Essex Pattern Perfect System User Manual

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essex inc.

P a t t e r n P e r f e c t

version 3.1

SYSTEM

OWNER’S MANUAL

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PatternPerfect Owner’s Manual

TABLE OF CONTENTS

Overview 2

Selecting a Style 3

Selecting a Yarn Type 4

Selecting a Beam 5

Updating the Style List 6

Testing 8

Troubleshooting 9

Spare Parts 10

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OVERVIEW

The Essex Inc. PatternPerfect System is designed to make the creeling process simple, improve creeling accuracy, and reduce time spent creeling by providing a visual indication (green LED) of the correct position for each yarn package.

Creeling diagrams for each style and/or beam are stored in the PatternPerfect Style Database. Upon selecting a style, a beam (if applicable) and a yarn type, the proper creel configuration will automatically load and the proper LEDs will light, showing where the yarn packages should be placed.

PatternPerfect System Touch Screen Layout

push-

buttons

pattern database FTP server address

touch sensitive screen

Upon power-up the Start-Up screen will momentarily appear. The Main/Style Selection screen will automatically display after all communication connections are established, indicating that the system is ready for use.

The Main/Style Selection screen of the system can be obtained at any point in the system by pressing the MENU pushbutton.

START UP SCREEN

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SELECTING A STYLE

To select a style to begin creeling, first locate the slider on the Main or Style Selection page. By pressing the up or down arrow buttons on the slider, the list of styles located in the middle of the screen will scroll. These are the styles as pre-defined in the PatternPerfect database. When the desired style is highlighted press the Select button at the bottom of the page. If the system is equipped with an optional scanner, simple scan the barcode which represents the desired style, and style selection occurs automatically and is complete.

Main / Style Selection Screen

style name

slider bar

MAIN/STYLE SELECTION SCREEN

Upon selecting a style, either the Beam Selection screen or the Yarn Selection screen will automatically display depending on which is applicable to the system.

To return to the previous screen in order to choose a different style, press the MENU pushbutton.

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SELECTING A BEAM

Once a style has been selected, one or more Beam buttons will display on the Beam Selection screen, if the system is designed for a Warper application. These buttons correspond to the beams necessary for the chosen style. To select a beam to creel press the desired Beam button. If the system is designed for a Tufting machine, this option will not be available.

Beam Selection screen

BEAM SELECTION SCREEN

Upon selection of a beam, the Yarn Type Selection screen will automatically display.

To return to the Main / Style Selection screen in order to choose a different style, press the MENU pushbutton.

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SELECTING A YARN

If the PatternPerfect system is designed for a Tufting machine the necessary yarns will display as alpha- betically indicated buttons upon selecting a style, or for a Warper system they will display after selecting a beam. To creel a yarn select the corresponding Yarn button, and the green LED position indicators will light. Place the yarn packages in the appropriate positions and select the next yarn until all yarn packages for this style are in position.

Yarn Selection screen

selected style name

YARN SELECTION SCREEN

The Tie-Offs button, located at the bottom of the page, indicates the positions which are not part of the selected style. Press the Tie-Offs button to light the LED indicators which should have no yarn packages.

To indicate creeling completion, press the Style OFF button, which will return the Main/Style Selection screen.

To return to the Main / Style Selection screen at any time, press the MENU pushbutton.

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UPDATING THE STYLE LIST

Whenever new styles are added to the plant database, the PatternPerfect database should be refreshed, so that the new styles are included and accessible. Begin the refresh process by pressing the top pushbutton on the main screen. A hidden button will become available, although it will remain invisible, just off the upper right-hand corner of the slider (as shown below). Press this button to access the refresh procedure.

Main / Style Selection Screen

hidden button

Upon pressing the hidden button, the Testing/Refresh Style screen will appear.

MAIN/STYLE SELECTION SCREEN

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UPDATING THE STYLE LIST

continued

Testing/Refresh Style Screen

TESTING/REFRESH STYLE SCREEN

To initiate the refresh process press the Refresh button. The PatternPerfect style database will update to include any new style information contained in the customer style database.

Upon refresh completion, the Main/Style Selection screen will automatically appear.

To return to the Main/Style Selection screen without refreshing, press the MENU pushbutton.

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LED TESTING

The PatternPerfect system should regularly be tested for LED functionality. Access the test options from either the Main/Style Selection screen or the Testing/Refresh Style screen.

To test all LED positions:

Press the Test button on the Main/Style Selection screen to turn all the LED Indi-

cators in the system on. Press the Test button a second time to turn all the lights off.

MAIN/STYLE SELECTION SCREEN

To adjust the rate at which the lights appear for testing purposes, find the Testing/Refresh Style screen as indicated on page 5. Use the rate slider

to set the test speed, with “0” being the

fastest.

rate slider

Single position

To return to the Main/Style Selection screen, press the MENU pushbutton.

selection numeric

entry pad

TESTING/REFRESH STYLE SCREEN

To test a single LED position:

Press the Single Position Test button on the Testing/Refresh screen to turn on a particular LED. A numeric entry pad will automatically display. Enter the needle position number and press the Enter button to light the corresponding LED. To turn the LED off press the OFF button that will automatically display.

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TROUBLESHOOTING

PROBLEM SOLUTION

communication failure during data refresh

procedure, indicated by “connection failed, data not updated” message

single LED does not light during testing procedure

LED does not light when expected during creeling

whole module does not light during testing or creeling

 power system OFF / ON  check that the database FTP server ad-

dress displayed on the Start-Up screen is valid

 check to make sure Ethernet connec-

tions between the Essex PatternPerfect System and the in-plant network are intact and repair if necessary

 replace LED  replace LED socket

 run Test procedure and if LED does not

work during testing see above for single LED replacement

 run Test procedure and if LED does

work during testing contact Essex technical support to diagnose in-plant pattern database problem

 check Ethernet module cable for dam-

age and replace with standard Ethernet cable if necessary

 check in-line module coupler for dam-

age and replace if necessary

Essex Technical Support:

336-761-1112 866-851-1076

[email protected]

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SPARE PARTS

Item # Description Unit Price

24.15.000.LED led ea 1.10

24.15.000.LED.S led socket ea 1.50

24.15.000.LED.L led lens ea 1.10

24.15.1071 in-line module coupler ea 3.50

24.15.G306 6” PatternPerfect touch screen ea 1750.00

24.15.G150 6amp 24vdc power supply ea 94.50

24.15.G050 2.1amp 24vdc power supply ea 60.00

24.15.6232 ethernet bus coupler ea 420.00

24.15.6282.2 32 point ethernet output ea 350.00

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essex inc.

PO Box 20784 Winston-Salem, NC (ph) 336.761.1112 (fax) 336.499.6237. (email) [email protected]