KTF/RW-MF
(Constant Tension Feeder - ReWinder - MicroFeeder)
YARN CONTROL SYSTEM
Operating Manual
ENGLISH
Rev. 3.0 – December 2004
KTF/RW-MF – Rev. 3.0 – December 2004
Copyright - BTSR – All rights reserved.
This manual is intended for the users of KTF/RW-MF yarn feeding systems. You are kindly
recommended to carefully read the instructions reported in this manual before making the connections
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 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.
WindowsTM is a registered trademark of Microsoft Corporation
BTSR® is a registered trademark “Best Technology Study & Research” of BTSR International S.p.A.
Table of Contents
TABLE OF CONTENTS
INTRODUCTION
The modular solution for yarn preparation machines ............................................................................................I.1
How to use this manual ..............................................................................................................................................I.2
Symbols used ...............................................................................................................................................................I.2
Reference Documentation ..........................................................................................................................................I.2
Chapter 1 - OVERVIEW
System Components................................................................................................................................................... 1.1
Modules and accessories of KTF/RW-MF system .................................................................................................. 1.2
Main Characteristics of KTF/RW-MF Systems...................................................................................................... 1.3
Advantages obtained by using the KTF/RW-MF systems ..................................................................................... 1.4
Further Advantages obtained by using the SMART KTF 2000 terminal combined with
KTF/RW-MF systems................................................................................................................................................ 1.4
Further Advantages obtained by using the PC-Link KTF Software on a Personal Computer connected to
KTF/RW-MF Systems ............................................................................................................................................... 1.5
Chapter 2 – TECHNICAL DATA AND INSTALLATION
Technical Features..................................................................................................................................................... 2.1
Electrical interface (Device Connection).................................................................................................................. 2.2
Electrical interface (Pin Assignment)....................................................................................................................... 2.3
SMART KTF 2000 – SM-DIN/RW-MF Connection .............................................................................................. 2.4
PC – SM-DIN/RW-MF Connection.......................................................................................................................... 2.5
Overall dimensions and fastening distances (in mm).............................................................................................. 2.6
SM-DIN/RW-MF module (Fastening on DIN rail or with screws) ......................................................................... 2.6
KTF/100RW yarn feeding unit ................................................................................................................................ 2.7
TS4/xxxyRW tension sensor ................................................................................................................................... 2.7
Optimum working positions
KTF/100RW yarn feeding unit, TS4/xxxyRW tension sensor and BYRW001 yarn braking device ...................... 2.8
The BTSR solution with accessories RWI.SP.005 – RWO.SP.010......................................................................... 2.9
Chapter 3 – KTF/RW-MF OPERATION
Operating Characteristics of KTF/RW-MF System............................................................................................... 3.1
Programming the KTF/RW-MF System ................................................................................................................. 3.3
General Diagram of Simple Programming Environment (PPS) .............................................................................. 3.3
Advanced Programming of KTF/RW-MF Systems................................................................................................ 3.4
General Diagram of P1÷P4 Advanced Programming Levels (PPA) ....................................................................... 3.5
Real-Time check of KTF/RW-MF internal temperature ....................................................................................... 3.6
Temporary lock of Yarn Feeding Motor ................................................................................................................. 3.6
P1 Programming Level.............................................................................................................................................. 3.7
P2 Programming Level............................................................................................................................................ 3.10
P3 Programming Level............................................................................................................................................ 3.14
Characteristics of the various working mode (Mode 00 ÷ 04)............................................................................... 3.15
KTF/RW-MF
-i-
Table of Contents
P4 Programming Level............................................................................................................................................ 3.17
INC/DEC Programmable Commands and Tension Alarm Activation ............................................................... 3.19
Mode 00................................................................................................................................................................. 3.19
Mode 01................................................................................................................................................................. 3.20
Mode 02................................................................................................................................................................. 3.21
Mode 03................................................................................................................................................................. 3.21
Increment/Decrement of Yarn Tension in Automatic Mode................................................................................ 3.22
Tension Profiler ....................................................................................................................................................... 3.23
Textile Machine Interfacing Modes when Tension Profiler and/or Target Functions are Enabled................. 3.24
Chapter 4 – KTF/RW-MF TROUBLESHOOTING AND MAINTENANCE
Indications Provided by the Red Leds on SM-DIN/RW-MF unit ......................................................................... 4.1
Troubleshooting on KTF/RW-MF System .............................................................................................................. 4.1
Ordinary Maintenance .............................................................................................................................................. 4.3
Repairs ........................................................................................................................................................................ 4.3
Updating the Software Version on SM-DIN/RW-MF System through the Microprocessor Replacement........ 4.4
APPENDIX A
- ii -
KTF/RW-MF
Introduction
INTRODUCTION
Congratulations for choosing a BTSR product.
With our KTF/RW-MF (Constant Tension Feeder - ReWinder - MicroFeeder)
yarn feeding systems, you got an innovative, unique solution able to offer you
multiple advantages concerning quality of your production.
The modular solution for yarn preparation machines
The KTF/RW-MF system comes from the experience built with KTF/100HP yarn
feeding device and it is mainly oriented to applications implemented on yarn
preparation machines: winding, doubling, copwinding machines, etc.
The main difference with respect to KTF/100HP device is due to the fact that while
KTF/100HP collects within a single physical device all the elements such as the
control electronics, the tension control sensor and the yarn feeding motor, the
KTF/RW-MF system has a modular structure consisting of separate elements, thus
allowing greatest installation and configuration freedom, etc. to meet the specific
machine requirements.
The KTF/RW-MF systems 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 regardless of the speed at which the textile machine
is running (either high or low speed) and the tension is kept constant even when the
yarn package tension is subject to change due to environment conditions such as
humidity, temperature, etc., or when the yarn packages are gradually emptying
during the normal working process.
The KTF/RW-MF systems are fully programmable and can easily be adapted to
any kind of yarn or tension adjustment. Furthermore, these systems are
manufactured using very high quality and precision electronic components which
guarantee an exact display of the yarn tension as well as an accurate real-time
control of the tension itself, all features which are unique to BTSR KTF systems.
Thanks to its modularity characteristics, the KTF/RW-MF system is capable of
managing not only the TS4.. tension sensor, but also the IS3.. image scanning
sensor, thus allowing the user to obtain a complete quality control for what
concerns both the yarn tension and the correct yarn running condition.
This is particularly important on doubling machines where multiple yarns are fed
using the same device, in order to stop the machine in case of breakage or lack of
one or more yarns.
KTF/RW-MF
- I.1 -
Introduction
How to use this manual
This Operation Manual consists of 4 Chapters + 1 Appendix.
Chapter 1 – Overview describes the main features, components and the operation
principle of KTF/RW-MF system.
Chapter 2 – Technical Data and Installation gives the instructions needed to
correctly install the system.
Chapter 3 – KTF/RW-MF Operation gives a detailed description of the operations
required to setup and program the KTF/RW-MF system according to the
application needs.
Chapter 4 – Troubleshooting and Maintenance provides a quick guide to solve
the main failures of KTF/RW-MF system.
Appendix A – shows the details concerning the possible configurations (including
the relevant accessories and corresponding codes) of the yarn feeding devices:
KTF/100MF and KTF/100RW.
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.
2) TENSION ERROR
All the items concerning the device programming menus, within
this manual, are always show in CAPITAL LETTERS.
Reference Documentation
- I.2 -
Manual
SMART KTF 2000 – Rev. 2.0 – 05/2002
(KTF/RW-MF Programming/Monitoring using the SMART KTF 2000
Terminal).
Manual
PC LINK KTF – Rev. 1.0 – 01/2005
(Programming/Monitoring using a Personal Computer and PC-Link
KTF Software).
KTF/RW-MF
Overview
1 - OVERVIEW
System Components
The KTF/RW-MF system can be programmed and used either in individual and
autonomous way, or they can be connected to a monitoring/programming unit, thus
obtaining a complete system providing further levels of analysis, adjustment,
control and speeding-up of the production cycles, as well as providing statistical data
processing capabilities, particularly useful to reach the quality and saving goals
stated in the Introduction of this manual.
The programming/monitoring unit may be either a dedicated BTSR terminal
(SMART KTF 2000) or a Personal Computer operating under WindowsTM
environment with BTSR application software (PC-Link KTF).
The solution based on personal computer and PC-Link KTF software, besides a
greater operating flexibility, offers a set of additional functionalities which allow you
to customize the application according to your specific requirements (e.g. the
Tension Profiler) and to display/print in real time and in graphical form all the
significant data concerning the KTF/RW-MF system functionality.
As mentioned in the Introduction chapter, the KTF/RW-MF systems consist of
various independent modules and accessories, each one installable in the most
suitable position, depending on the type of textile machines.
The following page lists and shows all the modules and accessories which constitute
the system.
KTF/RW-MF
- 1.1 -
Overview
Modules and accessories of KTF/RW-MF system
Modules
Description
SM-DIN/RW-MF
Electronic unit containing the microprocessor, the
memory unit and the management logic of the whole
system. Besides the connectors used to interface all
the other I/O devices aimed at the control and
adjustment functions, it contains the alphanumeric
display, the operating push buttons and the signaling
LEDs. It can be fastened on DIN rails/screws within the
electrical cabinet or attached to the front panel by
means of suitable cover plates.
KTF/100/xx
Yarn feeding motor device. It is available in 2 versions:
See Appendix
!
KTF/100MF - up to 25 mN/m (Micro Feeder)
A
!
KTF100RW - up to 100 mN/m
TS4/xxxyRW
Yarn tension sensor. It is available in 2 versions:
!
TS4/100DRW – up to 100 g - Type D eyelet
!
TS4/1000ERW – up to 1000 g - Type E eyelet
IS3x/TS
Electronic sensor capable of detecting the image
variation provided by the yarn running.
It is available in 2 versions:
!
IS3W/TS = Wide version
!
IS3N/TS = Narrow version
RWI SP 004/005
Input bracket
RWO SP 003 ÷ 010
Output bracket
Type of eyelet
D
E
TS4/100DRW
TS4/1000ERW
(*) As an alternative
- 1.2 -
Note
KTF/RW-MF
Optional
Overview
Main Characteristics of KTF/RW-MF Systems
The KTF/RW-MF system is a high tech digital instrument that allows setting the
exact tension value at which you want to operate. The data setting is done through a
small three-button key-pad and a 3 digits display, located on the font side of
SM-DIN/RW-MF modules.
In normal operating conditions the alphanumeric display provides a real time
visualization of the exact yarn tension (in grams) during the manufacturing process.
In addition, the operator may read at any time the internal temperature of the device
(in °C) and the current absorption (in A), using the
Reset button.
An excessive increase of the temperature and/or current could in fact indicate a
wrong use of the device; for this reason, the software on board of the system
performs a continuous monitoring of both the internal temperature and the absorbed
current.
If such temperature exceeds 100°C or the absorbed current exceeds 3A (motors
KTF/100MF) or 6A (motors KTF/100RW), the NO1 STOP output is activated.
Thanks to a configurable safety code, all parameters can only be changed by
authorized personnel, knowing such safety code.
The KTF/RW-MF system may easily be programmed also using the SMART KTF
2000 terminal which, thanks to its flexibility allows programming of many devices at
a glance. Once you have chosen the desired working values on a given machine, you
will just transfer the selected setting data to the SMART KTF 2000 and then from
SMART KTF 2000 to other KTF/RW-MF systems installed on different machines;
all this in about 1 second (i.e. the time needed to complete the data transfer).
With a single SMART KTF 2000 monitoring/programming terminal, you will have
the possibility to control multiple SM-DIN/RW-MF units connected in daisy chain
configuration.
The flexibility of KTF/RW-MF system and the availability of standard communication
interfaces, also offer the possibility to program and monitor the system itself using a
Personal Computer or Notebook with BTSR software (PC-Link KTF).
The device has been designed bearing in mind not only the technological aspects, but
also the ergonomic ones. Thanks to these characteristics, the system can be perfectly
fitted within the machine structure, without compromising the machine spaces which
are usual to the operator.
The KTF/RW-MF system can work with a wide range of yarns, including very thin
yarns such as bare and covered elastomers, always guaranteeing a perfect control of
yarn tension values chosen by the user, which results in a high quality of the
manufactured product.
The KTF/RW-MF systems are controlled by an internal microprocessor ensuring
great versatility (parameters may be programmed depending on the various yarn
processing conditions).
The tension value displayed on SM-DIN/RW-MF’s display indicates the actual
tension with which the system is working. This guarantees a constant and accurate
monitoring of the working process.
KTF/RW-MF
- 1.3 -
Overview
Advantages obtained by using the KTF/RW-MF systems
# Constant yarn tension both when the machine speed changes and when the yarn
packages gradually get empty.
# Best efficiency by eliminating the yarn breakage (tears and extra tensions), and
possibility to work at the highest speed offered by the machine.
# Possibility to work with a wide range of yarn types including:
- Very thin yarns, such as bare elastomers 11/17 DTEX.
- Very difficult yarns; Elasticized yarns either bare or covered
- Nylon, cotton, viscose, wool, silk, etc.
# Yarn tension graduation capability, with 0.1 g. resolution (INC/DEC function BTSR Patent).
# Possibility to feed the strap elastic or wrist band, guaranteeing a constant
compression (hosiery machines).
# Possibility to perform gradual compression with no limits, and with a minimum
resolution of 0.1 grams (hosiery machines).
# Possibility to handle up to a maximum of 16 sensors of the IS3x/TS series, for
doubling machine applications where more than one yarn must be simultaneously
fed (by means of KTF/100xx) and controlled (by means of IS3x/TS).
Further Advantages obtained by using the SMART KTF 2000 terminal
combined with KTF/RW-MF systems
# Using the SMART KTF 2000 terminal connected to KTF/RW-MF systems you
have the possibility to develop a wide range of functions which facilitate the
practical use of the installed KTF/RW-MF units (immediate download and
upload of data), as well as to display fundamental data such as, yarn consumed
and yarn tension.
# Possibility to create up to 99 “articles”, saving them into a Data Base for an easy
subsequent recall. Without the need to setup new parameters, these will simply be
recalled from the Data Base and subsequently transferred to the KTF/RW-MF
systems installed on textile machines.
# Possibility to use the TARGET function (meter count) and the NO2 Stop output,
when reaching the amount of meters setup, with possible automatic bobbin
change enabling (autodoffing).
# Possibility to control and quickly correct the tension adjustments, thus eliminating
the defects due to irregular tensions, tears and wrong yarn unwinding.
# Possibility to identify the connected KTF/RW-MF units using an automatic
numbering procedure (BTSR Patent).
# Monitoring and control possibility of the stitch consumption related to the article
(during the production of manufactured articles such as knitted work,
stockings…), by means of the CONTROL function.
In CONTROL environment, a yarn consumption self learning function (LEARN) is
available (BTSR Patent). With this function you can learn the amount of yarn fed
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.
# Possibility to obtain a progressive tension graduation (with 0.1 g resolution)
depending on the TARGET set (during the rewinding phases). E.g.: the user could
set the Target = 1000 m, the initial tension value = 10 g, and choose to increment
the tension by 1 g every 100 m. When reaching the TARGET, the system resumes
the initial tension value: 10 g.
! For more details, please refer to SMART KTF 2000 operating manual.
- 1.4 -
KTF/RW-MF
Overview
Further Advantages obtained by using the PC-Link KTF Software on a
Personal Computer connected to KTF/RW-MF Systems
# Using a Personal Computer connected to the KTF/RW-MF systems through
either a RS232 serial port or an USB port, with the aid of BTSR PC-Link KTF
software, you may program in quick and intuitive way, all the operating
parameters of KTF/RW-MF systems; in addition, you may display, through a
single synoptic screen, the operating status of all connected systems, thanks to an
easily interpretable color code.
# Possibility to associate each article with a “Tension Profiler” allowing you to
rapidly and effectively adapt the working parameters of KTF/RW-MF systems to
your specific application requirements.
# Possibility to display and/or print several graphics showing the real-time dynamic
variation of the significant operative items (such as yarn tension, current
absorbed by the motor, motor torque, etc.); this allows you to speed-up and
optimize the “tuning” of the whole system.
# Possibility to update the SM-DIN/RW-MF system’s software without having to
physically replace the microprocessor.
# The following screen shots have a merely indicative purpose, i.e. to show the
characteristics of the PC-Link KTF software graphical interface.
! For more detailed information, please refer to the PC-Link KTF operating
manual.
PC-Link KTF – Example of synoptic view with 20 KTF/RW-MF devices configured
over 10 machine sections (2 devices for section).
- Devices 1 - 12 =
Running
- Devices 13 - 14 =
Stopped (STOP)
- Devices 15 - 20 =
not connected (COMM ERROR)
KTF/RW-MF
- 1.5 -
Overview
PC-Link KTF – Example of graphic showing the dynamic progress of yarn tension
on devices 1 and 2, plus real-time display of speed, torque %, current and
temperature values.
PC-Link KTF – Example of graphic showing the dynamic progress of yarn tension,
motor torque and current absorbed by device 1.
- 1.6 -
KTF/RW-MF
Overview
PC-Link KTF – Examples of KTF/RW-MF device operation parameters
programming.
KTF/RW-MF
- 1.7 -
Overview
PC-Link KTF – Example of graphic screen showing the upload of working
parameters (style) to the KTF/RW-MF.
- 1.8 -
KTF/RW-MF
Technical Data and Installation
2 – TECHNICAL DATA AND INSTALLATION
Technical Features
SM-DIN/RW-MF control unit
Power supply voltage
Absorption
2 STOP Outputs (NO1 –Alarms – NO2 Target)
INC/DEC/EXC input voltage
Programmable yarn tension
Programmable alarms
Integrated keypad
Signaling
Dimensions
Operating Temperature range
Mounting type
Protection
24 Vdc ± 20% ; 24 Vac ± 10%
Typical: 0.2 A; Max: 6A
Relay contacts NO 120Vac/24Vdc – 1A
Min. 5 Vdc ; Max 30 Vdc
TS4/100DRW: 0.5 ÷ 100 gr. (resol. 0.1 gr.)
TS4/1000ERW: 5 – 1000 g (resol. 1 gr.)
0.1 ÷ 10 sec.
3 push buttons
3 digit display + 8 signaling LEDs
138 x 125 x 35 mm
10° ÷ 70 °C
Inside the cabinet: on DIN rail, or fastening
screws.
On panel: with cover plates
Self-restoring fuse, 5A
KTF/100xx yarn feeding device
Motor torque
KTF/100MF: up to 25 mN/m
KTF/100RW: up to 100 mN/m
TS4/xxxyRW Sensors
Power supply voltage
Absorption
12 .. 24 Vdc ± 20%
30 mA (max 50 mA)
0 - 10V
With integrated LEDs
50 x 25 x 12,5 mm
Analogue Output
Signaling
Dimensions
Temperature range
10° ÷ 60 °C
IS3x/TS Sensors
Power supply voltage
Absorption
STOP output
STOP output protection
Maximum Current of STOP output
Reaction Delay
Sensitivity
Signaling
Dimensions (mm)
Temperature range
12 .. 24 Vdc ± 20%
10 mA (max 15 mA)
NPN
Protection against over-voltages/short-circuits
200 mA continuous; 500 mA peack
Programmable from 5 to 1000 msec
Programmable (10 levels)
With integrated LEDs
15 x 15 x 36,5 (Narrow) - 25 x 15 x 36,5 (Wide)
10° ÷ 60 °C
SMART KTF 2000 Terminal
Power supply voltage
Maximum absorption
Dimensions
Operating Temperature range
LCD graphic display
Integrated Touch-pad
Protection
KTF/RW-MF
24 Vdc ± 20%
100 mA
135 x 95 x 40 mm
10° ÷ 60° C
80 x 40 mm
5 membrane buttons with integrated red LED
2 fuses 5 x 20 – 1A
- 2.1 -
Technical Data and Installation
Electrical interface (Device Connection)
As an alternative
Next SM-DIN/RW-MF units
Connector for Future Expansions
External interface
(INC+/-, DEC+/-, EXC+/-)
AC/DC power supply + Stop Output
Concerning all electrical systems, it is a suggested rule to ensure that the ground cable
(GND) is connected to the device support.
- 2.2 -
KTF/RW-MF
Technical Data and Installation
Electrical interface (Pin Assignment)
Concerning all electrical systems, it is a suggested rule to ensure that the ground cable
(GND) is connected to the device support.
KTF/RW-MF
- 2.3 -
Technical Data and Installation
SMART KTF 2000 – SM-DIN/RW-MF Connection
Concerning all electrical systems, it is a suggested rule to ensure that the ground cable
(GND) is connected to the device support.
- 2.4 -
KTF/RW-MF
Technical Data and Installation
PC – SM-DIN/RW-MF Connection
Concerning all electrical systems, it is a suggested rule to ensure that the ground cable
(GND) is connected to the device support.
KTF/RW-MF
- 2.5 -
Technical Data and Installation
Overall dimensions and fastening distances (in mm)
SM-DIN/RW-MF module (Fastening on DIN rail or with screws)
A
Space for DIN rail fastening
B
Holes for M4 x 20 fastening screws
- 2.6 -
KTF/RW-MF
Technical Data and Installation
KTF/100RW yarn feeding unit
A
Ceramic element for coil separations – ø 5
B
Adjustment screw for coil separation M4 x 12
C
Fastening holes with M4 x 20 screw
TS4/xxxyRW tension sensor
A
Fastening hole with M4 x 20 screw
B
Loading cell (tension sensor)
KTF/RW-MF
- 2.7 -
Technical Data and Installation
Optimum working positions
KTF/100RW yarn feeding unit, TS4/xxxyRW tension sensor and BYRW001 yarn braking
device
RECOMMENDED MOUNTING
BYRW001
D1
Suggested distance = 38 mm
D2
Suggested distance = 24 mm
D3
Suggested distance = 50 mm
D4
Suggested distance = 60 mm
P
- 2.8 -
TS4/xxxyRW
KTF/RW-MF
Yarn path
KTF/RW-MF
Technical Data and Installation
The BTSR solution with accessories RWI.SP.005 – RWO.SP.010
RECOMMENDED MOUNTING
RWI.SP.005
RWO.SP.010
KTF/RW-MF
- 2.9 -
Technical Data and Installation
Page intentionally left blank
- 2.10 -
KTF/RW-MF
KTF/RW-MF Operation
3 – KTF/RWKTF/RW-MF OPERATION
Operating Characteristics of KTF/RW-MF System
For programming and control of KTF/RW-MF system, 3 push buttons, 8 red
signalling LEDs and a 3 digit display are available to the operator.
E (ENTER) PUSH BUTTON
Press and hold down this push-button to gain access to the simple or advanced
device’s programmable functions.
During the programming phase, press it to confirm the displayed parameter.
Pressing and holding down this push-button for about 3 seconds on particular
parameters, you will have the possibility to enable/disable the corresponding function.
– (RESET) PUSH BUTTON
Press this push-button to cancel possible error signalling on SM-DIN/RW-MF
display (STOP RW LED on). During the Programming phase, press it to decrease
the value of displayed parameter. During the Control phase, without an alarm
condition in progress, it allows you to display the device’s internal temperature.
+ (CONTROL) PUSH BUTTON
Press this push-button to temporarily de-activate the motor (STOP RW LED on);
press it again to reactivate the motor. This button also allows de-activating (OFF)
the power unit. During the programming phase, press it to increase the value of
displayed parameter.
Press this push-button whenever you need to operate on the yarn
feeding motor (i.e. for yarn threading, coil separation device adjustment,
etc.) to avoid undesired start-up of the motor.
KTF/RW-MF
- 3.1 -
KTF/RW-MF Operation
LCD DISPLAY
It provides the real time display of measured and adjusted tension values, as well as
the parameters programmable within the various menus, the alarm signallings, etc.
Alarm/Warning Signallings
During the normal machine operation, the display shows, in real time the following
warning alarm or fault operating signallings.
Tension Alarm (see “characteristics of the various working mode” page 3.15)
(*)
Target reached
(*)
Motor locked; internal protection triggering.
TS4 sensor’s OFFSET out of calibration, TS4 sensor disconnected, dirty loading
cell, etc.
Temperature error.
Current error.
System error. External protection triggering due to over current.
INC/DEC overflow alarm.
INC/DEC underflow alarm.
(*) The signalling automatically disappears as soon as the generating condition is
removed.
!
- 3.2 -
As far as the failure signallings are concerned, please refer to chapter 4
“Troubleshooting”
KTF/RW-MF
KTF/RW-MF Operation
Signaling LEDs
Indicates with 1 flashing the increment of main tension.
Indicates with 1 flashing the decrement of main tension.
On = indicates the activation of Exclusion condition
On = P1 tension active – Off = P2 tension active
Flashing = Communication in progress between SM-DIN/RW-MF and SMART KTF
2000 or PC
On = Stop condition generated by an IS3x/TS sensor (if used)
On = Indicates the condition of feeding motor locked by means of
Flashing = indicates an alarm condition
button;
On = indicates the SM-DIN/RW-MF power on condition
Programming the KTF/RW-MF System
The KTF/RW-MF system offers two programming environments:
1) SIMPLE (allows programming exclusively the system’s main tension)
2) ADVANCED (allows programming all the system’s parameters)
To have access to the programming environment, press and hold down for 3 seconds the
ENTER button, while the systems is operating in Control environment.
To switch from SIMPLE to ADVANCED and vice versa, press and hold down for 3 seconds
the ENTER button.
! To avoid undesired changes of operating parameters, after the installation of
KTF/RW-MF systems and after having setup and checked all the working parameters
in ADVANCED programming environment, it is advisable to activate the SIMPLE
programming environment, so that when the operator will subsequently enter the
programming environment, he/she will only have the possibility to change the main
tension (1st variable of P1 menu).
General Diagram of Simple Programming Environment (PPS)
MAIN
TENSION
KTF/RW-MF
- 3.3 -
KTF/RW-MF Operation
Advanced Programming of KTF/RW-MF Systems
With the ADVANCED programming environment, each KTF/RW-MF can be programmed
with specific control parameters which depend on the type of yarn under processing, and
on the type of application:
•
•
•
•
•
•
MAIN TENSION
ERROR TENSION
TIME ALARM
INC-DEC TENSION
EXIT TENSION
MODE
Control Tension
Tolerance beyond which an Error is generated
Time for which the tension may stay out of tolerance
∆ Tension for INC/DEC graduation
Device Tension with machine stationary
Operating modes of INC/DEC command
The 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
requirements, using the advanced programming features.
KTF/RW-MF systems offer 4 advanced programming levels: P1, P2, P3 and P4, clearly
indicated in the messages area of LCD during the programming sequences.
Within the P1 level the following parameters can be programmed:
P1.1
! MAIN TENSION
P1.2
! ERROR TENSION
P1.3
! TIME ALARM
P1.4
! INC-DEC TENSION
Within the P2 level the following parameters can be programmed:
P2.1
! EXIT TENSION
P2.2
! RAMP UP
P2.3
! RAMP DOWN
P2.4
! SYSTEM REACTIVITY CONSTANT
Within the P3 level the following parameters can be programmed:
P3.1
! OFFSET
P3.2
! MODE
P3.3
! ACCESS CODE
P3.4
! KTF IDENTIFICATION CODE
Within the P4 level the following parameters can be programmed::
P4.1
! MOTOR ROTATION DIRECTION
P4.2
! TENSION SENSOR SIZE IN GRAMS
P4.3
! COMMUNICATION BAUD RATE
! TYPE OF MOTOR/ADJUSTMENT
ALGORITHM USED
P4.4
To move from a programming level to the next level, press the + (Control) button, when
the display shows the label P1, P2, etc.
(Reset) button used to quit the programming environment
- 3.4 -
KTF/RW-MF
KTF/RW-MF Operation
General Diagram of P1÷P4 Advanced Programming Levels (PPA)
NOTE: The values shown indicate the default parameters (set by BTSR).
KTF/RW-MF
- 3.5 -
KTF/RW-MF Operation
Real-Time check of KTF/RW-MF internal temperature
At any time, you can check the internal temperature of a KTF/RW-MF system, by
simply pressing the
button.
button, for more than two seconds the system will
Holding down the
automatically show the value of absorbed current.
! The values shown in the example above indicate a temperature of 39°C and a current
absorption of 1.2 A.
Temporary lock of Yarn Feeding Motor
Prior to operate on yarn feeding device, you should temporarily lock the motor
pressing the
button.
In this condition the STOP RW LED turns On and the display shows the main
tension value (P1).
Press the
button whenever you need to operate on the yarn feeding
motor (i.e. for yarn threading, coil separation device adjustment, etc.) to
avoid undesired start-up of the motor.
- 3.6 -
KTF/RW-MF
KTF/RW-MF Operation
P1 Programming Level
ADVANCED
#
MENU P1
The P1 programming level allows you to setup 4 parameters:
1)
System’s main tension ;
2)
Tolerance with respect to the main tension;
3)
Max deviation time from tolerance band;
4)
Increment/Decrement resolution of graduated tension.
With the KTF/RW-MF in CONTROL status, press
seconds.
The display will show the label PPA (ADVANCED).
and hold it down for 3
to continue.
to start programming of parameters belonging to P1 menu.
1) MAIN TENSION
Tension value with which the systems must operate to create the desired article
(INC/DEC active). [Allowed values 0.5 ÷ 99.5 grams].
to continue
During programming phase you cannot set a tension value lower than the ERROR
TENSION value or greater than the difference between the full scale value (99.5 g.)
and the ERROR TENSION value.
Choose the desired value using:
(to increase the value) or
(to decrease the value).
to confirm.
2) ERROR TENSION
Tolerance band beyond which the machine will be stopped.
to continue
An error indication and a machine stop occur only if such tolerance is exceeded for
the time period set in the next parameter (TIME ALARM).
[Allowed values ± 0.1 ÷ 99.5 grams (with automatic limitation to 0.4 grams for
what concerns the negative tolerance)].
Choose the desired value using:
(to increase the value) or
(to decrease the value).
to confirm.
KTF/RW-MF
- 3.7 -
KTF/RW-MF Operation
- 3.8 -
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
KTF/RW-MF
KTF/RW-MF Operation
3) TIME ALARM
Time during which the tension value may exit from the tolerance band set by the
previous parameter (ERROR TENSION).
to continue
You may disable (OFF) this feature by holding the Enter button pressed for 3
seconds. [Allowed values 0.1 ÷ 10 seconds].
Choose the desired value using:
(to increase the value) or
(to decrease the value).
to confirm.
Example:
Main Tension: 2.0 g
Error Tension: ± 0.5 g
Time Alarm: 2.0 sec.
4) INC-DEC TENSION
Increment/decrement resolution of the tension graduated by INC/DEC external
pulses. [Allowed values 0.1 ÷ 25.0 grams].
to continue
(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)). Chose the desired value using
or
to confirm and return to the beginning of P1 Menu.
to move to P2 Menu.
to return to CONTROL status without programming P2, P3 and P4 Menu.
KTF/RW-MF
- 3.9 -
KTF/RW-MF Operation
P2 Programming Level
ADVANCED
#
MENU P2
The P2 programming level allows you to setup 4 parameters:
1)
Device tension with machine stationary;
2)
Control of change-over speed from a given working tension to a higher
tension (RAMP UP);
3)
Control of change-over speed from a given working tension to a lower
tension (RAMP DOWN);
4)
System reactivity constant.
to select the P2 level.
to continue with programming of P2 menu parameters.
1) EXIT TENSION
Tension value of the device when the machine is stationary or out of yarn working
zone (INC/DEC pulses deactivated).
to continue.
Setting a value higher or lower than the value set with MAIN TENSION parameter of
P1 menu, you can control the deceleration phase of KTF/100xx device.
This function may be either enabled (with values ranging from 0.5 to 99.5 grams)
or disabled (OFF). To disable the function press and hold down for 3 seconds the
Enter button.
The OFF indication means 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 confirm.
- 3.10 -
KTF/RW-MF
(to decrease the value).
KTF/RW-MF Operation
2) RAMP UP
This parameter allows you to control the change-over speed from a given working
tension to a higher tension, in such a way as to avoid undesired yarn breakages.
[Allowed values 1 ÷ 100]
The RAMP UP (t) is calculated using a reference table that determines an exponential
increase of the ramp time depending on the programmed value: [1 = very fast ramp
time (1ms) ... 100 = very slow ramp time (500 msec)]:
where
N = value programmed with parameter P2.2 (Ramp Up)
T1 = final tension value (high)
T2 = initial tension value (low)
Example 1:
Final tension = 10 g
Initial tension = 4 g
N=5
Example 2:
Final tension = 10 g
Initial tension = 4 g
N = 20
Example 3:
Final tension = 10 g
Initial tension = 4 g
N = 100
to continue.
Choose the desired value:
(to increase the value) or
(to decrease the value).
to confirm.
KTF/RW-MF
- 3.11 -
KTF/RW-MF Operation
3) RAMP DOWN
This parameter allows you to control the change-over speed from a given working
tension to a lower tension, in such a way as to avoid excessive yarn relaxations.
[Allowed values 1 ÷ 100]
The RAMP DOWN (t) is calculated using a reference table that determines an
exponential increase of the ramp time depending on the programmed value: [1 =
very fast ramp time (1ms) ... 100 = very slow ramp time (500 msec)]:
where
N = value programmed with parameter P2.3 (Ramp Down)
T1 = final tension value (low)
T2 = initial tension value (high)
Example 1:
Final tension = 4 g
Initial tension= 10 g
N=5
Example 2:
Final tension = 4 g
Initial tension= 10 g
N = 20
Example 3:
Final tension = 4 g
Initial tension = 10 g
N = 100
to continue.
Choose the desired value:
(to increase the value) or
to confirm.
- 3.12 -
KTF/RW-MF
(to decrease the value).
KTF/RW-MF Operation
3) SYSTEM REACTIVITY CONSTANT
This parameter represents a multiplier that affects the control algorithm depending
on the yarn elasticity characteristics.
[Allowed values 1 ÷ 5] (1 = Rigid Yarn…… 5 = Elastic Yarn)
to continue.
Choose the desired value according to the yarn characteristics, using:
(to increase the value) or
(to decrease the value).
to confirm and return the beginning of P2 Menu.
to move to P3 menu.
to return to CONTROL status without programming P3 and P4 menu.
KTF/RW-MF
- 3.13 -
KTF/RW-MF Operation
P3 Programming Level
ADVANCED
#
MENU P3
The P3 programming level allows you to setup 4 parameters:
1)
Offset;
2)
System operation mode;
3)
Access code to programmable functions;
4)
KTF/RW-MF identification code.
to select the P3 level.
to continue.
1) OFFSET
This function is used to adjust the mechanical clamping position of TS4 tension
sensor. It clears possible measurement errors due to the different clamping position
of the sensor on textile machine.
to continue.
The displayed indication is the actual OFFSET value resulting from the clamping
to
position of the sensor. While lifting the yarn above the load cell, press
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.
! If the actual tension value, detected with the OFFSET (P3.1) function is
lower than 1 gram, the offset operation is not performed and a E03
warning message appears (this prevents the offset procedure from being
executed in case of sensor temporarily disconnected or faulty.
2) MODE
Here you can select the different working modes of INC/DEC commands.
[Mode: 00, 01, 02, 03, 04].
to continue.
Choose the desired working mode using
to select the next parameter.
- 3.14 -
KTF/RW-MF
or
KTF/RW-MF Operation
Characteristics of the various working mode (Mode 00 ÷ 04)
Mode 00 - Standard INC/DEC commands selection
By selecting Mode 00, the KTF/RW-MF system will work as explained in
“INC/DEC programmable commands” paragraph (see the relevant example on
page 3.19);
in particular, whenever the INC/DEC commands are simultaneously disabled, the
related tension graduations performed, will be immediately reset (upon each
machine stop).
Mode 01 - INC/DEC commands selection for medical socks
By selecting Mode 01, it will be possible to “freeze” the graduated tension value
(upon each machine stop and each pause for “heel” processing). The graduation
performed will be cleared only when the INC/DEC commands will be
simultaneously deactivated/activated/deactivated within a time period of 1 second
(upon each exit from thread guide) (see example on page 3.20).
Mode 02 - Function selection without INC/DEC commands
By selecting Mode 02, the KTF/RW-MF system will be able to work without
INC/DEC commands. In such condition the system will use the parameters
programmed within P1 menu (MAIN TENSION – ERROR TENSION – TIME ALARM).
The KTF/RW-MF activates the ERROR TENSION alarm as soon as the programmed
tension goes out from limits set in ERROR TENSION. The alarm will automatically
be cleared as soon as the tension value will return within the programmed limits
(see example on page 3.21).
Mode 03 - Function selection without INC/DEC commands
By selecting Mode 03, the KTF/RW-MF will be able to work without INC/DEC
commands. In such condition the system will use the tension value programmed in
EXIT TENSION (P2) as well as in ERROR TENSION and TIME ALARM (P1). The
KTF/RW-MF will activate the ERROR TENSION alarm as soon as the programmed
tension goes out from limits set in ERROR TENSION. The alarm will automatically
be cleared as soon as the tension value will return within the programmed limits
(see example on page 3.21).
Mode 04 (available from version 2.9) – Operating mode specific for machines
that work with elasticised yarns at a very high tension
In this type of machines, the system cannot easily manage the braking phase;
therefore it reverses the motor rotation direction to maintain the correct tension.
Warning! If you select Mode 04 without the presence of yarn, the motor
starts immediately a rotation, trying to recovery the yarn.
! For further information about modes 00-04 and the effects of INC/DEC
commands, please refer to the examples shown on pages 3.19 – 3.23.
KTF/RW-MF
- 3.15 -
KTF/RW-MF Operation
3) KEY CODE
This function allows you to define a secret numeric code to prevent non authorized
personnel from accessing the P1, P2, P3, P4 programmable functions.
to continue.
This function may be either enabled or disabled by holding down the
for 3 seconds
OFF indicates that the function is currently disabled.
button
If you enter an access code, this will be requested each time you attempt to activate
the programming environment.
When the Cod request appears, type the secret key-code using
buttons.
and
to increase the value of secret key code.
to decreases the value of secret key code.
to save the key-code and move to the next parameter.
4) KTF CODE
This function allows you to display the identification numeric code used as
identification address of the KTF/RW-MF in question. This function can be used
when the SM-DIN/RW-MF is connected to the SMART KTF 2000 terminal or to
the machine’s computer via the RS485 communication port.
to continue.
Enter the system’s code using the
and
buttons.
to confirm and return to the beginning of P3 menu
to move to P4 menu.
to return to CONTROL status without programming P4 menu.
- 3.16 -
KTF/RW-MF
KTF/RW-MF Operation
P4 Programming Level
ADVANCED
#
MENU P4
The P4 programming level allows you to setup 4 parameters:
1) Yarn feeding motor rotation direction;
2) Size in grams of TS4 tension sensor used (either 100 g. or 1000 g.);
3) Communication baud rate over the serial interface;
4) Type of motor used (25 mN/m or 100 mN/m).
to select the P4 level.
to continue.
1) MOTOR ROTATION DIRECTION
This function allows you to choose the rotation direction of yarn feeding motor
(C = Clockwise, CC = Counter-Clockwise).
to continue
To move from C value (Clockwise) to CC value (Counter-Clockwise) or vice versa,
press and hold down for 3 seconds the
button.
to move to next parameter.
2) TENSION SENSOR SIZE IN GRAMS
[Allowed values 101 or 102]
to continue
Choose the size in grams of the TS4 tension sensor used:
(101 if you use the TS4/100DRW sensor or 102 if you use the TS4/1000ERW
sensor)
to confirm.
KTF/RW-MF
- 3.17 -
KTF/RW-MF Operation
3) COMMUNICATION BAUD RATE
This parameter allows you to setup the communication speed on the
SM-DIN/RW-MF serial interface.
[Allowed values: 09.6 (9600 baud) – 19.2 (19200 baud) – 38.4 (38400 baud) –
57.6 (57600 baud) – 115 (115000 baud)]
to continue.
Choose the desired speed using
and
.
to confirm.
4) TYPE OF MOTOR AND YARN USED
This parameter allows you to choose the type of motor used in the KTF/100xx yarn
feeding device as well as the type of algorithm used for motor handling, depending
on the type of yarn to be feed.
[Allowed values]:
1
2
3
Elastic yarns
Non-elastic yarns with discontinuous absorption (*)
Non-elastic yarns with continuous absorption (**)
1
2
Small motor (KTF/100MF)
Large motor (KTF/100RW)
(*) Machines with stroke effect
(**) Beam warpers
to continue.
Choose the desired speed using
and
.
to confirm and return to the beginning of P4 menu.
to return the CONTROL status.
- 3.18 -
KTF/RW-MF
KTF/RW-MF Operation
INC/DEC Programmable Commands and Tension Alarm Activation
Using the INC-DEC commands it is possible to either Increment or Decrement the
tension set in P1 (MAIN TENSION).
The reset of INC/DEC graduation, as well as the management of “Error Tension”
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/RW-MF operates with P1
Tension (MAIN TENSION).
Immediate
Graduations
Reset
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 be at least 60 msec.
KTF/RW-MF
- 3.19 -
KTF/RW-MF Operation
MODE 01
The typical characteristics of Mode 01 are the following:
!
!
Reset of graduated tension synchronized through a defined sequence of INC/DEC
(deactivation/activation/deactivation);
“Error Tension” Alarm active only when KTF/RW-MF operates with P1 tension.
Graduations
Reset
! 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.
- 3.20 -
KTF/RW-MF
KTF/RW-MF Operation
MODE 02
The typical characteristics of Mode 02 are the following:
!
!
!
INC/DEC commands usable like for Mode 00;
The KTF/RW-MF 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 returns within the programmed tolerance band.
“Error Tension” Alarm active only when KTF/RW-MF operates with P1
tension (MAIN TENSION)
Main Tension:
Error Tension:
Time Alarm:
2.0 g.
± 0.5 g.
2.0 sec.
MODE 03
The typical characteristics of Mode 03 are the following:
!
!
!
INC/DEC commands usable like for Mode 00;
The KTF/RW-MF system 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 returns within the programmed
tolerance band.
“Error Tension” Alarm active only when KTF/RW-MF operates with P2
Tension (EXIT TENSION)
Exit Tension:
Error Tension:
Time Alarm:
4.0 g
±1g
3 sec.
MODE 04
The typical characteristics of Mode 04 are the following:
! INC/DEC commands usable like for Mode 00;
! “Error Tension” alarm active only in P1 (MAIN TENSION);
! Motor rotation direction reverse after a stop, to recovery the yarn.
KTF/RW-MF
- 3.21 -
KTF/RW-MF Operation
Increment/Decrement of Yarn Tension in Automatic Mode
(Function available only when using the SMART KTF 2000 Programming Terminal)
In the KTF/RW-MF System, the yarn winding tension can be controlled either at
hardware level (using the INC/DEC inputs, according to the modes described on
page 3.15) on at software level through the automatic graduation parameters setup
on SMART KTF 2000 terminal (NEW/MODIFY functions) or via machine
computer.
In this case, the KTF/RW-MF System will increment or decrement by a fixed
amount, at regular intervals, the main working tension, until the target value is
reached; then the tension will be restored to its initial value (MAIN TENSION).
Example:
- 3.22 -
-Initial Main Tension =
-Target =
-Automatic Increment (resolution) =
-Increment Interval =
KTF/RW-MF
10g
10000m
0,1g
100m
KTF/RW-MF Operation
Tension Profiler (Function available only when using the PC-Link KTF
Programming/Monitoring Software on Personal Computer)
The “Tension Profiler” function allows you to adjust in dynamic way the yarn
tension during the textile machine operation, setting some control parameters during
the article programming phase through the Style menu of PC-Link KTF software.
Thanks to the possibility to either enable or disable specific parameters and to use in
appropriate way the available input/output signals (EXC, NO1, NO2), you may obtain
different operating conditions to meet any application need. The programmable
parameters are the following:
START TENSION
Yarn tension at the position startup.
START METER
Number of meters for which the START TENSION is applied.
WORK TENSION
Yarn tension after the number of meters set in START METER.
INC/DEC TENSION
Increment/decrement amount of the WORK TENSION
(resolution) with the interval set in INC/DEC METER.
INC/DEC METER
Interval with which the WORK TENSION is incremented/
decremented by the amount set in INC/DEC TENSION.
TARGET TENSION
Yarn tension when reaching the target set in TARGET METER.
TARGET METER
Total amount of yarn to wind.
The above example refers to an application with a WORK TENSION of 14 grams and a
START TENSION of 20 grams to facilitate the yarn crimp. The start tension is applied for
50 meters (START METER), then the system switches to the work tension that will be
decremented by 0.1 grams (INC/DEC TENSION) every 1000 meter (INC/DEC METER) until
reaching the target (10000 meters, set in TARGET METER). After the target reset, the
system will start again with the START TENSION.
! For further details and application examples, please refer to the PC-Link KTF
manual (Menu Style → New)
KTF/RW-MF
- 3.23 -
KTF/RW-MF Operation
Textile Machine Interfacing Modes when Tension Profiler and/or Target
Functions are Enabled
The use of Tension Profiler and/or Target function allows you to implement some
functionalities that may result particularly useful in special applications.
Such functionalities may be obtained using in appropriate mode the hardware
input/output signals provided by SM-DIN/RW-MF system and the capability of Pc –
Link KTF software.
The usable input/output signals are typically the following:
- INC/DEC input – (EXT connector on SM-DIN/RW-MF)
- EXC input – (EXT connector on SM-DIN/RW-MF)
- Target output – NO2 – (POWER connector on SM-DIN/RW-MF)
- Error output – NO1 – (POWER connector on SM-DIN/RW-MF)
The functionalities that can be implemented are the following:
1 – Use of INC/DEC Input and Target Output (NO2) to Reset the Target Signalling
and Manage the Automatic Restart of Machine with Autodoffing Feature, after
the Target Reaching
The example shown below is based on the following assumptions:
- 3 different tension values have been programmed in Tension Profiler:
-
Start Tension
-
Work Tension
Target Tension
- The INC/DEC input is connected to the automatic Start/Stop signal of textile
machine.
- 3.24 -
KTF/RW-MF
KTF/RW-MF Operation
Event Sequence
1) The machine starts working (cycle 1) with the Start Tension.
The Inc/Dec input and NO2 output are both active.
2) After the number of meters set in Start Meter, the Work Tension is activated.
3) When reaching the target: the textile machine is temporally stopped l, the Target
Tension is activated, the NO2 output is activated and the
message appears
on the display of SM-DIN/RW-MF device.
The machine stop causes the de-activation of Inc/Dec input and the start of
Autodoffing operation.
4) The activation of Inc/Dec input causes the re-activation of NO2 output (with 1
second of delay), but the
message is maintained on display.
5) At the end of Autodoffing operation, the Inc/Dec input is re-activated, the
message disappears, the textile machine starts a new cycle (cycle 2) reactivating
the Start Tension ..... and so on!
2 – Use of INC/DEC Input and Target Output (NO2) to Reset the Target Signalling and
Manage the Restart of Machine with Manual Bobbin Replacement, after the Target
Reaching
This case is identical to the previous one, with only two differences:
1) The Inc/Dec input is connected to the machine Start/Stop button.
2) The time elapsing between the Inc/Dec signal de-activation and its re-activation is
not automatically managed by the textile machine, but is subordinate to the
operator intervention i.e. when the operator presses the start button after the
manual bobbin replacement.
KTF/RW-MF
- 3.25 -
KTF/RW-MF Operation
3 – Use of EXC Input to Reset the Target Signal and Manage the Machine Restart
In cases 1 and 2 described above, each machine position works in autonomous mode
controlled by its own SM-DIN/RW-MF system and the tension application (Start
Tension, Work Tension and Target Tension) is managed by the INC/DEC and Target
(NO2) interface signals for each individual position.
However, there are cases in which the bobbin collection must be carried out
simultaneously on all the machine position as soon as any of such positions reaches
the Target, even if the other positions have not yet reached it.
To implement this functionality it is possible to use the EXC input connecting it to
the Stop output (NO2) of all the SM-DIN/RW-MF devices.
In this way, the first device that reaches the Target activates its NO2 Stop output
which, in turn, activates the EXC input (3) and resets all the Target counters,
including those of the other positions.
As soon as the EXC input is de-activated (4), the machine will start a new cycle
(Cycle 2), re-activating the Start Tension ..... and so on!
- 3.26 -
KTF/RW-MF
Troubleshooting and Maintenance
4 – KTF/RWKTF/RW-MF TROUBLESHOOTING AND MAINTENANCE
Indications Provided by the Red Leds on SM-DIN/RW-MF unit
For the correct interpretation of signaling provided by red leds on front panel of SM-DIN/RW-MF unit,
please refer to Operating Characteristics of KTF/RW-MF System paragraph on page 3.3.
Troubleshooting on KTF/RW-MF System
Faults
Causes
Solutions
The display of
System power off
SM-DIN/RW-MF is blank
E02 displayed on the
SM-DIN/RW-MF display
! Check that the POWER connector is correctly
plugged in and that there is a 24 Vac/Vdc power
voltage on pins 1-2.
1) Motor locked
1) Check if the motor of KTF/100RW or KTF/100MF
module is correctly turning; remove possible yarn
residuals preventing the motor from turning
correctly.
Correctly thread the KTF/100RW or KTF/100MF
device as shown on page 2.8 and/or 2.9
2) Temporary triggering of internal
protections
2) Turn the electrical supply of device OFF and then
ON again
! If you cannot locate the cause of failure,
please contact your BTSR reseller (it could be
necessary to send the device to the BTSR
repair center).
E03 displayed on the
SM-DIN/RW-MF display
1) Presence of yarn residuals
under the loading cell of TS4
sensor.
1) Clean the loading cell of the sensor (see page 2.7),
using a light air blow (max 1 bar).
2) OFFSET value of TS4 sensor
device out of adjustment
2) Perform a correct adjustment of the OFFSET value
on TS4 device as described on page 3.14.
3) You are trying to perform the
offset procedure using the P3.1
menu function, but the tension
detected is lower than 1 gram.
3) Ensure that the KTF system on which you are trying
to perform the offset procedure does not have the
TS4 device disconnected or that the device itself is
not defective.
1) Parameter P1.3 is de-activated
The machine is not
(OFF)
stopped by SM-DIN/RWMF unit in case of yarn
2) The Increment and Decrement
breakage
controls are not correctly
managed within the machine
program
1) Check the correct programming of parameters on
SM-DIN/RW-MF unit.
2) Check the machine program handling the INC-DEC
controls. The INC-DEC and P1 leds must be ON.
3) The Stop function managed by
3) Check the machine program handling the STOP
the machine and associated with
input and confirm that it is enabled when the yarn
the KTF/RW-MF systems has
fed by KTF/100RW-MF is in working condition.
not been correctly enabled
within the machine program.
4) Wiring problem
4) If the STOP RW led turn on when the yarn breakage
occurs, check the machine connecting cables.
! To check the correct operation of the
SM-DIN/RW-MF STOP output press the
button and confirm that the STOP RW led turns
ON; if this does not occur please contact your
BTSR reseller (it could be necessary to send
the device to the BTSR repair center).
KTF/RW-MF
- 4.1 -
Troubleshooting and Maintenance
Faults
Causes
Solutions
A – o or A – u
displayed on
SM-DIN/RW-MF display
1) Incompatibility between the
SM-DIN/RW-MF programming
and the number of Increments/
Decrements generated by the
machine program
1) Check the SM-DIN/RW-MF programming, in
particular the INC-DEC tension parameters in P1,
and the machine program (check the number of
Increments/Decrements required).
E – t displayed on the
SM-DIN/RW-MF display
The internal temperature exceeded Check the usage conditions of the systems.
100°C
! If you cannot locate the cause of failure,
please contact your BTSR reseller (it could be
necessary to send the device to the BTSR
repair center).
E – c displayed on the
SM-DIN/RW-MF display
The current absorption of the
system exceed 3A in case of
KTF/100MF motor or 6A in case of
KTF/100RW motor.
Check the usage conditions of the systems.
E – S displayed on the
SM-DIN/RW-MF display
Internal protection triggered due to
over current.
Check the usage conditions of the systems.
The SM-DIN/RW-MF
unit does not
communicate with
SMART KTF 2000
terminal or with the PCLink KTF software on
Personal Computer
1) The identification code of
SM-DIN/RW-MF unit is not
correct
1) Check that the parameter corresponding to the
identification number (parameter P3.4) is correct; if
necessary carry out the numbering procedure using
the SMART KTF 2000 terminal.
2) Failure on SMART KTF 2000
terminal
2) Check the correct operation of SMART KTF 2000
terminal using the numbering procedure described
in the SMART KTF 2000 manual.
3) Wiring problem
3) Check the wiring on SM/IN and SM/OUT connectors
of SM-DIN/RW-MF units and on SMART KTF 2000
terminal.
! If you cannot locate the cause of failure,
please contact your BTSR reseller (it could be
necessary to send the device to the BTSR
repair center).
! If you cannot locate the cause of failure,
please contact your BTSR reseller (it could be
necessary to send the device to the BTSR
repair center).
4) Wrong communication baud rate 4) Check the configured baud rate (parameter P4.3)
(*) If you are using the PC-Link KTF software, run the
diagnostic functions provided by the software itself,
using the reference manual as a reference.
Even if the torque of KTF/100RW or KTF/100MF motor is very low and does not involve
hazards for the operator safety, it’s always advisable to lock the motor prior to operate on
the device (yarn threading, tilt adjustment of coil separation device, etc.) in order to avoid
undesired motor start-up events.
To lock the motor, just press the CONTROL
button on SM-DIN/RW-MF unit and check
that the STOP RW red LED turns-on.
At the end of the manual operation press again CONTROL
button and check that the
STOP RW red LED turn-off.
!
If the fault is not included in this table, please contact your local BTSR reseller, giving a detailed
description of the kind of fault and the conditions in which it occurred. In the case where the BTSR
Technical Service intervention would be required, before calling it is suggested to take note of the
code printed on the faulty device, as this information will make diagnoses for the BTSR technicians
easier.
Example:
Device code:
SM-DIN/RW-MF ……………………
- 4.2 -
KTF/RW-MF
Troubleshooting and Maintenance
Ordinary Maintenance
The KTF/RW-MF systems do not require special maintenance interventions,
except a periodical cleaning, depending on the environment condition in which
they operate.
For cleaning purposes, do not use solvent, but rather a soft cloth
dampened with neutral detergent or alcohol.
Repairs
Any repair intervention on KTF/RW-MF systems must be carried out
by specialized personnel from BTSR.
Any intervention attempt by non authorized personnel, voids the
warranty terms.
KTF/RW-MF
- 4.3 -
Troubleshooting and Maintenance
Updating the Software Version on SM-DIN/RW-MF System through the
Microprocessor Replacement
The software updating on SM-DIN/RW-MF system is a relatively easy operation.
However it must be carried out following scrupulously the instructions given in this
manual and using the indicated tools to avoid damaging the equipment and/or
microprocessor contacts.
Tools Needed:
1.5 mm Allen key
IC extractor
Operating Procedure:
1. Take note of the currently set parameters on the 4 menu
levels (P1 – P4).
Fig. 1
Fig. 2
2.
Disconnect the electrical supply of SM-DIN/RW-MF system
and check that all the leds as well as the display are off.
3.
Remove the SM-DIN/RW-MF system from its support bracket.
4.
Disconnect all the system connectors, tacking note of their
respective positions.
5.
Unscrew the 2 locking screws and remove the side 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 correct
orientation (Fig. 3).
8.
Applying a moderate and progressing pressure with both
thumbs, push the integrated circuit down into the socket
(Fig. 4).
9.
Reassembly the side cover and lock it using the 2 locking
screws.
10. Reconnect all connectors to their respective position.
11. Fasten the SM-DIN/RW-MF system on support bracket.
Fig. 3
12. Power on the system and check that:
-
All the leds turns on
The display shows
followed by the identification
code of the new software version.
13. Restore the parameters detected at step 1.
During this operation, avoid the conditions that
could cause static discharges!
Fig. 4
- 4.4 -
! If you are using the PC-Link KTF software, then the software
updating can be carried out directly through the serial line of
computer, without having to physically replace the
microprocessor. See the PC-Link KTF Manual.
KTF/RW-MF
Appendix A
APPENDIX A
The KTF/100MF and KTF/100RW yarn feeding devices may be equipped with
several accessories properly designed to optimize the operation of the devices
themselves depending on the application needs.
The following pages show the characteristics and order codes of such accessories.
! For further details please contact your BTSR dealer.
KTF/RW-MF
- A.1 -
Appendix A
- A.2 -
KTF/RW-MF
Appendix A
(-)
(30)
(33)
(AA)
KTF.SP.015
KTF.SP.030
KTF.SP.033
Other
(Orientable yarn brake with antiball. Ø65)
(Orientable yarn brake with antiball. Ø80)
(Orientable yarn brake with antiball. Ø65)
(-)
(HG)
(HH)
(XX)
MF.SP.001
(KTF/MF wheel carbon made)
MF.SP.001/HG (KTF/MF wheel rubber coated)
MF.SP.001/HH (KTF/MF wheel chrome coated)
Other
Micro-Feeder
(100) TS6/100A/MF (Tension Sensor gr. 100)
(-)
Without TS6/100A/MF
Product code
No.
Code
Description
REV.
Q.ty
1
KTF/MFB
Microfeeder device base
1
1
2
KTF.SP.015
Orientable yarn brake
3
1
3
MF.SP.001
KTF/MF wheel
1
1
4
TS6/100A/MF
Tension Sensor gr. 100 - Base
2
1
5
MM.2.091
Allen screw BRUN – UNI 5931 – M 2 X 5
--
--
KTF/RW-MF
- A.3 -
Appendix A
- A.4 -
KTF/RW-MF
Appendix A
(-)
(04)
(05)
(06)
(AA)
KTF.SP.003
KTF.SP.004
KTF.SP.005
KTF.SP.006
Other
(coil separator with diamond finishing)
(coil separator with chrome finishing)
(rotating coil separator)
(low friction coil separator)
(-)
(HG)
(HH)
(XX)
RW.SP.001
(KTF/RW wheel carbon made)
MF.SP.001/HG (KTF/RW wheel rubber coated)
MF.SP.001/HH (KTF/RW wheel nickel coated)
Other
ReWinder
(100) Torque 100 mN/m
Product code
No.
Code
Description
REV.
Q.ty
1
KTF/100RWB
Torque actuator 100 mN/m - Base -
1
1
2
RW.SP.001
KTF/RW wheel, carbon made
2
1
3
RW.SP.003
Standard coil separator
1
1
4
MM.2.085
3x6 Allen screw counter clockwise
--
--
KTF/RW-MF
- A.5 -
Appendix A
Page intentionally left blank
- A.6 -
KTF/RW-MF
DISTRIBUTOR
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 – 12/04