btsr WINDINGFEEDER Operating Manual

Copyright - BTSR - All rights reserved. This manual is intended for the users of WINDINGFEEDER yarn feeding devices. It is suggested to carefully read the instruction reported on this manual before making the connections and use the devices. 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 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 EMC 2004/108/EC. 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

WINDINGFEEDER - i - TABLE OF CONTENTS INTRODUCTION The ideal 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 Main Characteristics of WINDINGFEEDER Devices ........................................................................................... 1.1 Advantages obtained by using the WINDINGFEEDER devices........................................................................... 1.3 Advantages obtained by using the SMART MATRIX FEEDER Terminal combined with WINDINGFEEDER Devices .................................................................................................................................... 1.4 Further Advantages obtained by using a PC or Notebook connected to WINDINGFEEDER devices via serial line............................................................................................................................................................... 1.5 Chapter 2 – TECHNICAL DATA AND INSTALLATION Technical Features .................................................................................................................................................. 2.1 Electrical Interface of WINDINGFEEDER Devices............................................................................................... 2.2 SMART MATRIX FEEDER – WINDINGFEEDER Connection......................................................................... 2.3 Input/otput signals function...................................................................................................................................... 2.3 PC – WINDINGFEEDER Connection..................................................................................................................... 2.4 D WINDINGFEEDER overall dimensions (in mm) ............................................................................................... 2.5 Instructions for Correct Yarn Threading................................................................................................................ 2.7 Chapter 3 – OPERATION Operating Characteristics of WINDINGFEEDER Devices................................................................................... 3.1 Symbols shown on LCD ............................................................................................................................................ 3.2 Functions Directly Available to the Textile Machine Operator............................................................................. 3.3 1) Alarm Reset......................................................................................................................................................... 3.3 2) Current Yarn Type and Application Reading...................................................................................................... 3.3 3) Exclusion and Re-inclusion of a WINDINGFEEDER Device............................................................................ 3.4 4) Control of Temperature and Current Absorbed by WINDINGFEEDER............................................................ 3.4 Programming the WINDINGFEEDER Devices ..................................................................................................... 3.5 General Diagram of Simple Programming Environment......................................................................................... 3.5 Advanced Programming of WINDINGFEEDER Devices ..................................................................................... 3.6 General Diagram of P1÷P4 Advanced Programming Levels and Default Settings ................................................ 3.8 P1 Programming Level.............................................................................................................................................. 3.9 P2 Programming Level............................................................................................................................................ 3.12 P3 Programming Level............................................................................................................................................ 3.15 P4 Programming Level............................................................................................................................................ 3.17 Chapter 4 – WINDINGFEEDER TROUBLESHOOTING AND MAINTENANCE Indications Provided by the Red LEDs on WINDINGFEEDER Device .............................................................. 4.1 Troubleshooting Table .............................................................................................................................................. 4.2 Ordinary Maintenance.............................................................................................................................................. 4.4 Repairs........................................................................................................................................................................ 4.4

INTRODUCTION Congratulations for choosing a BTSR product. With our WINDINGFEEDER yarn feeding devices, with or without the SMART MATRIX FEEDER control unit, you got an innovative, unique solution able to offer you multiple advantages concerning quality of your production. The ideal solution for yarn preparation machines The WINDINGFEEDER device comes from the experience built-up by BTSR in the field of yarn feeling at constant tension. The WINDINGFEEDER devices are in fact high precision measurement and control instruments providing a real time display of the exact yarn tension and guaranteeing, through an accurate adjustment, a constant tension feeding of the yarn itself in every working condition. This occurs independently 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 WINDINGFEEDER devices are fully programmable and can easily be adapted to any kind of yarn or tension adjustment and to any operating speed of the textile machine on which they are installed. Furthermore these devices 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, exclusive characteristics of BTSR systems. Thanks to its modularity characteristics, the WINDINGFEEDER device is capable of managing not only the TS44.. 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.

WINDINGFEEDER How to use this manual This Operation Manual is divided into 4 Chapters. Chapter 1 – Overview describes the main features, components and the operation principle of WINDINGFEEDER devices. Chapter 2 – Technical Data and Installation gives the necessary instructions to install the devices. Chapter 3 – Operation gives a detailed description of the necessary operations to setup and program the WINDINGFEEDER devices according to the application needs. Chapter 4 – Troubleshooting and Maintenance provides a quick guide to solving the main failures of WINDINGFEEDER devices. Symbols used � Highlights notes, warnings and subjects to which the attention of the reader should be directed. Indicates a particularly sensitive situation which could have an effect on the safety or proper operation of the system. TENSION ERROR All the items concerning the device programming menus, within this manual, are always show in CAPITAL LETTERS. Reference Documentation For operating details about the programming/analysis and monitoring systems available for WINDINGFEEDER device management, please refer to the following BTSR manuals. SMART MATRIX FEEDER Manual – Rev. 2.2 – Ed. 03/2008 PC-LINK KTF Manual– Rev. 2.0 – Ed. 09/2005 PC-LINK KTF Studio Manual – Rev. 1.0 – Ed. 03/2005 P1.2

1 - OVERVIEW System Components The WINDINGFEEDER devices can be programmed and used either in individual and autonomous way, or they can be connected to a control/programming SMART MATRIX FEEDER terminal, thus obtaining a complete system providing further levels of analysis, adjustment, control and speed-up of production cycles, as well as statistical data processing, 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 SMATRIX FEEDER) 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 WINDINGFEEDER device functionality. Moreover, using a Personal Computer or Notebook with the aid of PC-LINK KTF Studio software running under WindowsTM environment, you can implement an efficient analysis & monitoring system which allows you to find and correct even the minimum critical conditions and behavior differences among the various devices. Main Characteristics of WINDINGFEEDER Devices Full Digital Technology The WINDINGFEEDER device is a fully high-tech digital instrument that allows setting of the exact tension value at which you want to operate. The data setting is done through a small three-button key-pad and a graphic LCD display. In normal operating conditions the LCD provides a real time display of the exact yarn tension (in grams) during the manufacturing process, the yarn consumption speed (LFA) (in m/min) and, in graphical form, both the average and peak values of the yarn tension. The WINDINGFEEDER devices are controlled by two DSPs (Digital Signal Processor) and by ASIC components (BTSR Patent) which provide great versatility (parameters may be programmed depending on the various yarn processing conditions) The Full Digital Technology also allows performing a number of extremely accurate controls on the device motor (absorbed current, speed, motor angular position, etc.). Temperature control In addition, the operator may display at any time the internal temperature (in °C) of both control board and motor, by pressing the Reset button.

WINDINGFEEDER An excessive increase of the temperature could infact indicate a wrong use of the device; for this reason, the software on board of device performs a continuous monitoring of the internal temperature. If such temperature exceeds 100°C, an alarm message (ERROR °C) appears in the graphic area of LCD, and the Stop output is activated. Safety Thanks to a configurable safety code, all parameters can only be changed by authorized staff knowing such safety code. External control The WINDINGFEEDER device may easily be programmed also using the SMART MATRIX FEEDER 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 MATRIX FEEDER and then to other devices installed on different machines; all this in about 1 second (i.e. the time needed to complete the data transfer). User friendly installation and management The WINDINGFEEDER is quite compact (290 x 86 x 94 mm). This permits you to install several devices on the same machine with limited encumbrances. The device has been designed bearing in mind not only the technological aspects, but also the ergonomic ones. Thanks to these characteristics, the device can be perfectly fitted within the machine structure, without compromising the machine spaces which are usual to the operator. Usable with any type of yarn The WINDINGFEEDER device 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 WINDINGFEEDER device considerably reduces the preparation tasks, thanks to a single self-threading ceramic eyelet that makes the operator job easier. The tension value displayed on LCD indicates the actual tension with which the device is working. This guarantees a constant and accurate monitoring of the working process. Easy to program Possibility of viewing and selecting directly from the navigation menu the desired application (rewind 1/2, warp 1/2, etc.) without the need of manually setting the relevant parameters.

Advantages obtained by using the WINDINGFEEDER devices � 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 extratensions), and possibility of working at the highest speed offered by the machine. � Possibility of working with a wide range of yarn types. � Accurate yarn feeding speed measurement (1 to 2,500 m/min) – (LFA m/min = Length of Absorbed Yarn). � Possibility of using the yarn up to the complete package emptying. � Better machine efficiency. � Possibility of finding the best application conditions of WINDINGFEEDER device: (No of coils to be wound around the roller, ideal programming values for parameters etc), thanks to the continuous visualization, in graphic form, of both average and peak values of yarn tension. � Possibility of handling 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 WINDINGFEEDER) and controlled (by means of IS3x/TS).

WINDINGFEEDER Advantages obtained by using the SMART MATRIX FEEDER Terminal combined with WINDINGFEEDER Devices � Using the SMART MATRIX FEEDER terminal connected to WINDINGFEEDER devices you have the possibility of developing a wide range of functions which facilitate the practical use of the installed WINDINGFEEDERs (immediate download and upload of data), as well as displaying fundamental data, such as yarn consumed and yarn tension. � Possibility of creating up to 99 “articles”, saving them to the Data Base for an easy subsequent recall. Without the need of setting up new parameters, these will simply be called from the Data Base and subsequently transferred to the WINDINGFEEDER devices installed on textile machine. � Possibility of using the TARGET function (meter count) and the Stop output, when reaching the amount of meters setup, with possible automatic bobbin change enabling (autodoffing). � Possibility of controlling and quickly correcting the tension adjustments, thus eliminating the defects due to irregular tensions, tears and wrong yarn unwinding. � Possibility of identifying the connected WINDINGFEEDERs using an automatic numbering procedure (BTSR Patent). � For more details, please refer to the SMART MATRIX FEEDER operating manual.

Further Advantages obtained by using a PC or Notebook connected to WINDINGFEEDER devices via serial line With PC-LINK KTF Software � Using a Personal Computer connected to the WINDINGFEEDER devices 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 WINDINGFEEDERs devices; 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 of associating each article with a “Tension Profiler” allowing you to rapidly and effectively adapt the working parameters of WINDINGFEEDERs to your specific application requirements. � Possibility of displaying and/or printing 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 of updating the WINDFEEDERs 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 WINDINGFEEDER 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)

WINDINGFEEDER 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.

PC-Link KTF – Examples of WINDINGFEEDER device operation parameters programming.

WINDINGFEEDER PC-Link KTF – Example of graphic screen showing the upload of working parameters (style) to the WINDINGFEEDER devices. With PC-LINK KTF Studio Software � Using the PC-LINK KTF Studio software or other application programs specifically developed by BTSR, you will have the possibility of upgrading (via serial line) the WINDINGFEEDER device firmware, without the need of physically replacing the microprocessor. In addition, the PC-LINK KTF Studio software offers several analysis and monitoring facilities that make easier the tuning of control parameters to the production managers. � Possibility of displaying in real-time up to 4 control graphics related to as many WINDINGFEEDER devices. � Possibility of displaying/saving and printing (for each graphic) up to 7 different control parameters (work tension, min/max tension, motor torque, motor speed, inlet tension). � Possibility of immediately checking the efficiency degree of WINDINGFEEDER devices by comparing the yarn inlet tension (not regulated) with the outlet tension (regulated by the WINDINGFEEDER device). � Possibility of checking (or comparing) the results obtained with two different versions of device control firmware. � For more details, please refer to the PC-LINK KTF Studio operating manual.

WINDINGFEEDER - 2.1 - 2 – TECHNICAL DATA AND INSTALLATION Technical Features WINDINGFEEDER Device Power supply voltage 24 VDC ± 10% or 24 VAC ± 20% 0.2 A (during normal operation); 1 A (under stress); Maximum absorption 3 A (at start-up) STOP Outputs: relay contacts (NO) 0.3 A 125 VAC 1 A 30 VDC Opto-insulated Inputs 0-24 VDC VIL Max 1.2 VDC VIH Min 5 VDC Max. voltage Iinputs,- Output) 30 VDC Programmable yarn tension 0.5 ÷ 100.0 gr. (resolution 0.1 gr.) or 5 ÷ 1,000 gr. (resolution 1 gr.) Depending on the type of TS44 sensor used Programmable alarms 0.1 ÷ 10 sec. Integrated keypad 3 push-buttons + STOP red LED Signaling With LCD graphic display Dimensions 290 x 86 x 94 mm Operating temperature range 10° - 60 °C Storage temperature -25° - +85° C Tension range 0 / full scale Useful tension range 0% - 95% full scale Max applicable tension 10 times the full scale value IS3x/TS Sensor Power supply voltage 12 .. 24 Vdc ± 20% Absorption 15 mA (max 20 mA) STOP output NPN STOP output protection Protection against over-voltages/short- circuits Maximum Current of STOP output 200 mA continuous; 500 mA peack Reaction Delay Programmable from 5 to 1,000 msec Sensitivity Programmable (10 levels) Signaling With integrated LEDs Dimensions (mm) 15 x 15 x 36,5 (Narrow) - 25 x 15 x 36.5 (Wide) Operating temperature range 10° - 60 °C Storage temperature -25° - +85° C TS44/xxxyRW Sensor Power supply voltage 12 .. 24 Vdc ± 10% Absorption 20 mA (max) Analogue Output 100 mV - 10V Analogue output resistance 1K Ohm Operating temperature range 10° - 50 °C Storage temperature -25° - +85° C Tension range 0 - fondo scala Useful tension range 0% - 95% fondo scala Max applicable tension 10 volte il fondo scala Drift error (a) 0.05% / °C Repeatability error (b) 0.5% Max linearity error (c) 2% (0 - fondo scala) Signaling Mediante LED integrati Dimensions 50 x 25 x 12.5 mm

- 2.2 - WINDINGFEEDER SMART MATRIX FEEDER Terminal Power supply voltage 24 VDC ± 10% Maximum absorption 100 mA Dimensions 140 x 80 x 31 mm Operating temperature range 10° - 60 °C Storage temperature -25° - +85° C LCD graphic display 80 x 40 mm Integrated Touch-pad 6 buttons + rotary selector Protection 2 fuses – 1.5A Electrical Interface of WINDINGFEEDER Devices TS44 Connector for TS44.. tension sensor connection SM/IN - SN/OUT Connectors for WINDINGFEEDER device daisy chain connection Ext Connector available for future expansions UNICO Connector for intelligent accessory connection IS3 Connector for IS3.. yarn image sensor connection

WINDINGFEEDER - 2.3 - Input/output signals function Inputs Function P1P2 It causes a switching between P1 and P2 tensions (*) The switch P2 → P1 only deletes the TARGET error. RESET This signal activation causes the alarms reset. EXC This signal activation causes a reset of the target internal counter. Output Function STOP1 It is activated when the Windingfeeder device generates an alarm. STOP2 It is activated when the Windingfeeder device reaches the target. (*) For more details about P1 e P2 tensions please refer to chapter 3 - Operation � Both: Inputs and Outputs can be programmed as normally open (NO) or normally closed (NC) contacts. The programming is global, i.e. every input (and every output in the same way) operates as NO or NC, depending on the selected option. For more details, please refer to chapter 3 – Operation – P4.7 SIGNAL POLARITY . SMART MATRIX FEEDER – WINDINGFEEDER 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 - WINDINGFEEDER PC – WINDINGFEEDER Connection Concerning all electrical systems, it is a suggested rule to ensure that the ground cable (GND) is connected to the device support.

- 2.6 - WINDINGFEEDER WINDINGFEEDER Unit A Ceramic element for coil separation – ø 5 B Allen screw for ceramic element inclination adjustment C Allen screw for ceramic element eccentric support adjustment TS44/xxxyRW Tension Sensor A Fastening hole with M4 x 20 screw B Loading cell (tension sensor) Note: the TS44.. device may automatically carry out the offset function upon special command issued by WINDINGFEEDER device (see OFFSET AUTO parameter on P3 programming level) A B C TS44

WINDINGFEEDER - 2.7 - Instructions for Correct Yarn Threading � Thread the yarn inside the lower buckle , thread it inside the yarn-brake , then make nn coils around the roller , passing beneath the separation element , as shown on the figure above. � Set the yarn over the loading cell of TS44 sensor  and thread it out of the upper buckle . � For correct separation of yarn coils on the coil separation element , slightly tilt the separation device, while the WINDINGFEEDER is running, turning the adjustment screw . � To adjust the yarn-brake pressure, set the adjustment wheel : � Push the adjustment wheel towards the yarn-brake to increase the braking effect (+). � Move away the adjustment from the yarn-brake to decrease the braking effect (-) + -

3 – OPERATION Operating Characteristics of WINDINGFEEDER Devices For programming and control of WINDINGFEEDER devices, 3 push-buttons, with green/red built-in LEDS and a LCD display are available to the operator. 1. E PUSH BUTTON (ENTER) Press and hold down this push-button to gain access to the 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. 2. PUSH BUTTON (RESET) Press this push-button to cancel possible error signaling on WINDINGFEEDER display (red LED flashing). During the Programming phase, press it to decrease the value of displayed parameter. During the Control phase, without an alarm condition in progress, this button allows you to display the device’s internal temperature.

WINDINGFEEDER 3. + PUSH BUTTON (CONTROL) Press this push-button to temporarily de-activate the device (lighting of front/rear LEDs and of ENTER, RESET, CONTROL push-button LEDs); press it again to reactivate the device. 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 device (i.e. for yarn threading, coil separation device adjustment, etc.) to avoid undesired start-up of the motor. � During normal operation, the three buttons (ENTER, RESET and CONTROL) show the green LEDs on. In case of alarm, the LEDs turn to red. 4. LCD DISPLAY It provides the real time display of measured and adjusted tension values, as well as the parameters programmable within the various menus, programming and error messages, device status, etc. Symbols shown on LCD A – Area Etichette OK Indicates the activation of any of the 3 push-buttons of WINDINGFEEDER device. COM Communication in progress with SMART MATRIX FEEDER terminal or with the PC. CONTROL Indicates that the WINDINGFEEDER device is operating in Control status. PROGRAM Indicates that the WINDINGFEEDER device is in Parameters Programming status. TARGET Indicates that the set Target has been reached. INC DEC Indicates with 1 flashing the increment of main tension. Indicates with 1 flashing the decrement of main tension. P1 P2 P3 P4 P5 In Control environment indicates that the operating tension is the one defined in P1 (MAIN TENSION). In Control environment indicates that the operating tension is the one defined in P2 (EXIT TENSION). Indicates the exclusion input activation. It indicates the detection of an optional accessory. Indicates Auto-Offset procedure in progress. B – Area Messaggi It shows, in the selected language, the various programming menu items, as well as the error messages during the device operation, the yarn feeding speed (LFA nnnn), the device internal temperature, etc.

C – Value Visualization Area It shows the yarn tension value, during the normal operation, or the parameter being programmed. D – Graphic Visualization Area It shows, in graphical form (through a logarithmic scale) both average and peak tension values. Functions Directly Available to the Textile Machine Operator The operator of a textile machine equipped with WINDINGFEEDER devices has the possibility of carrying out some simple manual operations on the device themselves, without having to request the aid of a supervisor or production manager: 1) Alarm reset 2) Current yarn type and application reading 3) Exclusion and re-inclusion of a WINDINGFEEDER device. 4) Real-time control of device temperature and current absorbed by the device’s motor. 1) Alarm Reset When a WINDINGFEEDER device detects an Error condition (E2, Tension Error, etc.), the device stops and the LFA nnnn indication on display is replaced by the error message. To reset the alarm, once you have removed the cause that generated the error, press the button on the device. 2) Current Yarn Type and Application Reading At any time, pressing the button, you may check the yarn type and the application currently configured on the device. Press : The display will show the yarn type (either ELASTIC or ALL YARN) and the application currently configured on the device (REWIND 1/2, WARP 1/2, ETC..). The LEDs of push buttons , , turn to red. Press to return to LFA menu.

WINDINGFEEDER 3) Exclusion and Re-inclusion of a WINDINGFEEDER Device When needed, it is possible to temporarily exclude a WINDINGFEEDER device, in order to avoid undesired starts due to vibrations, etc. To exclude and re-include a device, operate as follows: Exclusion: Press and hold down for 3 seconds : The display will show the exclusion confirmation request. to confirm the exclusion. to cancel the operation. The <> indication, shown on display indicates that the device is currently excluded. Re-inclusion: To re-activate the device press and hold down for 3 seconds . to confirm the re-inclusion. to cancel the operation. � In order to temporarily de-activate a WINDINGFEEDER device simply press . The condition of device temporarily de-activated is signaled by the lighting the red LEDS inside the 3 push-buttons and inside theTS44 tension sensor. 4) Control of Temperature and Current Absorbed by WINDINGFEEDER At any time, pressing the button, you can check the internal temperature (T) of the control board (32°C in the example below) and of the motor (31°C in the example below), as well as the current absorbed by the motor (C) in Ampere (0.1 A in the example below).

Programming the WINDINGFEEDER Devices The WINDINGFEEDER device offers two programming environments: 1) SIMPLE (allows programming exclusively the device main tension) 2) ADVANCED (allows programming all the device parameters) To get access to the programming environment, press and hold down for 3 seconds the ENTER button, while the device is operating in Control environment. If you keep the button pressed for less than 3 seconds, the device Firmware version will temporarily appear on the display. To switch from SIMPLE to ADVANCED and viceversa, press and hold down for 3 seconds the ENTER button. � To avoid undesired changes of operating parameters, after the installation of WINDINGFEEDER devices 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 of changing the main tension (1st variable of P1). General Diagram of Simple Programming Environment (A) LFA = Length of Absorbed Yarn in m/min

WINDINGFEEDER Advanced Programming of WINDINGFEEDER Devices With the ADVANCED programming environment, each WINDINGFEEDER can be programmed with specific control parameters which depend on the type of yarn under processing, and on the type of application. • MAIN TENSION Control Tension • ERROR TENSION Tolerance beyond which an Error is generated • TIME ALARM Time for which the tension may stay out of tolerance • EXIT TENSION Device Tension with machine stationary • RAMP UP Raising ramp in case of tension increase • RAMP DOWN Lowering ramp in case of tension decrease • K-PID Reactivity constant of the device In addition, you can program particular functions and/or service parameters that affect the device operating mode: • APPLICATION Device operating mode, pre-defined according to the application. The following pre-defined applications are currently available: REWIND 1/2, WARP 1/2. • YARN TYPE Possibility of presetting the device for management of elastic yarns • OFFSET Possibility of reading/setting the OFFSET value as well as enabling the device Auto Offset function. • ACCESS CODE Possibility of setting a protection password to prevent undesired access to the device programmable functions. • U-FEEDER CODE Possibility of visualizing and/or directly setting the device identification code. • LANGUAGE Possibility of choosing the language used to show the message on the device display. • SIGNAL POLARITY Possibility of choosing the INPUT and STOP signal polarity (NO or NC contact). The setting of these parameters is already done by BTSR during the device manufacturing (default values), however it can be easily changed by the textile machine operator, to meet specific requirements, using the advanced programming features. WINDINGFEEDER devices 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: � MAIN TENSION � ERROR TENSION � TIME ALARM Within the P2 level the following parameters can be programmed: � EXIT TENSION � RAMP UP � RAMP DOWN � K-PID

Within the P3 level the following parameters can be programmed: � OFFSET AUTO � MOTOR CALIBRATION � ACCESS CODE � DEVICE IDENTIFICATION CODE Within the P4 level the following parameter can be programmed: � MOTOR ROTATION DIRECTION � SENSOR TYPE � BAUDRATE � APPLICATION (REWIND 1/2 – WARP 1/2) � YARN TYPE (ALL YARN OR ELASTIC) � LANGUAGE SELECTION � USE OF INTELLIGENT TENSION CONTROL ACCESSORY Press the (Control) button to switch from one programming level to the next one. Press (Reset) button to quit the programming environment.

WINDINGFEEDER General Diagram of P1÷P4 Advanced Programming Levels and Default Settings NOTES: The values shown refer to the default parameters (set by BTSR). (A) LFA = Length of Absorbed Yarn in m/min (B) The selectable languages are Italian, English, French, Spanish, German, Japanese.

P1 Programming Level LFA m/min � ADVANCED � MENU P1 The P1 programming level allows you to setup 3 parameters: 1) Device main tension; 2) Tolerance with respect to the main tension; 3) Max deviation time from tolerance band; With the WINDINGFEEDER in CONTROL status, (LFA nnnn displayed on LCD) press and hold it down for 3 seconds. The display will show the ADVANCED label and the WINDINGFEEDER will switch to PROGRAM status. or to continue. to start programming of parameters belonging to P1 menu. P1.1 MAIN TENSION (P1) Tension value with which the WINDINGFEEDER device must operate to create the desired article. [Allowed values 0.2 ÷ 99.5 grams]. Choose the desired value using: (to increase the value) or (to decrease the value). to confirm. P1.2 ERROR TENSION Tolerance band beyond which the machine will be stopped. The error indication and machine stop occur only if such tolerance is exceeded for the time period set in the next parameter (TIME ALARM). [Allowed values ± 0.0 (*) ÷ 99.5 grams (with automatic limitation to 0.4 grams for what concerns the negative tolerance, if the tension is greater than 0.5 gr., otherwise it is automatically stepped down, or AUTO)]. (*) Where setting AUTO, the system automatically calculates the error threshold value as 50% of MAIN TENSION. This means that changing the MAIN TENSION value (P1.1), the ERROR TENSION value too changes accordingly, without the need of changing it manually. Choose the desired value using: (to increase the value) or (to decrease the value). to confirm.

WINDINGFEEDER Example 1: Main Tension: 20 g Error Tension: ± 5 g Example 2: Main Tension: 50 g Error Tension: ± 20 g Example 3: Main Tension: 5.0 g Error Tension: ± 6 g

P1.3 TIME ALARM Time during which the tension value may exit from the tolerance band set by the previous parameter (ERROR TENSION). You can disable (OFF) this feature by holding the Enter button pressed for 3 seconds. [Allowed values 0.0 (*) ÷ 10 seconds]. (*) Setting 0.0 activates the AUTO mode; this means that the system will automatically calculate the best alarm generation and machine stop time, depending on the feeding speed. At low speed, such time is 500 ms; as the speed increases it will be reduced up to a minimum of 50 ms; this allows a quick machine stop during normal operation avoiding, however, the risk of false stops when working at low speed. 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.

WINDINGFEEDER P2 Programming Level LFA m/min � 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. P2.1 EXIT TENSION (P2) Tension value of device when the machine is stationary or out of yarn working zone. By setting a value higher or lower than the value set with MAIN TENSION parameter of P1 menu, you can control the deceleration stage of WINDINGFEEDER device. This function may be either enabled (with values ranging from 0.2 to 100.0 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 decrease the value). to confirm. P2.2 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 ÷ 250] The RAMP UP (t) is calculated using a reference table that determines an increase of the ramp time depending on the programmed value: [1 = very fast ramp time (1ms) ... 250 = very slow ramp time (250 msec)]. See the following examples 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 P2.3 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 ÷ 250] The RAMP DOWN (t) is calculated using a reference table that determines an increase of the ramp time depending on the programmed value: [1 = very fast ramp time (1ms) ... 250 = very slow ramp time (250 msec)]: See the following examples 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

WINDINGFEEDER Example 3: Final tension = 4 g Initial tension = 10 g N = 100 Choose the desired value using: (to increase the value) or (to decrease the value). to confirm. P2.4 K-PID 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) Choose the desired value using: (to increase the value) or (to decrease the value). to return to the beginning of P2 menu. to switch to P3 menu. to return to CONTROL status without programming P3 and P4 menus.

P3 Programming Level LFA m/min � ADVANCED � MENU P3 The P3 programming level allows you to setup 4 functionality: 1) Offset reading/execution and Auto Offset enabling; 2) Device operation mode; 3) Access code to programmable function; 4) WEENDINGFEEDER identification code. to select the P3 level. to continue. P3.1 OFFSET By “offset” we means the calibration of the TS44.. sensor’s mechanical clamping position. It clears possible measurement errors due to the different clamping position of the device on textile machine. The displayed indication is the actual OFFSET value resulting from the clamping position of the device. While lifting the yarn above the loading cell, press to check whether the stored OFFSET value corresponds to the actual OFFSET value. If the two values are different, press briefly to align them. You may either enable or disable the Automatic Offset function keeping pressed for 3 seconds. If the function is disabled, then AUTO does not appear on the display. If it is enabled, then at every machine stop the device loosens the yarn until this is completely relaxed and it carries out an automatic correction of the Offset value. � You are recommended to enable the Auto Offset function only for low tensions (lower than 1.0 grams). Auto-Calibration of the Loading Cell Holding down for 3 seconds you may activate the loading cell Auto- Calibration function which brings back the Offset value to 5.0 grams (factory calibration value of Windingfeeder devices). During the auto-calibration process, an “OFFSET INT-CALI” message is temporarily shown on the display. to select the next parameter. � The auto-calibration function can be carried out only when using theTS44.. sensor (not available on TS4.. sensor):

WINDINGFEEDER P3.2 MOTOR CALIBRATION Automatic function reserved to BTSR service staff, in case of motor replacement. It allows executing the automatic calibration of the new motor. To activate the motor calibration procedure, press and hold down for 3 seconds. The OFF indication will be replaced by 000 and the motor will automatically carry out a number of movements to both directions, in order to adjust the calibration, then it will stop and the OFF indication will re-appear. to select the next parameter. P3.3 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. This function may be either enabled or disabled by holding down the button for 3 seconds. OFF indicates that the function is currently disabled. If you specify an access code, this will be requested each time you attempt to activate the programming environment. When the CODE ??? request appears, type the secret key-code using and buttons. increase the value of secret key code. decreases the value of secret key code. Press to save the key-code and move to the next parameter. P3.4 FEEDER CODE This function allows you to visualize and/or set the numeric code corresponding to the identification address of the WINDINGFEEDER device. Set the desired identification code using (to increase the value) or (to decrease the value). � Usually the setting of device identification code is carried out from SMART MATRIX FEEDER terminal using the serial communication port; however in particular circumstances (for instance after the replacement of a WINDINGFEDER device), it may be useful to set the code operating directly on the new device. to return to the beginning of P3 menu. to switch to P4 menu. to return to CONTROL status without programming P4 menu.

P4 Programming Level LFA m/min � ADVANCED � MENU P4 The P4 programming level allows you to select the various device operating modes: 1) Yarn feeding motor rotation direction (clockwise or counter clockwise); 2) Size in grams of TS44.. tension sensor used (either 100 g. or 1,000 g.); 3) Communication baud rate over the serial interface; 4) Application on which the device will be used; 5) Yarn type: either normal or elastic; 6) Language used to display menus and messages; 7) Polarity of Input and Stop signals (Normally Open or Normally Closed contact). 8) Automatic detection of the optional intelligent accessory. to select the P4 level. to continue. P4.1 MOTOR D This function allows you to choose the rotation direction of yarn feeding motor (CW = Clockwise, CCW = Counter-Clockwise). To move from CW value (Clockwise) to CCW value (Counter-Clockwise) or vice versa, press and hold down for 3 seconds the button. to move to next parameter. P4.2 SENSOR TYPE Choose the size in grams of the TS44.. tension sensor used: allowed values 101 or 102. (101 if you are using the TS44/100DRW sensor or 102 if you are using the TS44/1000ERW sensor) Use the or buttons to toggle from 101 to 102 and vice versa. to confirm.

WINDINGFEEDER P4.3 BAUDRATE This parameter allows you to setup the communication speed on the WINDINGFEEDER serial interface. [Allowed values: 57600 or 115200] or to choose the desired speed. to confirm the speed shown on display and move to the next parameter. P4.4 APPLICATION SELECTION This function allows you to choose one of the pre-defined applications. or to choose the desired option: REWIND1, REWIND2, WARP1 or WARP2. to confirm the application shown on display and move to the next parameter. P4.5 ELASTIC This function allows you to set the yarn characteristics. or to choose between ELASTIC * or ALL YARN options. to confirm the application shown on display and move to the next parameter. * The ELASTIC mode allows a better handling of bare elastic yarns. P4.6 LANGUAGE SELECTION This function allows you to select the language used to display menu items, messages and errors. or to scroll forward/backward the list of available languages: ITALIANO – ENGLISH – FRANCAIS – ESPANOL – DEUTSCH – JAPANESE to confirm the language indicated on display and return to the beginning of P4 menu. P4.7 SIGNAL POLARITY This function allows you to setup the polarity of INPUT and STOP signals. to toggle the INPUT signal between NO and NC. to toggle the STOP signal between NO and NC. to confirm the option shown on display and move to the next parameter. � Both: Inputs and Outputs can be programmed as normally open (NO) or normally closed (NC) contacts. The programming is global, i.e. every input (and every output in the same way) operates as NO or NC, depending on the selected option.

P4.8 UNICO This function allows you to set up the automatic detection feature of a possible intelligent accessory connected to the WINDINGFEEDER device. The detection condition is indicated by the lighting of label P4. for 3 seconds to toggle between AUTO and OFF. to confirm and return to P4 menu. to return to CONTROL status. Management of “Tension Error” Alarm EXAMPLE � The WINDINGFEEDER 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 the WINDINGFEEDER device operates with P1 tension (MAIN TENSION) Main Tension: 2.0 g. Error Tension: ± 0.5 g. Time Alarm: 2.0 sec.

WINDINGFEEDER - 4.1 - 4 –WINDINGFEEDER TROUBLESHOOTING AND MAINTENANCE Indications Provided by the Red LEDs on WINDINGFEEDER Device Status of WINDINGFEEDER device Led on the TS44.. sensor Identification BLINKING GREEN/RED ALTERNATE FLASHING ERROR E2 BLINKING GREEN/RED ALTERNATE FLASHING MOTOR LOCKED (with CONTROL button)(*) ON ON TENSION ERROR BLINKING GREEN/RED ALTERNATE FLASHING (*) This condition is obtained when you are working with the tension defined in P2. If you are working with the tension defined in P1, even if you press the Control button, the LEDs remain off. However, pressing the Control button, the tension defined in P1 will be displayed. � To interpret the failure condition and restore the normal operating conditions, please refer to the following table

- 4.2 - WINDINGFEEDER Troubleshooting Table Faults Causes Solutions The WINDINGFEEDER display is blank Device powered off � Check that the I/O connector is correctly plugged in and that there is a 24 Vdc power voltage on pins 1-2. E2 displayed on WINDINGFEEDER display 1) Motor locked 2) Temporary triggering of internal protections 1) Check if the motor is correctly turning; detach the feeding wheel to remove possible yarn residuals preventing the motor from turning correctly Correctly thread the WINDINGFEEDER device as shown on page 2.7 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 centre). E3 displayed on WINDINGFEEDER display 1) Presence of yarn residuals under the loading cell. 2) OFFSET value of WINDINGFEEDER device out of adjustment 1) Clean the loading cell of TS44 sensor using a light air blow (max 1 bar). 2) Perform a correct adjustment of the OFFSET value on WINDINGFEEDER device as described on page 3.15. ES ES-CONT displayed on WINDINGFEEDER display 1) Internal protection against overcurrents 1) Reset the alarm; if the problem persists, contact your BTSR reseller. MT-BUS displayed on WINDINGFEEDER display 1) Supply voltage lower than 15 Vdc 1) Check the supply voltage, if the problem persists, contact your BTSR reseller.. CURRENT displayed on WINDINGFEEDER display 1) The current absorbed by the device exceeded the maximum allowed value. 1) Check the usage conditions of the systems. � If you cannot locate the cause of failure, please contact your BTSR reseller (it could be necessary to send the device to the BTSR repair centre). TE displayed on WINDINGFEEDER display 1) The motor temperature of control exceeded the maximum expected value 1) Check the usage conditions of the systems. � If you cannot locate the cause of failure, please contact your BTSR reseller (it could be necessary to send the device to the BTSR repair centre).

WINDINGFEEDER - 4.3 - Anomalie Cause Rimedi TM displayed on WINDINGFEEDER display 1) La temperatura del motore è superiore a quella massima prevista. 1) Check the usage conditions of the systems. � If you cannot locate the cause of failure, please contact your BTSR reseller (it could be necessary to send the device to the BTSR repair centre). The machine is not stopped by WINDINGFEEDER device in case of yarn breakage 1) The third parameter of the P1 programming level has been de-activated (OFF) 2) Wiring problem. 1) Confirm the correct programming of WINDINGFEEDER parameters. Check the correct connection of P1-P2 inputs. 2) If the red LEDs on WINDINGFEEDER device turn on when the yarn breakage occurs, than check for correct machine connections. � To check the correct operation of the WINDINGFEEDER STOP output press the "Control " button and confirm the lighting of red LEDs; if this does not occur please contact your BTSR reseller (it could be necessary to send the device to the BTSR repair centre). The WINDINGFEEDER device does not communicate with SMART MATRIX FEEDER terminal 1) The identification code of WINDINGFEEDER device is not correct 2) Failure on SMART MATRIX FEEDER terminal 3) Wiring problem 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 MATRIX FEEDER terminal or set directly the identification code on WINDINGFEEDER device (parameter P3.4). 2) Check the correct operation of SMART MATRIX FEEDER terminal using the numbering procedure described in the SMART MATRIX FEEDER manual. 3) Check the overall device wiring. ASC1010 COM-ERROR displayed on WINDINGFEEDER display 1) Missing communication between main DSP and loading cell DSP. 1) Reset the alarm; if the problem persists, contact your BTSR reseller.

- 4.4 - WINDINGFEEDER Anomalie Cause Rimedi ASC1010 EEP-ERROR displayed on WINDINGFEEDER display 1) Loss of calibration data 1) Reset the alarm; if the problem persists, contact your BTSR reseller. WATCHDOG displayed on WINDINGFEEDER display 1) Device internal error 1) Reset the alarm; if the problem persists, contact your BTSR reseller. Even if the torque of motor driving the roller rotation is very low and does not involve hazards for the operator safety, it’s always advisable to lock the motor prior to operate on the devices (yarn threading, tilt adjustment of coil separation element, etc.) in order to avoid unexpected motor startup events. To lock the motor, just press the button on the WINDINGFEEDER device and check the lighting of buttons’ red LEDs and of TS44 sensor. At the end of the operation, press again the button and make sure that all the red LEDs turn off. � If the fault is not included in the above table, please contact your local BTSR reseller, giving a detailed description of the kind of fault and the conditions in which it occurred. Should be necessary to call the BTSR Technical Service Department, read the code printed on the faulty device, as this information could be useful to BTSR technicians. Example: Device code: WINDINGFEEDER …………………… Ordinary Maintenance The WINDINGFEEDER devices 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 WINDINGFEEDER devices must be carried out by specialized BTSR technicians. Any intervention attempt by non authorized personnel, voids the warranty terms.

Via S. Rita 21057 OLGIATE OLONA (VA) Phone 0331-323202 Fax 0331-323282 Internet: www/btsr.com REV. 3.0 – 03/11 DISTRIBUTOR