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SMART CLEARER & ISSC.

YARN CONTROL SYSTEM

Operating Manual

Rev. 3.0 – July 2003

ENGLISH

Summary of Contents for SMART CLEARER

Page 1: ...SMART CLEARER ISSC YARN CONTROL SYSTEM Operating Manual Rev 3 0 July 2003 ENGLISH ...

Page 2: ...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 profita...

Page 3: ...ameters that affect the sensor detection features 3 7 Preliminary operations for using the SMART CLEARER terminal 3 11 Operating Sequences 3 12 Machine Start Procedure 3 13 Preliminary Instructions for the Correct Use of ISSC Sensors 3 13 Restart after an Alarm Condition on a Single Position 3 13 Enabling the SETUP Menu Functions CONFIG 3 14 Enabling the SETUP Menu Functions NEW MODIFY ERASE 3 15 ...

Page 4: ... New Article Characteristics of the Slub Tangle defect 3 38 YARN Creating a New Article Characteristics of the Missing Ply defect 3 39 YARN Creating a New Article Characteristics of the Added Ply defect 3 40 NOYARN Creating a New Article Characteristics of the Yarn Missing Defect 3 41 MODIFY Modifying an existing Article 3 42 ERASE Erasing an existing Article 3 42 SCAN Displaying Articles currentl...

Page 5: ...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 summarises the sequence of operations that staff who have had sufficient experience in handling the sys...

Page 6: ...o normally closed ST NcO Stop Output programmable as Normally Closed NC or Normally Open NO contact NcO normally open ST Cp Cp continous signal ST cP Stop output programmable as Continous Signal C or Pulse Signal P cP pulse signal 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 program...

Page 7: ...que features which make it a true microcomputer dedicated to the yarn quality control SMART CLEARER is a fully parametric system this means that for each type of defect the use 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 ...

Page 8: ... of an automatic numbering procedure Programmable Functions The system allows programming and saving all the quality control characteristics associated with various articles Multi sensor System The system allows connecting up to 200 yarn quality control sensors of the ISSC series Easy Monitoring Besides the information shown on graphical display of SMART CLEARER each ISSC sensor has a red LED that...

Page 9: ...se 2sec 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 Signaling With integrated LED Dimensions 15 x 15 x 36 5 Temperature range 10 50 C Installation The installation of the SMART CLEARER system depends on the type of...

Page 10: ...l data and installation 2 2 SMART CLEARER Interface Connectors on SMART CLEARER Concerning all electrical systems it is a recommended rule to ensure that the ground cable GND is connected to the sensor support ...

Page 11: ...SMART CLEARER 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 Signaling Light etc MA2FE8 Extension Cable 4x0 35 mm with Male and Female connector MA50 FEC Length 50 cm MA100 FEC Length 100 cm MA2...

Page 12: ...e of Generic Application Connection A Machine Start Stop Contact ENABLE For further details see ENABLE Signal Function page 3 5 Concerning all electrical systems it is a recommended rule to ensure that the ground cable GND is connected to the sensor support ...

Page 13: ...f 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 signalling the operating status and levels in w...

Page 14: ...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 Durin...

Page 15: ... 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 ...

Page 16: ...s nep Yarn reduction slub Slubs and tangles slub Added yarns yarn Missing yarns yarn Yarn not present broken noyarn As the ISSCs are parametric devices it is possible to set freely title error percentages and lengths referred to the above mentioned defects easily adapting quality control to the real needs The ISSC devices are very easy to use as they are ready to accommodate a large variety of acc...

Page 17: ...rresponding to DELAY CONTROL Green LED flashing resumes the normal control Green LED permanently lit Electrical Characteristics of the STOP Signal Protection against short circuits Collector continuous current 200 mA Peak collector current 500 mA Vce 1 2V with I_ collector 500mA ENABLE Signal Function The ENABLE signal represents for the ISSC sensor an Input signal having two different effects on ...

Page 18: ...tion a stop due to a fault detection a machine position is working a standstill machine position Interpretation of the signalling lights located on the sensors Green Led ON Sensor under normal control No defects detected by the sensor Green LED FLASHING Sensor under automatic numbering procedure Sensor in Delay Control phase Sensor disabled via HW or SW Red LED FLASHING During machine operation th...

Page 19: ...missing ply YARN added ply NOYARN yarn missing SPEED yarn collection speed in meters per minute The quality control performed by ISSC sensors is also affected by other factors such as DELAY CONTROL waiting time before starting the control process MONITOR CONTROL sensor operating mode LOCK UNLOCK touch light button operating mode STOP NO NC Stop output operating mode STOP CP STOP output as continuo...

Page 20: ...centage 1 999 against nominal ø Minimum Defect Length 0 1 40 m The ISSC sensor signals an error when it detects a defect matching the programmed settings Thickening Percentage Minimum defect Length NO YARN This function allows to detect the yarn missing condition according to the following programmable characteristics Reduction Percentage 1 99 against nominal ø Minimum Defect Length 0 1 40 m The I...

Page 21: ...sh of the red Led without activating the Stop output CONTROL Activates the Stop output and signals the error by means of a variable sequence of the red Led 1 red flash NEP 2 red flashes SLUB 3 red flashes SLUB 4 red flashes YARN 5 red flashes YARN 8 red flashes Yarn not running in the correct position or non homogeneous dirtiness accumulation permanently lit NOYARN STOP C P It defines the operatin...

Page 22: ...sor will continuously adapt the reference Title depending on possible variations dirtiness accumulation tension charge etc CAL AM It allows you to perform the sensor calibration in two different modes Automatic or Manual Am AUTOMATIC mode When a sensor switches to alarm status red LED on the system automatically activate the calibration procedure During the restart phase the yarn must be kept outs...

Page 23: ... the memory of the SMART terminal Press to reset the error The system will erase all settings entered by the user and will reload the default values If the error persists refer to Troubleshooting chapter If the system displays one of the messages that you can see on the left hand side of this page it means that the terminal is working correctly and that it is possible to activate one of the four o...

Page 24: ...ncludes four items SETUP allows the completion of tasks and CONTROL allows the activation of control mode WORK allows the completion of tasks READ allows the completion of tasks The following five operating sequences show how to activate the four items of the main menu and how to choose the desired function within each item The following pages will describe in detail each task providing all the ne...

Page 25: ...arm condition occurred on a single machine position red LED continuously flashing on the sensor operate as follows 1 Put the SMART CLEARER system in CONTROL mode 2 Start the position using the Start Stop button keeping the yarn outside the sensor 3 Wait until the sensor after turning to flashing green features a single red LED about 3 seconds then insert the yarn inside the sensor and confirm that...

Page 26: ...Operation 3 14 SMART CLEARER Enabling the SETUP Menu Functions CONFIG ...

Page 27: ...Operation SMART CLEARER 3 15 Enabling the SETUP Menu Functions NEW MODIFY ERASE ...

Page 28: ...Operation 3 16 SMART CLEARER Enabling the WORK Menu Function Enabling the READ Menu Function ...

Page 29: ... 17 CONTROL Function XX sensor number ZZZZ defect type NEP SLUB SLUB YARN YARN NOYARN NN No defects detected by sensor XX Further details about the identification of possible problems can be found on the Troubleshooting chapter ...

Page 30: ...mber of sensors actually connected to the system is reached At this point press to confirm This screen indicates that the phase of automatic sensor numbering is starting YYY shows the total amount of sensors to be numbered ZZZ shows the number of the first sensor and subsequently the next one to be numbered Check that the sensor being numbered has the green LED FLASHING which indicates Sensor read...

Page 31: ...cts only when such delay time has elapsed The delay time is indicated by the green Led flashing When working in automatic mode the D CNTR parameter must be 5 seconds Once you have selected the D_CNTR function from CONFIG function press to have access to the function Set the desired value 1 250 seconds using or Press to confirm the entered value The D_CNTR WAIT message shown for a few seconds indic...

Page 32: ...OCK UNLOCK condition set with this function Once you have selected the LK ULK function from CONFIG menu press to have access to the function If necessary press to select the desired option either UNLOCK CONFIG to enable the button currently disabled or LOCK CONFIG to disable the button currently enabled Press to confirm Either UNLOCK WAIT UNLOCK PRG OK or LOCK WAIT LOCK PRG OK will appear to indic...

Page 33: ...gned to all connected sensors while if you choose the Monitor mode you may assign this mode to either all or just a given configurable range of sensors for instance on a machine having 40 sensors installed you could choose to program the Monitor mode only on sensors 7 to 20 in this way sensors 1 to 6 and 21 to 40 will automatically be programmed in Control mode Once you have selected the MO CTR fu...

Page 34: ...o confirm the set values The display shows for a few seconds the messages CONTROL WAIT CONTROL PRG OK or MONITOR WAIT MONITOR PRG OK to indicate that the function has been programmed correctly Setting the Monitor mode can be particularly useful during the parameters tuning phase immediately after installation to avoid continuous stops which could hinder the system test and calibration phases Press...

Page 35: ...BLE signal operation please refer to the Interface Specification paragraph Once you have selected the EN NCO function from CONFIG menu press to have access to the function If necessary press to select the desired option either ENAB NO CONFIG or ENAB NC CONFIG Press to confirm the selection The display shows for a few seconds the messages ENAB NO WAIT and ENAB NO PRG OK or ENAB NC WAIT and ENAB NC ...

Page 36: ...STOP signal operation please refer to the Interface Specification paragraph Once you have selected the ST NCO function from CONFIG menu press to have access to the function If necessary press to select the desired option STOP NO CONFIG or STOP NC CONFIG Press to confirm the selection The display shows for a few seconds the messages STOP NO WAIT and STOP NO PRG OK or STOP NC WAIT and STOP NC PRG OK...

Page 37: ...have selected the ST Cp cP function from CONFIG menu press to have access to the function If necessary press to select either ST_Cont CONFIG or ST_Puls CONFIG Once you have selected the ST_Cont ST_Puls function from CONFIG menu press to access the function Press to confirm the selection The display shows for a few seconds the messages ST_Cont WAIT and ST_Cont PRG OK or ST_Puls WAIT and ST_Puls PRG...

Page 38: ... on the operator must simply press the touch light keeping the yarn onside the sensor only during this short operation At restart time detected by means of the Enable signal the sensor will automatically perform the calibration procedure without the need to keep the yarn outside the sensor If the operator does not press the touch light the sensor will restart working with the old calibration The m...

Page 39: ...mulation tension changes etc In both cases the AUTOSET procedure will be activated when an error is detected or the ZEROSET function is carried out only if the sensor ENABLE signal is connected to the machine s Start Stop contact Once you have selected the ABS REL function from CONFIG menu press to have access to the function If necessary press to select the desired option either ABS CONFIG or REL...

Page 40: ...e of your choice from 1 to 7 alphanumeric characters using the following buttons Increases the character where the cursor is positioned Decreases the character where the cursor is positioned Moves the cursor one position to the right Confirms and stores the code which has been set If no code is entered the function is disabled and you will not be asked for an access code when entering the SETUP an...

Page 41: ...s DD day MM month YY year dd mm yy New values if needed Increases the value Decreases the value Alternatively selects dd mm yy fields Once you have checked and setup if necessary the date press to confirm HH MM Read values HH hours MM minutes hh mm New values if needed Increases the value Decreases the value Alternatively selects hh and mm fields Once you have checked and setup if necessary the ho...

Page 42: ...ss to have access to the Test function This screen indicates that the sensor test is going to start Press to continue DEV XXX indicates the sensor which is being tested initially sensor no 1 Check that the Red LED of sensor XXX is flashing and there are no other sensors with the Red LED FLASHING If the Red LED of the sensor that should respond to the number XXX is not flashing it means that the se...

Page 43: ...n signalled by the sensors Press until the TEST CONFIG menu option is displayed Press to have access to the Test function Press to select the Communications Test This screen indicates that the Communications Test is going to start Press to begin the test From this moment on the system communicates repeatedly with all connected sensors The running test status is signalled by the flashing red LED in...

Page 44: ... to continue XXX Number of ISSC device n n Software version loaded on XXX device Press to select in sequence all the connected devices and check the software version loaded Press to return to the VERS TEST screen Press to select the UPG menu item Press to access the updating procedure This screen means that the software updating procedure on ISSC devices is in progress n n Software version that wi...

Page 45: ...2 NO YARN 1 99 default 25 0 1 40 m default 2 The SPEED parameter indicates article collection Speed on the machine in M min The NEP SLUB SLUB YARN YARN and NOYARN represent instead the possible defects detectable by ISSC sensors on the article for each of these parameters you will have to indicate the TIT and LMIN values which respectively represent the Thickening Reduction percentage with respect...

Page 46: ... parameters if you press the CONTROL key the parameter an under configuration will be disabled to re enable the parameter simply press again the CONTROL key Now you will have to program the sequence of control parameters related to the article being created SPEED NEP SLUB SLUB YARN YARN NOYARN ...

Page 47: ...d SETUP NEW SPEED Press to have access to the function Set the desired speed in M min using Press to confirm This screen displayed for a few seconds indicates that the previously set speed XXX M min will be assigned to the article being created Press to select the next parameter NEP ...

Page 48: ...using Press to continue This screen displayed for a few seconds indicates that the previously set parameter has been programmed correctly Press to select the Minimum Length of the Nep defect LMIN Press to continue Set the Minimum Length of Nep defect using Press to continue This screen displayed for a few seconds indicates that the Minimum Length parameter has been programmed correctly Press to re...

Page 49: ...le using Press to confirm the entered value This screen displayed for a few seconds indicates that the previously set parameter has been programmed correctly Press to select the Minimum Length of the reduction LMIN Press to continue Set the Minimum Length of reduction using Press to continue This screen displayed for a few seconds indicates that the Minimum Length parameter has been programmed cor...

Page 50: ...ress to confirm the entered value This screen displayed for a few seconds indicates that the previously set parameter has been programmed correctly Press to select the Minimum Length of the Slub Tangle defect LMIN Press to continue Set the Minimum Length of Slub Tangle defect using Press to continue This screen displayed for a few seconds indicates that the Minimum Length parameter has been progra...

Page 51: ...rm the entered value This screen displayed for a few seconds indicates that the previously set parameter has been programmed correctly Press to select the Minimum Length of the Missing Ply defect LMIN Press to continue Set the Minimum Length of the Missing Ply defect using Press to continue This screen displayed for a few seconds indicates that the Minimum Length parameter has been programmed corr...

Page 52: ...ed value This screen displayed for a few seconds indicates that the previously set parameter has been programmed correctly Press to select the Minimum Length of the Added Ply defect LMIN Press to continue Set the Minimum Length of Added Ply defect using Press to continue This screen displayed for a few seconds indicates that the Minimum Length parameter has been programmed correctly Length paramet...

Page 53: ...ds indicates that the previously set parameter has been programmed correctly Press to select the Minimum Length of the Yarn Missing defect LMIN Press to continue Set the Minimum Length of Yarn Missing defect using Press to continue This screen displayed for a few seconds indicates that the Minimum Length parameter has been programmed correctly Press once to return to the Article Parameters Menu or...

Page 54: ...fied by selecting it among those already existing inside the data base using ERASE Erasing an existing Article SETUP ERASE This function allows removing from the data base a previously created article Press to have access to the function Select the article to be removed using and press to continue Press to confirm the erase function During the erase process the OK WAIT message is displayed BTSR TS...

Page 55: ...icle is loaded in particular YYY shows the first sensor on which the article has been loaded KKK shows the last sensor on which the article has been loaded Press to go to the next article Press to leave the function When scanning of all the articles currently loaded has finished the END SCAN message appears to indicate that there are no other articles beyond those displayed until now Press once to...

Page 56: ...itioned Decreases the number where the cursor is positioned Moves the cursor between XXX and YYY fields Press to confirm the setting and go to the next screen Press to load the parameters of the article in the selected range of sensors During the loading phase the message OK WAIT is shown for a few seconds If you try to load an article into a range of sensors in which another article was previousl...

Page 57: ...s loaded Press to have access to the function Press once or several times until the name of the required article that you wish to unload from the sensor appears At this point press to have access to the function Press to unload the settings of the article from the sensors which were previously detecting that article When finished press to leave the function At the end press once to leave the funct...

Page 58: ...ivated only if the sensor ENABLE signal is connected to the machine Start Stop contact allows to simultaneously start all the machine positions for instance at the beginning of a new working cycle During the execution of this procedure all the sensors will perform an Automatic Learning of the yarn diameter Autoset Press to have access to the function when it is sure that all the sensors do not hav...

Page 59: ...ast sensor position to be included in the report Select the desired range using Once you have selected the desired positions press to start the printout This screen indicates that the printout is in progress When the printing is completed the REPORT xxx yyy screen will re appear allowing you to select a new sensor range for report printing In case of communication error between SMART CLEARER termi...

Page 60: ...Operation 3 48 SMART CLEARER Sample report referred to four positions 001 004 ...

Page 61: ...system If the problem persists replace the sensor If the problem persists connect a set of sensors at a time trying to isolate the problem The sensor does not provide the Stop signal Failure in the Stop circuit Check the Stop circuit connections Check the configuration of Stop signal ST NCO If the problem persist replace the sensor The sensor cannot be reset Touch Light defective Verify that the s...

Page 62: ...detection features to remain unaffected even when some traces of dirt are present However it is recommended to clean the sensors periodically For maintenance operations on printer device i e paper roll replacement please refer to the operating manual supplied with the printer itself For cleaning purposes do not use solvent but rather a soft cloth dampened with neutral detergent or alcohol Repairs ...

Page 63: ...sconnect all the connectors from the rear side of terminal tacking note of their respective positions 5 Unscrew the 4 locking screws and remove the rear cover Fig 1 6 Using the IC extractor remove with care the Integrated Circuit from the socket located on the right top corner of PCB Fig 2 7 Place the Integrated Circuit containing the new software version over the socket paying attention to its co...

Page 64: ...onfiguration values it is suggested to take note of the defined settings for each article which have been created The following tables are intended to help you in this task Article SPEED M m Parameter TIT LMIN NEP SLUB SLUB YARN YARN NO YARN Article SPEED M m Parameter TIT LMIN NEP SLUB SLUB YARN YARN NO YARN Article SPEED M m Parameter TIT LMIN NEP SLUB SLUB YARN YARN NO YARN ...

Page 65: ...ance SMART CLEARER 4 5 Article SPEED M m Parameter TIT LMIN NEP SLUB SLUB YARN YARN NO YARN Article SPEED M m Parameter TIT LMIN NEP SLUB SLUB YARN YARN NO YARN Article SPEED M m Parameter TIT LMIN NEP SLUB SLUB YARN YARN NO YARN ...

Page 66: ...Troubleshooting and Maintenance 4 6 SMART CLEARER Page intentionally left blank ...

Page 67: ...le on the SMART CLEARER system The use of the quick reference guide supposes that the user has already acquired a certain ability in handling the system therefore there are no detailed explanations of each screen shot there is only a global overview of the required steps for each function For an explanation of the symbols used in the quick reference guide please refer to Symbols key shown at the b...

Page 68: ...Appendix A Quick Reference A 2 SMART CLEARER Symbols Key ...

Page 69: ...Appendix A Quick Reference SMART CLEARER A 3 Symbols Key ...

Page 70: ...Appendix A Quick Reference A 4 SMART CLEARER Symbols Key ...

Page 71: ...Appendix A Quick Reference SMART CLEARER A 5 Symbols Key ...

Page 72: ...Appendix A Quick Reference A 6 SMART CLEARER Symbols Key ...

Page 73: ...Appendix A Quick Reference SMART CLEARER A 7 Symbols Key ...

Page 74: ...Appendix A Quick Reference A 8 SMART CLEARER Symbols Key ...

Page 75: ...Appendix A Quick Reference SMART CLEARER A 9 Symbols Key ...

Page 76: ...Appendix A Quick Reference A 10 SMART CLEARER Symbols Key ...

Page 77: ...Appendix A Quick Reference SMART CLEARER A 11 Notes ...

Page 78: ...Appendix A Quick Reference A 12 SMART CLEARER Page intentionally left blank ...

Page 79: ...Example SMART CLEARER B 1 INSTALLATION EXAMPLE INSTALLATION EXAMPLE INSTALLATION EXAMPLE INSTALLATION EXAMPLE The example included in the next page shows the interconnection of devices that constitute the SMART CLEARER system ...

Page 80: ...Installation Example B 2 SMART CLEARER SMART CLEARER ELECTRICAL CONNECTIONS EXAMPLES Concerning all electrical systems it is a suggested rule to ensure that the ground cable GND is connected to the sensor support ...

Page 81: ...BTSR International S p A Via S Rita 21057 OLGIATE OLONA VA Tel 0331 323202 Fax 0331 323282 Internet www btsr com REV 3 0 07 03 DISTRIBUTOR ...

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