical Characteristics Power supply voltage 12 15 VAC 24 VDC Current absorption 200 mA Max Protection fuse Board protection 5 A Protection fuse Sensor power supply 3 A 0 3 A 125 VAC Stop output NO NC 1A 30 VDC 0 24 VDC VIL Max 1 2 VDC Inputs ...

Page 71: ...SM DIN QUILT Technical Characteristics SMART MATRIX QUILT 3 9 ID and Transmission Speed Configuration on Each SM DIN Board P01 P02 Parameters 01 10 ...

Page 72: ...ding two independent synchronization signals SLOW EXT and FAST EXT Possibility of using two different sets of parameters one for the ramp stage at low speed the other for the normal rate condition by simply setting two different values of Delay Control in SLOW and FAST example 2 PRXpulses and 5 PRX pulses and connecting both inputs SLOW EXT and FAST EXT to the machine startup signal Parameters use...

Page 73: ... through the parameters DELAY SLOW and DELAY FAST as indicated on previous section SLOW FAST Control Parameters As an alternative you may simulate the SLOW and FAST states using the PRX signal as timing element Notes about the style parameters programming STYLE EDIT menu If the PRX pulses are too fast then you may use a signal divider setting the PRESCALER parameter STYLE PRX SETUP screen Example ...

Page 74: ...by the SMART MATRIX Terminal This operation is performed by the RESET signal which can be generated either Manually or Automatically see Choice of Reset Mode within the SETUP menu When you choose the Auto Reset operation in case of failure detected the system activates the STOP signal it controls the machine status waiting for the complete stop of the machine it self then it releases the STOP sign...

Page 75: ...BTSR International S p A Via S Rita 21057 OLGIATE OLONA VA Tel 0331 323202 Fax 0331 323282 Internet www btsr com REV 1 1 01 10 DISTRIBUTOR ...

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