Classimat 5 Help

USTER CLASSIMAT 5 ®
Operating Instructions
THE YARN CLASSIFICATION SYSTEM
Version 1.0 / Mat. No.318 104-40020

Regional Service Centers
Head office Switzerland

Uster Technologies AG
Sonnenbergstrasse 10
CH-8610 Uster / Switzerland
Phone +41 43 366 39 00
Fax +41 43 366 39 55
uster.service@uster.com
spares@uster.com
repairs@uster.com
Regional Service Centers are also located in China, India, Thailand, USA and Turkey.
For details please go to www.uster.com/service
Uster Technologies AG
Sonnenbergstrasse 10
CH-8610 Uster / Switzerland
Phone +41 43 366 36 36
Fax +41 43 366 36 37
www.uster.com
sales@uster.com SW 318 104-40020 Printed in Switzerland © Copyright 2012 Uster Technologies AG
Operating Instructions Keywords, Terms, Abbreviations 0
Contents
Page
0 Keywords, Terms, Abbreviations 3
0.1 Terms 3
0.1.1 General Terms 3
®
0.1.2 Terms used with the USTER CLASSIMAT 5 3
0.2 Definitions 4
0.3 Abbreviations 5
0.4 Version History 6
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USTER CLASSIMAT 5 09.12 1 (6)
0 Keywords, Terms, Abbreviations Operating Instructions
© Copyright 2012 by Uster Technologies AG. All rights reserved.

09.12 Printed in Switzerland
2 (6) 09.12 USTER® CLASSIMAT 5

0 Keywords, Terms, Abbreviations
0.1 Terms
0.1.1 General Terms
Operating Instructions
These operating instructions are an essential document that must be included in
the delivery of every product. They contain all the information necessary to operate
and maintain the product safely.
®
Along with the USTER CLASSIMAT 5 operating instructions, the operating instruc-
tions for independent equipment or for system parts from outside suppliers, are also
supplied insofar as they belong to the product or form a functional unit with it.
®
These documents are enclosed with the USTER CLASSIMAT 5 on dispatch, and
this will be referred to several times in the operating instructions.
0.1.2 Terms used with the USTER® CLASSIMAT 5
Yarn body The Yarn body represents the nominal yarn with tolerable,
frequent yarn faults.
Dense area The Dense area represents the nominal yarn with frequent
foreign fiber or VEG faults.
Estimated clear- Estimation and illustration of the clearing limits applied on the
ing limit winding machine to remove outliers or disturbing faults (for
the tested article).
Inspection limit CLASSIMAT 5 offers the possibility for visual inspection of
yarn faults. Limits define the level above which a fault – thick,
thin faults or foreign matter will be cut. After a cut, the fault
can be manually collected from the wound package and visu-
ally inspected.
Outliers (limit) Outliers are yarn faults that are significantly beyond the nor-
mal distribution and therefore have a disturbing effect on the
fabric or productivity in downstream processes.
Clearing limit Limits defined on the yarn clearers on winding machines
which a fault is considered disturbing and therefore needs to
be eliminated.
Affected share The affected share gives the percentage (%) of the affected
length compared to the total test length. Concerning the
calculation of this parameter, the total test length is devided
into several samples which are analyzed for the
corresponding criteria.
USP13 Presents the Uster Statistics 2013 percentile value for the
Affected share.
52 week best Best value of the same article and regarding a certain criteria
that has been achieved within the last 52 weeks. The 52
week best value is calculated as soon as 5 tests of the same
article are available and is to be compared with the indicated
affected share.
®
0.2 Definitions
Definition of NSL thick places
Faults Description
N-faults Thick places from 0.2 cm to < 1 cm  very short thick places (neps)
S-faults Thick places from 1 cm to < 8 cm  short thick places
L-faults Thick places from 8 cm to 200 cm  long thick places
Parameters used for NSL/T and F/VEG
Parameter Description
Reflectance (%) is a parameter for the inspection limits of
Reflectance
the relevant fault type. The reflectance setting raises (less
sensitive) or lowers (more sensitive) the clearing limit.
Reference length (cm) is a parameter for the inspection
Reference length
limits of the relevant fault type and shifts the inspection limit
to the right (less sensitive) or to the left (more sensitive).
Parameters used for PP
Sensitivity (%) is a parameter for the inspection limits of the
Sensitivity
relevant fault type. The sensitivity setting raises (less sensi-
tive) or lowers (more sensitive) the clearing limit.
The reference length (cm) is a parameter for the inspection
Reference length limits of the relevant fault type and shifts the inspection limit
to the right (less sensitive) or to the left (more sensitive).

0.3 Abbreviations
Commonly used abbreviations:
‘Chapter’ - symbol (in a cross-reference):


e.g. See Chapter 6.5.1
CMT5 CLASSIMAT 5
CMT5-CU USTER® LAB Control Unit
CMT5-CCU CLASSIMAT 5 Control Unit
CMT5 iMH CLASSIMAT 5 intelligent Measuring Head
CV Coefficient of variation of yarn evenness

F Foreign matter
FD Foreign matter Dark
FL Foreign matter Light
iCSA Intelligent Clearer Spindle Adapter Quad group
JPA Jump Alarm (yarn)
JPM Jump Monitoring (yarn)
L Long thick place
MMI Man Machine Interface (keyboard, display, printer)
N Neps (very short thick places)
PF Periodic Fault
PP Polypropylene
S Short thick place
SP Spinning / winding Position
T Thin place
VEG Vegetable
IP Imperfection
H Hairiness
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0.4 Version History

The following table shows the version history of these Operating Instructions:
Chapter Edition Description of change Date of change Carried out by

All 09.2012 Original document 30.09.2012 Uster Technologies AG

Operating Instructions System Description 1
Contents
Page
1 System Description 3
1.1 Legal Regulations 3
1.2 Original Language 3
1.3 Application 3
1.4 Installation Overview 4

1.4.1 Complete Installation 4
1.4.2 Identification of the Product 5
1.5 Technical Data 6

1.5.1 Dimensions and Weight 6
1.5.2 Electrical Connection 6
1.5.3 Compressed Air 6
1.5.4 Ambient Conditions 6
1.6 Equipment 7
1.6.1 Condition as delivered 7
1.6.2 Scope of Delivery 9
USTER® CLASSIMAT 5 09.12 1 (10)

1 System Description Operating Instructions


1 System Description
1.1 Legal Regulations

This manual as well as the software described in this manual are provided under li-
cense and may only be used or copied in accordance with the license terms.
Unless allowed explicitly by the license agreement, no part of this documentation

may be reproduced, stored in databases or transmitted, duplicated or distributed in
any form whatsoever (i.e. electronically, photo mechanically, on sound storage
media, etc.) without the prior written approval of Uster Technologies AG. In case of
any violation against this regulation, Uster Technologies AG reserves the right to
claim damages.
All and any information contained in this manual is not binding. The supplier re-
serves the right to modify the products at any time. Any liability of the supplier for
damages resulting from possible discrepancies between this manual and the char-
acteristics of the products is explicitly excluded.
The supplied system software as well as the updated versions of the system soft-
ware is intended exclusively for the operation of the USTER® CLASSIMAT 5. The
software must not be used for any other purposes.
Uster Technologies AG will not accept any liability for losses of data (customer or
production data) that result from incorrect operation or improper use or from defec-
tive or malfunctioning hardware or software.
The passing on of registered marks, trade names, brand names, product names,
etc. in these operating instructions does not entitle anyone to consider such names
not being protected by the trade mark protection legislation.
1.2 Original Language

The language in which the document was prepared is referred to as the original
language.
The original language of these operating instructions is English.
1.3 Application
The USTER® CLASSIMAT 5 installation is an instrument for classification and
analysis of yarn faults in staple spun yarns.
Other Applications
Any use that is not consistent with the above specifications is considered non-
intended. Uster Technologies will therefore not be liable for the consequences of
any claims that result from non-compliance with these regulations.
Improper Handling
The USTER® CLASSIMAT 5 installation may not be operated outdoors and outdoor
storage is not permitted even if suitable packing is used.

1.4 Installation Overview

1.4.1 Complete Installation
The following figure shows the components used for USTER® CLASSIMAT 5 in-
stallation.
5
3
1 4
2
6
7
8
9 9 9
Up to 12 winding positions may be connected to a CLASSIMAT 5 system.
15
10
12
13
11
14
System components
1 CMT5-CCU 9 iCSA Quad group
2 Table 10 CMT5 iMH cable, Valve cable
3 Printer 11 CLASSIMAT 5 Module complete
4 Flat screen, Keyboard, PC-Mouse 12 CMT5 iMH: C15F30, C20F30
5 Climate Sensor incl. cable 13 Maintenance Unit
6 CMT5-CU 14 Air gun with safety glasses
7 Network Cables 15 Winding machine – is not part of
8 Cable power/comm.CMT5-CCU - iCSA the delivery

1.4.2 Identification of the Product

A type plate is provided on the housing of CLASSIMAT 5 components. The infor-
mation on that plate specifies the component and also indicates possible customer-
specific modifications. When contacting Uster Technologies, always include the
complete data provided on the type plate. With this information, the customer ser-
vice of Uster Technologies will be able to give you the fastest possible support.
The type plate is placed on the CMT5-CU, CMT5-CCU or on the respective built-in
units as shown in the following examples.
If you have any questions regarding the diagnosis of malfunctions, please indicate
the version of the software.

1.5 Technical Data

1.5.1 Dimensions and Weight
CMT5-CU
Dimensions depth 462 mm, width 210 mm, height 460 mm
Weight: 11.5 kg
CMT5-CCU
Dimensions: depth 300 mm, width 515 mm, height 300 mm
Weight: 14.5 kg
1.5.2 Electrical Connection

Mains: Single phase mains with protective conductor
CLASS I EQUIPMENT
Mains switch: CMT5-CU checked for EN 61 085
Mains voltage range: 220-240 VAC
Mains frequency: 50-60 Hz
Power consumption: CMT5-CU typical* 110 VA (max. 500 VA)
CMT5-CCU typical* 90 VA (max. 150 VA)
Fuse: CMT5-CU 2.5 AT (slow)
CMT5-CCU 1 AT (slow)
*) typical means: Mains = 230 VAC, operation with 6 positions, printer is excluded
1.5.3 Compressed Air

Air quality: According to ISO 8573.1, class 3
Min. pressure at inlet of air filter regulator: 0.6 MPa
Air consumption per position: Ca. 210l/h
Min. inner diameter of the connection: 8 mm
Max. Length of the connection: 5m
Safety air gun
- Noise level : < 80 dB(A)
- Max. blowing out pressure: < 3.5 bar
1.5.4 Ambient Conditions

Standard climate
Since the repeatable measurement results of textile tests (e.g., evenness, imper-
fections, number of yarn defects) depend on the climatic conditions and type of
material, comparisons with, for example, USTER® STATISTICS are admissible only
where defined conditions are adhered. For this purpose, the relevant textile testing
norms (e.g., ISO 139, EN 20 139, DIN 53802) recommend the following ambient
conditions:
Recommended humidity: (65 ± 2) % relative humidity
Recommended temperature: (20 ± 2) °C in moderate zones
(27 ± 2) °C in tropical zones
Operating Climate
Temperature: 15-30 °C
Humidity: 45-85 % relative humidity, noncondensing
Location: ≤ 2’500 m above sea level
Storage with the original Packing intact

Temperature: 5-55 °C
Humidity: 20-90 % relative humidity, noncondensing

1.6 Equipment
1.6.1 Condition as delivered
®
The USTER CLASSIMAT 5 installation is delivered in perfect technical condition
and working order.
Functional Scope
Three classification standards • CLASSIMAT 5

(for thick and thin places only): • CLASSIMAT QUANTUM
• CLASSIMAT 3
CLASSIMAT 5 classification: • Yarn body and scatter plot of yarn faults in the
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USTER CLASSIMAT 5 matrix.
• Classing of the yarn faults into 30 thick place
classes and 15 thin place classes.
Foreign-Matter: • Dense area and scatter plot of the foreign fibers
®
in the USTER FOREIGNCLASS matrix.
• Classing of the foreign fibers into 32 classes.
• Classification of vegetable content into 32 clas-
ses (only for cotton and cotton blends).
Polypropylene: • Short Polypropylene and long Polypropylene.
Tailored classes: • Customer-specific thick place and thin place
class can be defined.
• Customer-specific Foreign-Matter class can be
defined.
Periodic faults (PF): Classification of periodic faults and affected share
Result-Evaluation: • For individual and all winding positions.
• Cumulative or per class.
• Absolute or per 100 km.
Disturbing faults: Outliers – neps, thick, thin, Foreign-Matter, Poly-
propylene, evenness (CVm), imperfections and
hairiness.
Clearing limit analysis: Analysis of applied clearing limits and indication
of clearing index to optimize clearing limits to
reduce outliers.
Quality comparison: Comparison of up to five articles according irregu-
larity, outliers & Foreign-Matter to classify yarns
for optimal use and thereby optimal price.
Long-term analysis: Analysis of long term trends of all CLASSIMAT 5
parameters and compare them to internal or in-
ternational benchmarks. Graphical and tabular
reports.
®
Benchmarks: • International benchmarks – USTER STATIS-
TICS
• Compare to internal benchmarks of the mill –
Mill statistics.
• Compare test results to the best results
achieved over the last one year- ‘52 week best’.

Climate measurement: Sensor for measurement of humidity and temper-

ature in the environment of the laboratory.
Reports: Preconfigured standard reports.
Data storage: Data storage and Backup.
Diagnosis: Technical alarms, Log-files, Remote support pos-
sibilities.
Languages (Application SW): EN, CN (Later TR, VN, DE, FR, IT, ES)
Unit system: Nec, New, Nm, Tex, Denier
Sensor principle
Classification of thick and thin Capacitive measurement

places:
Determination of quality data: Capacitive measurement
Detection of Foreign-Matter: Optical measurement
Detection of Polypropylene: Capacitive and Optical measurement
No. of positions
CLASSIMAT 5 is available for 6 or 12 positions
Measuring Head Type

Choice between CMT5 iMH type C15F30 and C20F30 depending on the count
range.
Yarn Count Range and Measuring Head Types

CMT5 iMH-C15F30: Nm 20 to 340 Nec 12 to 200 3 to 50 tex
CMT5 iMH-C20F30: Nm 5 to 135 Nec 3 to 80 7 to 200 tex
Application
• Classification of yarn faults and outliers of staple spun yarns (natural, synthetic
fibers and blends).
• Yarn speed winding: 200 to 1200 m/min
• Recommended sample length per test: 200 km
Winder
• Manual precision winders are recommended for accuracy and stability reasons
e.g. SIMET, MOTOCONO, SSM, PS VERSA, RESHMI, MILHAN.
®
• Further winder types – Please contact USTER Service.
Technical Alarms
Alarms are triggered by the following events:
• Faults in the CMT5-CCU
• Faults in the CMT5 iMH

1.6.2 Scope of Delivery

The installation components are shown in the illustrations of this chapter.
• CMT5-CCU with installed software

• Table
• Printer
• Flat screen, Keyboard, PC-Mouse
• CMT5-CU with Microsoft Windows Operating system and
®
USTER CLASSIMAT 5 specific hardware and software:
- Backup Unit – 2nd Hard disk of identical capacity
- Network cards integrated
• Dongle
• Recovery USB Stick
• Climate Sensor including cable
• CLASSIMAT5 Module (provided with CMT5 iMH, Yarn Tensioner, Blowing unit)
• iCSA Quad group
• Cable power/comm. CMT5-CCU to iCSA
• Network cables
- Connection CMT5-CCU to CMT5-CU (3 m crossed)
- Connection CMT5-CU to Network (30 m UEX grey)
• Valve cable
• Fastening material
• Pneumatics
- Air inlet
- Maintenance unit
- Air gun
- Air hose
- Safety glasses
• Accessories set:
- Operating documentation, incl. yarn cards
- Maintenance tools
• Spares included in every shipment
- 1 pc spare CMT5 iMH
- 1 pc iCSA
- 2 pcs. spring 0.5x11x22.4 mm (> 60 Ne)
- 2 pcs. spring 0.42x11x22.4 mm (≤ 60 Ne)
- 12 pcs. tensioner disk


Operating Instructions Safety Regulations 2
Contents
Page
2 Safety Regulations 3
2.1 General Information 3

2.1.1 Target Readership 3
2.1.2 Observance of the Safety Regulations 3
2.2 References and Symbols 4
2.3 Basic Safety Information 5

2.3.1 Safety Concept and its Limits 5
2.3.2 Safety Measures 5
2.3.3 Removal of Protection Devices 5
2.3.4 Product Observation Duty 5
2.3.5 Location of the Operating Instructions 5
2.4 General Safety Rules 6

2.4.1 Legal Regulations 6
2.4.2 Intended Use 6
2.4.3 Non-intended Use 6
2.4.4 Inspection and Maintenance Duty 6
2.4.5 Spare Parts 6
2.4.6 Power Supplies 7
2.4.7 Compressed Air 7
2.4.8 Modifications 7
2.4.9 Specific Safety Regulations in the individual Chapters 8
2.5 Responsibilities 8
2.5.1 Authorized Persons 8
2.5.2 Areas of Responsibility (Functions) 8
2.5.3 Qualification and Training 9
2.6 State of Technology 9

2.6.1 Applied Standards (Safety) 9
2.6.2 Risk Analysis 9
2.7 Services 10
2.7.1 Technical Customer Service 10
2.7.2 Training 10
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2 Safety Regulations Operating Instructions

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2 (10) 09.12 USTER CLASSIMAT 5
2 Safety Regulations
2.1 General Information

2.1.1 Target Readership
This chapter describes the safety regulations that must be strictly observed when
®
operating the USTER CLASSIMAT 5 installation.
®
All persons working on or with the USTER CLASSIMAT 5 installation are obligat-
ed to read and understand the chapters of the Operating Instructions that are rele-
vant to their respective activities.
This applies in particular to the Chapter ‘Safety Regulations’, which concerns all
persons and all activities.
2.1.2 Observance of the Safety Regulations

®
Before carrying out any type of work with or on the USTER CLASSIMAT 5 installa-
tion you must read and understand the safety regulations contained in Chapter 2 of
the Operating Instructions. All work has to be carried out in compliance with the
Operating Instructions.
®
The USTER CLASSIMAT 5 installation has passed a final inspection prior to de-
livery and has left the factory in perfect operating condition. Uster Technologies AG
is hereby expressly indemnified and held harmless against any responsibility
and/or liability whatsoever for damage resulting from non-compliance with the in-
structions and references contained in the Operating Instructions. This applies in
particular to:
• Damage resulting from improper use or incorrect operation.
• Damage caused by unauthorized third-party software installed on the computer.
• Damage due to non-observance of safety-related information in the Operating
Instructions Manual or of warning signs on the equipment.
• Damage resulting from faulty or not-executed maintenance work.
Unauthorized conversions and alterations can affect safety and are not permitted.
Cleaning the equipment is only permitted at standstill of all moving parts.

Maintenance and repair is only permitted after the equipment has been switched
off.
®
2.2 References and Symbols

Three types of hazard alerts are used to draw attention to known residual dangers
and to important technical requirements. A note refers to technical or economical
requirements. Information contains useful details for an optimal usage of the sys-
tem.
DANGER
Information on dangers which may immediately lead to death or
serious injuries.
WARNING
Information on dangers which may lead to serious injuries.
CAUTION
Information on dangers which may result in less serious and minor
injuries, or material damage.
Note
Non-observance can lead to disturbances, inefficiency and possi-
bly to loss of production.
Information
i Text marked with this symbol contains practical information and is

aimed at facilitating optimum use of the installation or of the de-
vice. If this information is not observed, it is possible that the per-
formance stated in the technical specifications may no longer be
ensured.
®
2.3 Basic Safety Information

2.3.1 Safety Concept and its Limits
®
The USTER CLASSIMAT 5 installation is integrated in a textile machine. The
safety concept of the respective textile machine must be observed.
®
The safety concept of the USTER CLASSIMAT 5 is autonomous. It does neither
consider nor influence the respective textile machine. Uster Technologies AG dis-
claims any liability for whatsoever damage caused by the textile machine.
2.3.2 Safety Measures

The protection against personal dangers is primarily based on a safety concept
and a safe construction.
All functional units with parts carrying dangerous voltages are protected against
accidental contact by appropriate covers and protected earth.
2.3.3 Removal of Protection Devices

Protection devices may only be removed after the installation is switched off and
disconnected from the power supply. The covers in particular may be removed and
reinstalled by authorized persons only.
Before putting the installation into operation again, the safety elements must be
checked for proper functioning.
2.3.4 Product Observation Duty

The operating personnel must immediately report any changes in the operating
performance or modification on safety-related installation components to the per-
son responsible or to the manufacturer.
2.3.5 Location of the Operating Instructions

The Operating Instructions is to be stored near or directly at the machine and must
be available there at any time.
®
2.4 General Safety Rules

2.4.1 Legal Regulations
The applicable national and local regulations for safety and accident prevention as
well as complementary rules on site must be strictly complied with and observed.
2.4.2 Intended Use

®
The USTER CLASSIMAT 5 installation is to be used only for the classification and
analysis of yarn faults in staple spun yarns. The simultaneous determination of all
relevant quality data can be evaluated and printed out at any time.
2.4.3 Non-intended Use

Any application that is not consistent with the ‘intended use’ (see above) is consid-
ered ‘non-intended’. Also considered ‘non-intended’ is any application that does not
comply with the regulations, operating procedures and specifications contained in
these Operating Instructions.
2.4.4 Inspection and Maintenance Duty

®
The user is obligated to keep and operate the USTER CLASSIMAT 5 installation
in proper and undamaged condition. The maintenance intervals specified in the
Operating Instructions must be strictly observed. Malfunctions and mechanical
damage must be corrected immediately.
2.4.5 Spare Parts
CAUTION
Non-original spare parts.
Non-original spare parts may have unsatisfactory features. This

can cause malfunctioning, equipment damages or personal inju-
ries.
Use only original spare parts for maintenance and service work.
®
2.4.6 Power Supplies
DANGER
Dangerous voltage.
®
The USTER CLASSIMAT 5 contains parts connected to danger-
ous voltage. Touching these parts can cause a lethal electric shock.
Before removing any covers, or carrying out maintenance or repair

work, interrupt the power supply and disconnect the mains plug.
The complete equipment is free of any voltage only after the mains
cable has been unplugged.
DANGER
Incorrect wiring.
Incorrect wiring may cause a lethal electric shock or may lead to

damage of the equipment.
®
Connect the USTER CLASSIMAT 5 only to a grounded socket.
The functional units CMT5-CCU and CMT5-CU must only be con-
nected to the enclosed connector strip. See Chapter 5.4.
2.4.7 Compressed Air
WARNING
Dirt particles coming loose when using compressed air.
Danger of injury for eyes and unprotected skin areas during clean-
ing work with compressed air.
Do not use compressed air if the parts are heavily polluted (pre-
cleaning, e.g. with vacuum cleaner).
Always wear provided safety glasses and ear protectors during

cleaning work with compressed air.
2.4.8 Modifications
Technical changes in the form of extensions or conversions may only be carried
out with the written approval of Uster Technologies AG.
®
2.4.9 Specific Safety Regulations in the individual Chapters

Some chapters in these Operating Instructions contain additional safety regula-
tions. Unlike the general safety regulations that are contained only in Chapter 2
‘Safety Regulations’, these specific safety regulations apply only to the activities
described in the respective chapters.
2.5 Responsibilities
2.5.1 Authorized Persons
®
The USTER CLASSIMAT 5 installation may be operated by authorized personnel
only. Persons are considered authorized only if they meet the personnel qualifica-
tion as defined in ‘General information’ and, in particular, have read and under-
stood the ‘Safety Regulations’ contained in Chapter 2.
2.5.2 Areas of Responsibility (Functions)

Manufacturer
Uster Technologies AG or a company that has been officially designated by Uster
Technologies AG is considered the manufacturer of the installation components
supplied by Uster Technologies AG. Within the framework of an integral quality and
safety concept, the manufacturer is entitled to request information about the
®
USTER CLASSIMAT 5 installation from the respective user.
Owner
The owner is responsible for the correct use of the product as intended and for the
training and the assignment of the authorized personnel. He defines the areas of
responsibility and the power of instruction of the authorized personnel for his oper-
ation.
Operator / Customer service

®
• Sets up the USTER CLASSIMAT 5 installation for the material to be tested.
• Monitors the installation for proper functioning.
• Locates malfunctions and carries out or arranges for the troubleshooting.
• Takes care of the service and the basic maintenance.
• Checks the protection devices for proper functioning.
Service technician
The service technician is an employee of Uster Technologies AG or a person who
has been officially designated by Uster Technologies AG.
®
• Installs the USTER CLASSIMAT 5 installation at the user’s location and puts it
into operation.
• Carries out complex maintenance tasks and repair work.
®
2.5.3 Qualification and Training

User
• Person with technical training in a managerial function.

• Has relevant experience in personnel management and risk analysis.
• Has read and understood the Chapter ‘Safety Regulations’.
Operator
• The required personnel qualification with regard to specific work with or on the
®
USTER CLASSIMAT 5 installation is defined in the Sections ‘General Infor-
mation’ of the respective chapters.
Service technician
• Specialized vocational training (mechanical/electro technical/electronic).

• Has been trained by Uster Technologies AG.
2.6 State of Technology

2.6.1 Applied Standards (Safety)
®
The USTER CLASSIMAT 5 installation incorporates the latest technical advances
and meets the applicable safety regulations. The installation was designed and
built according to the guidelines described in the separate documentation
‘EC-DECLARATION OF CONFORMITY’ provided.
However, there are still certain risks and dangers to life and limb if the installation
is operated by unauthorized persons or if it is not used as intended.
2.6.2 Risk Analysis

As an integral part of the development process, the known risks have been sys-
tematically analyzed.
®
2.7 Services
2.7.1 Technical Customer Service
The technical customer service of Uster Technologies AG offers a wide range of
support:
Worldwide support
• More than 45 service centers and spare parts stores worldwide.

• Short replacement times.
• Specialized workshops for urgent repairs.
Perfect organization
• Expert analysis by qualified specialists.

• Support by field engineers in your area.
Customer-specific services
• Maintenance and repair contracts.

• With service contract: according to the terms of the contract.
2.7.2 Training
Uster Technologies AG offers training courses for your installation and products. If
requested, Uster Technologies AG will tailor a training program to suit your specific
requirements. Special programs may be designed to instruct and advise on opera-
tion, maintenance and application.
®
Operating Instructions Design and Functions 3
Contents
Page
3 Design and Functions 3
3.1 General information 3
3.2 Functional Diagram of the CMT5 Installation 3
3.3 Installation Components 4

3.3.1 General Information 4
®
3.3.2 USTER LAB Control Unit (CMT5-CU) 4
3.3.3 CLASSIMAT 5 Control Unit (CMT5-CCU) 4
3.3.4 CLASSIMAT 5 Module 5
3.3.5 Intelligent Measuring Head - CMT5 iMH 7
3.3.6 iCSA Quad group 8
3.3.7 Communication Bus 8
3.3.8 Valve Cable 8
3.3.9 Winding Machine 8

3 Design and Functions Operating Instructions


3 Design and Functions
3.1 General information

The CLASSIMAT 5 installation is used generally on manual or precision winding
machines.
The CLASSIMAT 5 installation consists of the installation components described in

Chapter 1 and the corresponding software.
3.2 Functional Diagram of the CMT5 Installation
1 2
7 5
Fig 3-2 Functional diagram
1) CMT5-CU
2) CMT5-CCU
3) Cable power/comm. CCU - iCSA
4) iCSA Quad group
5) iMH cable: iCSA to CMT5 iMH
6) Valve cable
7) CLASSIMAT 5 Module
8) CLASSIMAT 5 Module mounted on winding machine

3.3 Installation Components

3.3.1 General Information
The CLASSIMAT 5 is an electronic, microprocessor-controlled yarn fault classing
system. The system uses measuring heads that work according to a capacitive
measuring principle for the basic quality monitoring. An optical sensor is used to
detect foreign matter. Polypropylene detection uses both, capacitive and optical
foreign matter sensors.
3.3.2 USTER® LAB Control Unit (CMT5-CU)

The CMT5-CU is used to control the measuring process, the evaluation, analyzing
and representation as well as the storage of the results. A detailed description is
available in Chapter 1.6 ‘Functional Scope’.
3.3.3 CLASSIMAT 5 Control Unit (CMT5-CCU)

CMT5-CCU with MMI operating panel
CMT5-CCU with an operating panel
(Man-Machine Interface) comprises of a
computer and a display with a touch
screen for the operation.
Fig 3-33-a CMT5-CCU front panel
Functions of the CMT5-CCU
− Control of the CLISSIMAT 5 installation with the software installed on a data

carrier.
− Transfer of the application software to the CMT5 iMHs.
− Transfer of all the necessary parameters, inspection and alarm limits to the
CMT5 iMHs.
− Storage and processing of the registered events and the quality data.
− Providing data to CMT5-CU.
− Carrying out self-tests and monitoring of the CMT5 iMH functions.

Rear Panel Elements
2 3
Fig 3-33-b CMT5-CCU rear panel
1 Mains socket for power plug

2 Fuse holder
3 Cable gland - two cables will be lead through:
- Ethernet cable connection to the CMT5-CU
- Communication bus cable connection to the iCSA
3.3.4 CLASSIMAT 5 Module

The bracket of the CLASSIMAT 5 Module is equipped with the CMT5 iMH, yarn
tensioner and pneumatic valve for the blowing jet which is also located on the
bracket. The cable of the measuring head is connected to the iCSA.
Front View
1
2
3
5 4
7
Fig 3-34-a CLASSIMAT 5 Module front view
1 Bracket
2 Yarn plate out
3 CMT5 iMH
4 CMT5 iMH cable
5 Air jet device
6 Yarn tensioner
7 Thread guide

Rear view
10
Fig 3-34-b CLASSIMAT 5 rear view
8 Valve cable connection

9 Blowing valve
10 Air jet device

3.3.5 Intelligent Measuring Head - CMT5 iMH
Fig 3-35 CMT5 iMH
Function
The term ‘intelligent measuring head’ was chosen because the entire evaluation of
the yarn signal takes place in the measuring head.
This includes:
− Detection of thick and thin places
− Detection of periodic yarn faults
− Detection of foreign fibers
− Detection of vegetable fibers
− Detection of Polypropylene fibers
− Determination of yarn quality data (CV, IP, Hairiness Outliers)
− Stopping the winding machine based on the built-in cutting device
Sensors
Two sensor types are available for the detection of yarn faults and the determina-
tion of yarn quality data:
• CMT5 iMH C15F30
• CMT5 iMH C20F30
Determination of yarn quality

CMT5 iMH C… capacitive principle; the signal corresponds to the yarn mass.
Detection of foreign matter

CMT5 iMH F… optical principle; the signal corresponds to the reflectance or con-
trast.
Detection of polypropylene
CMT5 iMH C F capacitive and optical foreign matter measuring principle
corresponding to the change in color and material.

3.3.6 iCSA Quad group

The iCSA serves as an interface between the CMT5-CCU and measuring head.
Depending on the machine type and the degree of integration, it contains the fol-
lowing functions:
− Preparation of the supply voltages for the CMT5 iMHs
− Connection of the power/communication cable
− Connection of the CMT5 iMHs
− Connection of the valve cables
− Storage of the CMT5 iMH addresses
3.3.7 Communication Bus

The communication bus connects the CMT5-CCU with all CMT5 iMHs. It is used
for the exchange of all program, setting and event data between the CMT5-CCU
and the CMT5 iMHs. Each CMT5 iMH is contacted under its individual address by
the CMT5-CCU.
3.3.8 Valve Cable

The valve cable supplies +24VDC and controls the valve for the blowing jet.
The valve cable is connected to the communication bus, to the intelligent Clearing
Spindle Adapter and to the CLASSIMAT 5 Module.
3.3.9 Winding Machine

The winding machine has the task of carefully winding the yarn from the upstream
spinning packages onto the yarn cones with a constant thread tension and at high
speed.
®
The measuring heads of the USTER CLASSIMAT 5 system are fitted in the yarn
path with few additional diversions. Since the function, operation and safety of the
winding machine depends on the type and the manufacturer, please refer to the
corresponding descriptions and instructions supplied by the manufacturer.

Operating Instructions Operating Elements 4
Contents
Page
4 Operating Elements 3
4.2 Safety Devices 3
4.3 Operating and Display Elements - CMT5-CU 4
4.4 Operating and Display Elements - CMT5-CCU 5
4.5 Operating and Display Elements - CMT5 iMH 7
®
4 Operating Elements Operating Instructions

®
4 Operating Elements

This chapter describes the function and location of the safety devices and the op-
erating and displaying elements in detail. Safety devices are discussed first. These
are followed by the operating elements and their functions, arranged according to
the functional units.
4.2 Safety Devices

There are no operating elements relevant to safety on the USTER® CLASSIMAT 5
system. In particular, there is no emergency stop switch available on the CLAS-
SIMAT 5 system. However, since the USTER® CLASSIMAT 5 system always
works in conjunction with a winding machine, you must read the supplied manufac-
turer's documents relating to the winding machine before commissioning the sys-
tem and familiarize yourself with the operation.
®
4.3 Operating and Display Elements - CMT5-CU
Fig 4-3 Operating/display elements CMT5-CU
1 Mains switch
2 Soft key
3 Hard Disk indicator
4 Reset button
Mains switch
Pressing the toggle switch to position ‘1’ starts up the Operating System and the
CMT5 Application Software.
Soft key
CMT5-CU is switched on: Press once the soft key then a ‘shut down’ takes place.
The Application software and the Operating System shut down properly.
Shut down procedure

1. Close the Application Software
2. Shut down the Operating System using the mouse and click on Windows Start-
Menu ‘shut down’.
3. Switch off mains switch (position ‘0’)
Step 1 and 2 can be done in one step by pressing once the soft key
Hard Disk indicator

Indicates data access to the hard disk drive
WARNING
Pressing the toggle switch (Mains switch) to position ‘0’ will not
disconnect the CMT5-CU from the mains completely. The device is
completely disconnected from the power supply only by pulling the
power cord.
®
4.4 Operating and Display Elements - CMT5-CCU
3 4 5 6
Fig 4-4-a Operating/display elements CMT5-CCU
1 Touch screen
2 Connecting plug cover
3 Power indicator
4 Alarm indicator
5 Warning indicator
6 Key hole for Polykey
Mains switch
There is no mains switch on the CMT5-CCU. To switch on the CMT5-CCU connect
the power cord to the mains using the connector strip. To switch off the CMT5-CCU
remove power cord from the mains.
Touch screen
Simply touch the screen with your Do not use any sharp or pointed
finger. objects.
Connecting plug cover

Lift the cover to get access of the front panel connectors.
Power indicator (green)

Lights when power is supplied to the CMT5-CCU.
Alarm indicator (red)

Flashes in case of a technical alarm.
Warning indicator (yellow)

Flashes in case of a technical warning at a winding position or at the installation.
Key hole for

- Polykey to control access rights.
®
Front panel connections
Fig 4-4-b Front panel connections
7 Serial interface
8 USB connector
9 Ethernet connector
Serial interface connector

Service: Serial interface to connect the QC Terminal
USB connector
Connector for a memory stick to
- install and update CMT5-CCU software.
- save special reports and screen content.
Ethernet connector
This connector can be used for service purposes.
There is an additional connector on the inside of CMT5-CCU to connect the CMT5-
CCU to customer’s local network. In this case the front connector can’t be used
anymore.
®
4.5 Operating and Display Elements - CMT5 iMH

Indications on the CMT5 iMH
The CMT5 iMH is equipped with two red LED arrows. They indicate technical
alarms and other operating conditions.
LED arrow up
LED arrow down
Functions of the LED arrows
Arrows do not light up:

− CMT5 iMH is in normal operating condition
− CMT5 iMH is currentless
One or both LED arrows are flashing
− CMT5 iMH LED display function is switched on.
Upper or lower LED arrow is flashing alternately:

− CMT5 iMH LED will flash alternately until calibration is finished.
Upper or lower LED arrow lights up:

− CMT5 iMH LED function to display the yarn detector state is active.
LED arrows flashes once per second:

− CMT5 iMH indicates a technical alarm.
LED arrows lights up with short interrup-
tions:
− CMT5 iMH software download is taking
place.
LED arrows flashes every 3 sec
1, 2 or 3 times:
− CMT5 iMH waiting for ‘calibration start’
− CMT5 iMH is deactivated or communi-
cation with the CMT5-CCU interrupted.
− CMT5 iMH is waiting for the address
from the iCSA.
When pressing the button,
− a cut takes place.
− LED arrows flashes for 1 sec.
− a zero point adjustment of the CMT5 iMH takes place.
Both LED arrows lights up continuously:
− CMT5 iMH is in the addressing mode.
®
®
Operating Instructions Commissioning 5
Contents
Page
5 Commissioning 3
5.2 Safety Regulations 3
5.3 Placing of CMT5-CCU and CMT5-CU 4
5.4 Wiring USTER® CLASSIMAT 5 5
5.4.1 Mains Connections 5
5.4.2 CMT5-CU Connections 6
5.4.3 Valve Cable Connections 7
5.5 Pneumatic Connections 8
5.5.1 Pneumatic Maintenance Unit 8
5.5.2 Connection CLASSIMAT 5 Module 9
5.6 Installation of the Climate Sensor 9
5.7 Mounting CMT5 Module onto the Winding Machine 10
5.8 Dimensions of CMT5 Module 10
5.9 Assembling Tensioner Disks 11
5.10 Checking prior to the Testing 12
5.11 Checking iCSA Quad Group 12
5.12 Checking on CMT5-CU 12
5.13 Settings on CMT5-CCU 13
5.14 CMT5 iMH Software Download 16
5.15 Acceptance 18
5.16 Setting up a Test 18
5.17 Start-up after Switching off 18

5 Commissioning Operating Instructions


5 Commissioning

®
The USTER CLASSIMAT 5 installation is to be unpacked, installed and put into
operation by a specifically trained service technician of Uster Technologies AG.
®
Only he is authorized to install and to connect the USTER CLASSIMAT 5 to the
manual winder.
5.2 Safety Regulations

Electrical connection
All devices and equipment may only be connected to the mains supply by author-
ized persons who are trained according to local safety regulations.
Note
Before devices and equipment are connected, it must be en-
sured that they are set for the local mains voltage.
DANGER
CMT5-CCU and CMT5-CU are built and inspected according to
protection CLASS I EQUIPMENT. It is therefore absolutely neces-
sary to connect the protective conductor before making any other
electrical connections!
Non-observance of this warning can result in death, serious physi-

cal injury or psychological damage.

5.3 Placing of CMT5-CCU and CMT5-CU

Location of the CMT5-CCU
The yarn handling on the winding machine during the calibration needs an interac-
tive operation on the CMT5-CCU. Therefore the CMT5-CCU must be placed near
the winding machine.
Possible CMT5-CCU locations are:
CMT5-CCU placed on a table.
CMT5-CCU placed on the winding ma-

chine.
CMT5-CCU placed on the side panel of

the winding machine.
Distance CMT5-CCU - CMT5-CU

Length of the network cable provided is
30 m. 30 m
Power cord must be extended according to
the distance of the two units. Mains connec-
tion see Chapter 5.4.1.
Distance CMT5-CCU - Climate Sensor

Cable length is 3 m.
The sensor must not be exposed to warm
air but to realistic environmental air temper- 3m
ature mounting instruction see Chapter 5.6.

5.4 Wiring USTER® CLASSIMAT 5

5.4.1 Mains Connections
1
220-240 VAC
Fig. 5.4.1-a Mains Connections
Wall socket
®
Ensure that the USTER CLASSIMAT 5 installation is connected to a grounded
wall socket, with connected Protection Earth.
Main fuses
The ratings of the mains fuses are indicated on the label at the rear panel of
CMT5-CCU and CMT5-CU.
Preparing the power cord

Replace the power plug (1) from the power cord of the enclosed connector strip
with a power plug in accordance with the local standards.
L N
PE
DANGER
Incorrect connection of the Protection Earth
The housing of the installation may carry mains voltage. Touching

the housing may cause a lethal electric shock.
Connect the Protection Earth (PE=yellow-green) properly.

5.4.2 CMT5-CU Connections
1 1
Connection to
CMT5-CCU
Fig. 5.4.2 CMT5-CU Connection
1) Connect Mouse and Keyboard with PS2 connectors (1) provided.

2) Connect Climate Sensor (2) to an USB socket.
3) Connect Dongle to an USB socket
4) Connect the monitor with DVI cable (3) provided to the suitable socket.
5) Connect the network cable (4) directly to the socket position as encircled.
Note
Do not plug directly USB connectors of Mouse and Keyboard to
the CMT5-CU connectors. The reason is the ‘Electromagnetic
Compatibility’.

5.4.3 Valve Cable Connections

Valve cable connectors:
J1 Black connector – plugged on iCSA Quadgroup
J2 Black connector – plugged on iCSA Quadgroup
J3 Valve connector – plugged on CLASSIMAT 5 Module
J4 Valve connector – plugged on CLASSIMAT 5 Module
J5 Red connector – plugged on Cable power/comm. CMT5-CCU to iCSA
iCSA Quadgroup Valve cable CLASSIMAT 5 Module
Cable power/comm. CMT5-CCU - iCSA

Fig. 5.4.3 Valve cable

5.5 Pneumatic Connections

The inlet coupling must be connected to the end users compressed air supply.
WARNING
Improper pneumatic connections.
Improper connections can cause severe contusions to eyes and

skin.
Pneumatic hoses must only be connected by authorized persons!
5.5.1 Pneumatic Maintenance Unit
B
F
C E G
I
H
Several modules have to

be connected by using
T-pieces.
Fig. 5.5.1 Pneumatic installation
A Inlet pressure connection to be connected to the users air supply

B Inlet coupling
C Connection to maintenance unit
D Pressure regulation
E Connection to T-piece
F T-piece
G Connection to next T-piece or to last CLASSIMAT 5 Module
H Connection to CLASSIMAT 5 Module
I Connection to safety air gun
Pressure setting
Lift knob (D) and set to 0.4 MPa
Push down knob (D)

5.5.2 Connection CLASSIMAT 5 Module
Fig. 5.5.2 Connection CLASSIMAT 5 Module
5.6 Installation of the Climate Sensor
Fig. 5.6 Mounting of the Climate Sensor
Installation conditions:
1) Fix the climate sensor with the self-adhesive tape so that the cable outlet is at
the top  ‘This Side Up’.
2) The three holes must be facing downwards and the air must be able to circulate
easily.
3) The sensor must not be exposed to warm air but to realistic environmental air
temperature.

5.7 Mounting CMT5 Module onto the Winding Ma-

chine
Uster Technologies AG supplies various mounting material to mount the CMT5
Module onto the manual winding machine. In some cases additional mounting ma-
terial has to be provided by the customer.
5.8 Dimensions of CMT5 Module

The following figure shows the required space of the CASSIMAT 5 Module.
Fig. 5.8 Dimensions of CLASSIMAT 5 Module

5.9 Assembling Tensioner Disks

Uster Technologies AG delivers the disks in a disassembled state, this to prevent
damages during shipment.
Assembling order of the disks see below
1
2 3
4
5
4
6
7
8
9
Fig. 5.9-a Assembling tensioner disks
1 Shaft
2 Steel washer
3 Rubber washer
4 Tensioner disk
5 Eyelet with hook
6 Disk
7a Spring for yarn count ≤ 60 Nec  0.5x11x22.4mm
7b Spring for yarn count > 60 Nec  0.42x11x22.4mm
8 Safety screw
9 Spring alignment
Checking of the eyelet hook position

After the adjustment of the air jet or after replacement of the tensioner disks check
the eyelet hook position. The correct position of the hook is in front not at the back.
See picture below.
incorrect
correct
Fig. 5.9-b Eyelet hook position
Adjustment of the yarn tensioner see Chapter 6.22.5

5.10 Checking prior to the Testing

1. Has the electrical installation been completed?
2. Have the correct mains fuses been installed?
3. Has the compressed air been properly installed?
4. If these checks are OK, connect the equipment to the power supply.
5.11 Checking iCSA Quad Group

1 The switch position must be on
‘F’.
5.12 Checking on CMT5-CU

1 Check IP address:
192.168.189.1
Address is set by default ex

works Uster Technologies AG.
2 Check Software version and

check compatibility with
CMT5-CCU software. If a
software mismatch exists an
error message appears in the
status bar. See Chapter 8.3.1.
3 Enter Name, Address and if

available import customer’s
logo. The Logo appears on the
reports.

5.13 Settings on CMT5-CCU

The following actions are described in the style of a checklist. For detailed infor-
mation see Chapter 6.28.
Service
1 iMH – Machine interface
The Setup switch must be
set to 15. See switch posi-
tion ‘F’ in the iSCA Quad
group.
Startup
2 Options
Check that ‘EXPERT’,
‘CLASSIMAT’ and ‘Ad-
vanced classes’ are ac-
tive.
3 System settings – Gen-

eral
Select Language
4 System settings – Cus-

tomer
Enter Customer’s Name
and Address. These data
are copied to the Tech-
nical Data Sheet which
the Service Technician
has to fill out.

5 System settings - Hard-

ware
• System clock is set by
the CMT5-CU.
6 Machine settings - Ma-

chine
• Select Machine Type
 Manual Winder.
• Enter Machine Name.
• Enter number of used
spindles.
7 Machine settings –
Groups
Check, that there is only 1
group available (Gr 1).
Range contains the total
amount of spindles.
8 Machine settings - Ad-

dress iMH
a) Set Address range
(number of spindles)
b e
b) Start addressing pro-

cess and confirm with
‘Yes’

c) Press the first iMH Both LEDs light up continuously:

button for 2 sec  − iMH is in the addressing mode.
check LED’s: Both LEDs are off again:
iMH has been allocated with an ad-
d) Continue pressing (2 dress.
sec) rest of iMH but-
tons in series.
e) Check address of all
iMH
and confirm with ‘Yes’
9 The LEDs of the iMH of all

the winding positions
have to flash sequentially.
10 Machine settings - Display

iMH types
Shows all assigned iMH
types
(Upper Table).
11 iMH Software download

see Chapter 5.14
Note
®
Settings can only be made with the USTER Polykey plugged in or
with the password:
1491 Master level or 6281 Customer Service

5.14 CMT5 iMH Software Download

As soon during commissioning the machine settings are specified and the iMH has
received an address the CMT5-CCU checks whether valid application software is
loaded to the iMH. The technical alarm ‘iMH download required’ is generated if an
iMH has an incompatible or no program version loaded.
The CMT5 iMH program download procedure takes place in 4 steps
Step1
Display when a program download is required for one or more CMT5 iMH.
iMH CMT5-CCU
iMH-LEDs flashes Technical Alarm: iMH Download required

once per 3 s.
The state of the iMH is light blue = ‘Download waits for start’
Step 2
Start program-download:
Download to all iMH Download to an individual iMH

Touch Alarm record ‘iMH Download required’ and Touch Alarm record ‘iMH Download required’ and
press button. press button. Then enter the

iMH number in the dialog box
Download starts after a short time (10s).

Step 3
Display when program download is running.
iMH CMT5-CCU
iMH-LEDs are continuously

on with short interruptions.
The state of the iMH is blue = ‘Download active’
The Alarm display shows: ‘Download active’
CAUTION
The installation may not be switched off when an iMH download is
active! Switching off the power supply during the download pro-
cess can result in defective iMH.
Information
i If there is more than one Download alarm all acknowledgements

within a 10s period are grouped together into one single download.
If a second Download alarm is acknowledged when the first is
st
already running, the download starts as soon the 1 group is fin-
ished.

Step 4
Display when program download is finished.
iMH CMT5-CCU
iMH-LEDs flashes or is
switched off.
The state of the iMH is orange = ‘Blocked’
After the ‘Start calibration’ on the CMT5-CU and the warming up time of the iMH
the state changes to and info to ‘Application ready’.
5.15 Acceptance
After installation and start-up the USTER® CLASSIMAT 5, the service technician
releases the classing system for operation. The owner and the service technician
sign the acceptance report ‘Certificate of Acceptance’
5.16 Setting up a Test

In order to setup a test, proceed as described in the ‘Test sequence’.
See Chapter 6.6.3.
5.17 Start-up after Switching off

Whenever the system is switched off and then on again, the CMT5-CCU software
will carry out a warm start, i.e. all settings remain stored. All iMH are provided with
the test parameters.
Information
i After a power loss on the CMT5-CU, data can be lost by a
maximum of 500 meter per winding position.

Operating Instructions Operation 6
Contents
Page
6 Operation 5

6.1.1 Safety Regulations 5
6.1.2 Personnel Qualification 5
6.1.3 Training 5
6.1.4 Application Manual 5
6.1.5 Operational Overview 5
6.1.6 Switching on 6
6.2 Operation of the CMT5-CU 7

6.2.1 Windows Standard 7
6.2.2 Access Authorization 7
6.2.3 Layout of the Screen 8
6.2.3.1 Top Menu 8
6.2.3.2 Login 9
6.2.3.3 Main Menu 10
6.2.3.4 Status Bar 11
6.3 General used Functions 11

6.3.1 Filter Function 12
6.3.2 Import / Export Function 13
6.4 Menu Structure 14
6.5 Article Definition (Test) 16

6.5.1 Creating an Article 16
6.5.2 Editing an Article 17
6.6 Setup and Start a Test (Test) 18

6.6.1 Calibration Process 19
6.6.2 Measurement Window 20
6.6.3 Test Sequence 21
6.7 Test Run Management (Test) 22

6.7.1 Classimat Generation Overview 23
6.7.2 Standard and Advanced Classes for NSL/T 24
6.7.3 Outliers 25
6.7.3.1 Definition Yarn Body 25
6.7.3.2 Definition Outliers 25
6.7.3.3 Outliers – Yarn Fault Type 26
6.7.3.4 Outliers – Distribution Diagram 27
6.7.4 Periodic Faults 30
6.7.5 Tailored Classes 31
6.7.6 Class sums 31
6.7.7 Event report 31
®
6 Operation Operating Instructions
6.8 Reports 32
6.8.1 Report Templates 33
6.9 Clearing Limits (Analysis) 35
6.10 Yarn Body Comparison (Analysis) 36
6.11 Quality Comparison (Analysis) 38
6.12 Longterm Analysis (Analysis) 40
6.13 USTER® STATISTICS (Analysis) 42
6.14 Setting Inspection Limits (Articles) 43

6.14.1 Editing Inspection Limits 43
6.14.2 Inspection Limits NSL/T / Slub 45
6.14.3 Periodic Fault Settings 46
6.14.4 Inspection Limits F/VEG 47
6.14.4.1 Inspection Limits Dark Foreign Matter FD 48
6.14.4.2 Vegetable VEG Classification 49
6.14.4.3 Inspection Limits Light Foreign Fibres FL 49
6.14.5 Tailored Classes 50
6.14.6 Inspection Limits PP 51
6.14.7 Special Settings 52
6.14.8 Group Monitoring 53
6.15 System Settings (Setup) 55

6.15.1 General Settings 55
6.15.2 Customer / Supplier 55
6.15.3 Natural fibers 55
6.15.4 Synthetic fibers 55
6.16 CCU Configuration (Setup) 56
6.17 Class Sums (Setup) 58
6.18 User / Role Configuration (Setup) 59

6.18.1 User Overview 60
6.18.2 Edit selected User 60
6.18.3 Role / Access Rights 61
6.19 Log book (Setup) 62
6.20 USTER® STATISTICS (Setup) 62
6.21 Mill Statistics (Setup) 63
6.22 Measurements with USTER® CLASSIMAT 5 64

6.22.1 Positioning of the Yarn Package 64
®
6.22.2 Yarn Path 64

6.22.3 Yarn Position - Calibration Mode 65
6.22.4 Yarn Position - Measurement Mode 66
6.22.5 Adjustment of Yarn Tensioner 67
6.23 Operation of the CMT5-CCU 68

6.23.1 Layout of the CMT5-CCU Screen 68
6.23.2 Main Menu 69
6.23.3 Function Keys 69
6.23.4 General Icons 70
6.24 Menu Structure (CMT5-CCU) 75
6.25 Main Menu – Data Display (CMT5-CCU) 76

6.25.1 Summary 76
6.25.2 Yarn Faults 77
6.25.3 Textile Alarms 78
6.25.4 Special Counters 79
6.25.5 Q Data – NSL/T / FD / FL / VEG Classes 80
6.25.6 Q Data – Imperfection (IP) 81
6.25.7 Q Data – NSL/T 82
6.25.8 Q Data – FD / FL or PP Scatter Plot 83
6.25.9 Q Data – VEG Scatter Plot 84
6.25.10 Logbook 85
6.26 Main Menu – Alarm (CMT5-CCU) 86

6.26.1 Technical Alarms and Warnings 86
6.27 Main Menu – Reports (CMT5-CCU) 87

6.27.1 Procedure to Store a Report to an USB-Stick 87
6.27.2 Special Reports 88
6.27.3 Event Report 89
6.27.3.1 Configuration – Event Report 89
6.27.3.2 Print/Display – Event Report 90
6.28 Main Menu – Start up (CMT5-CCU) 91

6.28.1 System Settings – General 91
6.28.2 System Settings – Customer 91
6.28.3 System Settings – Hardware 92
6.28.4 Machine Settings – Machine 93
6.28.5 Machine Settings – Address Settings iMH (Service) 94
6.28.6 Machine Settings – Display iMH Types 95
6.28.7 Options 96
6.29 Main Menu – Service (CMT5-CCU) 97

6.29.1 iMH 98
6.29.2 System Info 99
6.30 Special Functions (CMT5-CCU) 100

6.30.1 Special Functions – Test Functions 100
®
6.30.1.1 Touch-Screen 100

6.30.1.2 Reboot CMT5-CCU 100
6.30.2 Special Functions – iMH LED Display 101
6.30.3 Special Functions – SW Update 102
6.31 Save Screen Contents (CMT5-CCU) 103

®
6 Operation

6.1.1 Safety Regulations
First read Chapter 2 "Safety regulations" of these operating instructions. Also take
note of all the danger references mentioned here, and follow all instructions for ac-
tions to avoid personal injury or material damage.
6.1.2 Personnel Qualification

®
The USTER CLASSIMAT 5 classing system must be operated only by authorized
persons.
Operating staff
®
A person is authorized to operate the USTER CLASSIMAT 5 if he or she:
• is a trained textile laboratory assistant or has equivalent training
• has read and understood the safety regulations contained in Chapter 2 of these
operating instructions
• has been inducted in the operation of the system by an instructor from the
manufacturer Uster Technologies or a client instructor trained on the
®
USTER CLASSIMAT 5
• has a basic knowledge of the Windows 7 operating system
6.1.3 Training
The company Uster Technologies AG offers introductory courses that cover the
necessary basics for the corresponding activity.
6.1.4 Application Manual

®
The USTER CLASSIMAT 5 application manual supplied with the
®
USTER CLASSIMAT 5 contains valuable information on the procedure.
6.1.5 Operational Overview

®
USTER CLASSIMAT 5 is based on a clear structure which is easy to operate.
Some of the operations have to be performed on the CMT5-CU, other operations
may alternately be performed on the touch screen of the CMT5-CCU.
The basics for working with the Windows graphical user interface are not described
in these instructions. Please refer to the Windows 7 manual or other literature on
this subject.
®
6.1.6 Switching on
First, it must be ensured that the CMT5-CCU is connected to the mains and is
®
ready for operation. Chapter 5 describes the commissioning of USTER CLAS-
SIMAT 5 system.
Switching on sequence of the CMT5-CU is: Monitor, printer and the CMT5-CU.
After the CMT5-CU has started up, the start window with the
®
USTER CLASSIMAT 5 logo appears.
Fig. 6.1.6 Start Window
The software modules are initialized and started. As soon as the system is ready
the logo disappears and the application is displayed. The system is now ready for
operation.
®
6.2 Operation of the CMT5-CU

The CMT5-CU is equipped with a graphical user interface and controls the actions
®
of the USTER CLASSIMAT 5. From here, all tests are configured and transferred
to the CMT5-CCU. The test results can be displayed, analyzed, printed or exported
as data files.
6.2.1 Windows Standard

Screen buttons grayed
As usual for Windows, presently not active menu items and screen buttons are
grayed out. These screen buttons will show no action if they are clicked.
«Tool tips»/«Data tips»

If you bring the mouse cursor to the function keys or other screen buttons, in most
of the cases the so-called «Tool tips», i.e. short explanatory texts, are displayed.
In some diagrams, «Data tips» are displayed too. These help to read values from
diagrams. The values correspond with the actual mouse cursor position.
6.2.2 Access Authorization

Different user groups with the corresponding access authorization are predefined.
Password
Access authorization can be protected by means of a programmed password. See
Chapter 6.18.
If no password is programmed, any person can log in as operator.
®
6.2.3 Layout of the Screen

The screen of the CMT5-CU is designed as follows:
A B C D E
F G
Fig. 6.2.3 Layout of the Sscreen
A Top menu
B Main menu
C Tabs
D Open panel; Close panel
E General filter function
F Selection panel
G Setting panel or Information panel (depends on the selected main menu)
H Status bar
6.2.3.1 Top Menu
Top menu Description

Control Remote CCU (CMT5-CCU)
Starts the remote connection to the CMT5-CCU. Opera-
tions of the CMT5-CCU see Chapter 6.22.
®
Exit Closes the application USTER CLASSIMAT 5.
Help About
Displays system information
Documentation
Starts the ‘Operating Instructions’
®
Top menu Description

Login Provides personalized access for different users (pass-
word protected).
Login as operator does not need a password. Head of
Laboratory requires a password.
User/Role configuration see Chapter 6.18
Language selection
Select a language from the drop down menu.
A new ‘start up’ of the software will always set the lan-
guage which is set in the Windows Operating system
‘regional setting’.
6.2.3.2 Login
1 Select desired access level by using the drop down menu and by clicking the
relevant User.
2 Enter password and press button.
Fig. 6.2.3.2 Login Menu
®
6.2.3.3 Main Menu
Main Menu Description

Test Run / Test Run Management / Articles
• Creating and editing Articles
• Setting up and starting a test
• Displaying results of running and completed Test Runs
• Setting up yarn definitions
• Setting up Inspection limits for NSL/T, F/VEG, PP, PF
• Setting up Tailored classes
• Selection of completed Test Runs.

• Selection of predefined report templates.
• Displaying of the results and well formated PDF-like reports.
• Estimated Clearing limits / Clearing index

• Yarn body comparison
• Quality comparison
• Longterm analysis
®
• USTER STATISTICS
• System Settings
- General
- Customer / Supplier
- Natural fibers
- Synthetic fibers
• CCU Configuration
• Class sums
• User / Role Configuration
• Log book
®
• USTER STATISTICS
• Mill Statistics
®
6.2.3.4 Status Bar

A B
C D
The status bar displays:

A Status of a running process: e.g. Calibration Process, Test Run
B Measurement progress: tested length and remaining testing time
C Communication between CMT5-CU and CMT5-CCU
D Temperature in °C, relative Humidity in %rH, Date and Time
6.3 General used Functions

The following tables explain generally used function keys in different windows.
Button Function
Confirmation key
Cancel
One position up in the list
One position down in the list

Opens a drop down box
Open / Close Selection panel
Apply
Undo
Save changes
Save as …
Edit
Delete
Copy
Print screen
Filter functions - see Chapter 6.3.1

Import / Export functions - see Chapter 6.3.2
<Ctrl><A> ticks all check boxes

<Back space> unticks all check boxes
Default Articles, default Class sums  cannot be modified
Active functions: the icons appear in red
Inactive functions: the icons appear in black
®
6.3.1 Filter Function

Filtering makes large spreadsheets more manageable and also reduces the time
you spend looking for. Two different types of filtering are available:
- Standard filter, related to ‘Office’ application filter (e.g. Excel).
- CLASSIMAT 5 filter
Button Description
After clicking the button a window opens where the filter crite-
ria can be set, e.g. ‘Last 50 Test Runs and
RING COMBED / NE 30’.
Wildcard (*) can be used for filtering. The asterisk (*) is a

substitute for any characters in a search.
A filter is set by showing button and ‘Active filters’ is set to 2/8

before it was 8/8. The article list shows only articles with ‘Last 50
Test Runs’ and name ‘RING COMBED / NE 30’. The filter criteria
are shown as well in the headline
To turn off the filtering, click on button.
Note that unless you click the button, CLASSIMAT 5

remains in the filter mode. While in filter mode, you may not be
able to see all articles.
A disabled filter shows the last 50 Test Runs.
®
6.3.2 Import / Export Function

Import / Export function is available for completed Test Runs, articles and several
user defined lists. An example shows how to import/export an article.
Button Description
Import articles
Click button and browse to the folder where the *.ustertp
(articles) are stored and select the files which have to be
imported.
If one article has to be imported which already exists in the

database, then you have the choice to overwrite the article, to
import with a different name or to cancel the import.
If several articles have to be imported which already exist in the

database, then no article is imported (prevents overwriting). A
message appears accordingly.
Export articles
Mark the desired article to be exported.
<Ctrl> <A> ticks all check boxes.
<Back space> unticks all check boxes
Click button and choose a folder to export all marked

articles.
®
6.4 Menu Structure

The following lists show all menus from the main menu and tabs. For these menu
items, cross-references take the user to the corresponding chapter in these Oper-
ating Instructions.
Depending on the access level, the menus are active or, if a higher access level is
required, they are not active. In that case, the menu items are displayed grayed.
Main menu Tab Refer to Chapter

Test Run  6.6
Test Run setup  6.6
Calibration process  6.6.1
Measurement window  6.6.2
Test sequence  6.6.3
Test Run Management  6.7

Classimat generation overview  6.7.1
Standard / Advanced classes  6.7.2
Outliers  6.7.3
Periodic Faults  6.7.4
Tailored Classes  6.7.5
Class sums  6.7.6
Event Report  6.7.7
Articles  6.5
Creating an Article  6.5.1
Editing an Article, Article- & Yarn definition  6.5.2
Setting Inspection Limits  6.14
Editing Inspection Limits  6.14.1
Inspection Limits for NSL / T / Slub  6.14.2
Periodic Fault Settings  6.14.3
Inspection Limits F/VEG  6.14.4
Inspection Limits FD  6.14.4.1
Inspection limits VEG  6.14.4.2
Inspection Limits FL  6.14.4.3
Tailored classes  6.14.5
PP Inspection Limits  6.14.6
Special settings  6.14.7
Group monitoring  6.14.8
®
Main menu Tab Refer to Chapter
Reports  6.8
Clearing limits  6.9

Yarn body comparison  6.10
Quality comparison  6.11
Longterm analysis  6.12
®
USTER STATISTICS  6.13
System Settings  6.15

General Settings  6.15.1
Customer / Supplier  6.15.2
Natural fibers  6.15.3
Synthetic fibers  6.15.4
CCU Configuration  6.16
Class Sums  6.17
User / Role configuration  6.18
User Overview  6.18.1
Edit selected User  6.18.2
Role / Access Rights  6.18.3
Log book  6.19
®
USTER STATISTICS  6.20
Mill Statistics  6.21
®
6.5 Article Definition (Test)

All articles contained in the database are listed in the selection panel (A).
The setting panel shows the article characteristics and inspection limits of a select-
ed article.
A C
Fig. 6.5 Article Definition
A List of articles
B Editor for article information, Yarn definition,
C Editor for Inspection limits, Periodic faults and Special settings
6.5.1 Creating an Article
1. Click on tab Articles (Test)

2. Select any article from the list
3.
Click on ‘Save as’ button
Popup menu appears

4. - Enter an article name and a number (name and num-
ber together must be unique)
- press ‘Accept’-button
Note:
Article name or article number may not contain
special characters such as \ / : * ? ” < > ¦.
5.
Click on button to save article changes or
Click on button to undo article changes.
®
6.5.2 Editing an Article
1. Click on tab Articles (Test)

2. Select the desired article by clicking on any items such as
Name, Number, Yarn type, Nominal count or Nominal
twist
3. Edit Article definition

- Click on ‘Article definition’ to edit Name and Number.
- Press Accept-button
4. Edit Yarn definition

Enter Nominal Count, Nominal Twist and select from drop
down menus the required data.
®
Select the relevant yarn type from the USTER STATIS-
®
TICS. If the USTER STATISTICS are not imported yet
®
see Chapter 6.20. To compare with USTER STATISTICS
the relevant yarn type must be selected before starting a
test.
Regular Yarn definition

Three different groups of fiber types are provided
- Cotton
- Natural fibers
- Synthetic fibers
- The list ‘Country of origin’ is predefined referring to the
fiber type.
- Variety/Brand for Cotton is predefined
‘Variety/Brand’ for Natural fibers can be defined in the

menu Setup / System Settings / Natural fibers. See
Chapter 6.15.3
‘Variety/Brand’ for Synthetic fibers can be defined in the

menu Setup / System Settings / Synthetic fibers. See
Chapter 6.15.4
®
6.6 Setup and Start a Test (Test)

Test Run describes:
Test Run • Setting up a test
• Calibration of iMH
• Starting a measurement
B
C
Fig. 6.6-a Test Run Setup
A User name / Time stamp

B ‘Select article’ button
C Description field
D Setup of test parameter
E Status display of measurement progress
Setup a Test
1.
Click on the button
Highlight the desired article and press Accept button
2. Test Run #
A test is identified by the Test Run number. The number is
given automatically by the system. For the next test the
number increments by one.
Alternatively you may enter a user defined Test number. If

this number already exists, a red frame will be displayed
and it is not possible to start a test. Click on but-

ton to discard the changes.
3. Enter Lot number, Machine name and Customer/ Suppli-

er. The latter has to be defined in tab Setup / System Set-
tings. See Chapter 6.15.2 (E. g. ‘My customer/supplier 1’).
®
4. Test length (default setting = 200 km)

Winding speed (default setting = 800 m/min.)
Startup time* (default setting = 3.0 s)
Length correction (default setting = 1.000)
Inspection stop (default setting = inactive)
Default settings have to be adapted to customers need.
*) Typical time duration is from laying-in the yarn up to the

final velocity of the winding machine.
After a restart of CLASIMAT 5 all values will be set

to default again.
Start a Test
5. 1) Click on 2) Click on 3) Click on 4) Click on
Fig. 6.6-b Test Run Setup
6.6.1 Calibration Process
Parameter / Icon Description
Enabled Winding position active
Winding position is temporarily set inactive, the status

Disabled displays . The winding position can generally be
deactivated in the tab Setup – CCU Configuration. See
Chapter 6.16.
Position List of active and inactive winding positions.
No communication to the iMH
Status
(during startup of appplication).
Winding position is set inactive.
Warm up time.
Adjusting / Running
Adjusted
Alarm.
Adjustment progress Status display of calibration process.

Alarm message Describes a reason of an alarm.
®
6.6.2 Measurement Window
After clicking button the data will be displayed in the measurement

window. The data are refreshed continuously. The measurement progress is
shown in the status bar
The measurement window is described in Chapter 6.7 ‘Test Run Management.
C
B
D
Fig. 6.6.2 Measurement Window
A View options.
B Graphical display of data.
C Numerical display of Outliers, Tailored classes, Class sums and Event report.
D Display of measurement progress.
®
6.6.3 Test Sequence

(CU is placed near the
Operation on CU winding position.)
Test Run Setup
• Create/Select articles
• Setup test parameter Operation on CCU
(CU is placed far away from
the winding position.)
LED display on iMH
Prepare Test Prepare Test
LEDs flash every 3 sec. CMT5

Check sample iMH is waiting for calibration
conditioning start
Prepare Calibration Prepare Calibration

Clean measuring
field on iMH
Download Calibr.-
Parameter to CCU
Start Calibration Start Calibration
Calibration Process Calibration Process
• Insert yarn • Insert yarn LEDs will flash alternately until
Operation on calibration is finished.
• Start winding position • Start winding position
winding position
• Calibrate with yarn • Calibrate with yarn
After calibration the LEDs flash

every 3 sec. CMT5 iMH is
waiting for test parameter.
Start Measurement Start Measurement
LEDs are off.

Last selected window
CMT5 iMH is operating normal-
is still displayed. ly.
• Insert yarn Operation on • Insert yarn

• Start winding position winding position • Start winding position
Measurement progress Measurement progress
Last selected window is

still displayed.
Information
Aborted or finished TestRun Technical alarms showing up on the CMT5-CCU
have to be acknowledged in any case on the CMT5-
Start new test CCU or via remote access from CMT5-CU, before
testing can be continued.
®
6.7 Test Run Management (Test)

The information displayed in Test Run Management window is equivalent to the
Test Run Management data display in the measurement window. Test Run Management shows results of
completed and aborted tests including outliers.
Filter and Import/Export functions see Chapter 6.3.1 and 6.3.2
C
B
A D E
Fig. 6.7 Test Run Management Window
A List of Test Runs

B Yarn definition & test parameters
C View options
D Graphical display of the test data
E Numerical values display of Outliers, Tailored classes, Class sums and Event
report
Description of icons in ‘Test Run Management’ and ‘Measurement’ window

Icon Description
Select the yarn fault type and displays all
* available relevant classification information,
scatterplot and yarn body.
Select Classimat generations: CLASSIMAT
Classimat 5  * 5, CLASSIMAT QUANTUM and
CLASSIMAT 3.
All positions  * Select all or individual winding positions.
Shows/hides class values and select be-

Abs./non-cum  * tween absolute, relative, cumulated or per
class values.
*
Shows/hides the scatterplot.
* Shows/hides the yarn body and dense area.
* Switches from standard class to advanced

classes.
Print screen of the main content

*) Classimat generation overview
®
6.7.1 Classimat Generation Overview
Classimat Yarn event Positions Class values

generation type
Classimat 5 NSL/T Winding scatter plot yarn body NSL30 / T15
Positions No class values .
FD
are selec- ABS/Class
F/VEG table for all
or specific Per 100 km/Class
FL positions.
PP not available for PP not available for PP
PF Display of Periodic Faults - bubble plot

OL Display of Outliers after a measurement is completed.
Classimat NSL/T Winding No class values Not available Not available NSL23 / T4
Quantum Positions .
table for all Per 100 km/Class
or specific
positions. ABS/CUM
Per 100 km/CUM
Classimat 3 NSL/T Winding No class values Not available Not available NSL23 / T10
Positions
table for all Per 100 km/Class
or specific
positions. ABS/CUM
Per 100 km/CUM
Description of class values

Class values Description
No class values Shows/hides classification values.
ABS/Class Absolute readings per class

Per 100 km/Class Readings relative to 100km per class.
Absolute readings of cumulated classes within the same class length.
example of cumulated class A and H:

ABS/CUM A1 = A1 + A2 + A3 + A4 H1 = H1 + H2
A2 = A2 + A3 + A4 H2 = H2
A3 = A3 + A4
A4 = A4
Readings relative to 100km of the cumulated classes within the same class
Per 100 km/CUM
length.
®
6.7.2 Standard and Advanced Classes for NSL/T

Standard class
A4 B4 C4 D4
A3 B3 C3 D3
A2 B2 C2 D2 NSL 19E
A1 B1 C1 D1
F G
H1 I1
H2
T4 I2
Classimat 5 advanced classes

A4 B4 C4 D4
A3 B3 C3 D3
A2 B2 C2 D2 NSL 30 E
A1 B1 C1 D1
A0 B0 C0 D0
F G
CP1 DP1
DP2 FP21 FP22 GP21 GP22
TD0 H01 H02 I01 I02

TB1 TC1 TD1 H1 I1
TB2 TC2 TD2 H2 T 15 I2
Classimat Quantum advanced classes

A4 B4 C4 D4
A3 B3 C3 D3
E
A2 B2 C2 D2 NSL 23
A1 B1 C1 D1
A0 B0 C0 D0
F G
H1 I1
H2
T 4 I2
Classimat 3 advanced classes

A4 B4 C4 D4
A3 B3 C3 D3
A2 B2 C2 D2 NSL 23 E
A1 B1 C1 D1
A0 B0 C0 D0
F G
TB1 TC1 TD1 H1 I1

TB2 TC2 TD2 H2 T 10I2
®
6.7.3 Outliers
6.7.3.1 Definition Yarn Body
Dark green area is representing the actual yarn body. The Light green area is rep-
resenting variations in the yarn body.
The vertical scale represents the increase or decrease in yarn mass and the hori-
zontal axis represents the length of events in cm.
Fig. 6.7.3.1 Yarn Body / Dense Area
A Area of the disturbing faults or outliers

B Area of the yarn body
Yarn body
Yarn body variations
Remaining events
Outliers
Faults – ‘Inspection stop’. See Chapter 6.6 / Step 4
6.7.3.2 Definition Outliers

CLASSIMAT 5 identifies disturbing faults named ‘outliers’ on the basis of the yarn
body and appearance in fabric for neps, short thick, long thick and thin places
(NSL/T), foreign matter including polypropylene and key quality parameters
Fig. 6.7.3.2 Outlier Definition
®
6.7.3.3 Outliers – Yarn Fault Type
Outliers for neps, short thick, long thick and

thin places (NSL/T) are represented as
symbol.
The outlier limit depends on the yarn body
and therefore adapts to the various types of
yarns.
- NSL outlier limit is set at 100% above the

yarn body (e.g. yarn body = 120%  Out-
lier limit = 240%)
- T Outlier limit is set at -65% of the yarn

body.
Outliers for colored foreign fibers - FD are
represented as symbol.
FD outlier limit is fixed for all yarns. The

curve passes the point of intersection at 8%,
2 cm.
Outliers for vegetable matters - VEG are
VEG outlier curve is fixed and applies for all

types of yarn. The curve passes the point of
intersection at 10%, 2.6 cm.
FL no outlier data available.
Outliers for polypropylene fibers- PP are

The outlier limit depends on the shape of the

dense area and adapts to the various types
of yarns.
®
6.7.3.4 Outliers – Distribution Diagram

Outliers are shown for each yarn fault type along a length diagram (A).
A longer bar indicates that the outlier lasted over several periods e.g. meters.
Tool tip outliers:
Tool tip quality outliers:

A
* * * * * Shows information about:

Type, Start, Length / Reference
*) Width: proportional to the tested length of Length, Mass (Amplitude) and
the position Position
Symbols of outlier types:
Outliers:
Symbol size is fix
Quality Outliers:
Symbol size depends on the affected length
Summary table of outliers
®
Quality Outliers
Parameters Calculation of Outlier limits Explanation

The range is indicative for the CVm variation of the
entire lot.
In the displayed example, the CVm values (100 m
yarn samples) are 10.8 to 12.7.
Evenness (CVm) Limits: The evaluation of the displayed data indicates that the
(-16%, +20%) MV – 16% Affected share (see explanation below) is 0%. That
MV + 20% means that within the Test Run, no single sample
(100 m) was declared being an outlier.
And therewith, during the last 52 weeks the best lot of
Where: the same article achieved an affected share of 0% as
MV = Mean value well.
Standard Imperfections: The range is indicative for the variation of the stand-
Neps: +200% ard imperfection classes of the entire lot.
Thick places: +50% In the example, the sum of the standard imperfections
Thin places: -50% (1000 m yarn samples) ranges between 22 and 72.
The Affected share is 2.2% where at least one of the

Imperfection Limits: standard imperfection classes exceeded one of its
Standard (3σ) MV of imperfection classes -3σ limits. In other words, in 2.2% of the inspected sam-
MV of imperfection classes +3σ ples, the number of corresponding events detected
was exceeding the -3σ or the +3σ border within the
distribution.
During the last 52 weeks the best lot of the same arti-
Where: cle achieved an affected share of only 0.7%, saying
σ = Standard deviation that about 3 times less samples were affected than in
MV = Mean value the current lot.
Sensitive Imperfections: The range is indicative for the variation of the sensi-
Neps: +140% tive imperfection classes of the entire lot.
Thick places: +35%
Thin places: -40% In the example, the sum of the sensitive imperfections
(1000 m yarn samples) ranges between 212 and 590.
The Affected share is 2.9% where at least one of the
Imperfection Limits: sensitive imperfection classes exceeded one of its
Sensitive (3σ) MV of imperfection classes -3σ limits. In other words, in 2.9% of the inspected sam-
MV of imperfection classes +3σ ples, the number of corresponding events detected
was exceeding the -3σ or the +3σ border within the
distribution.
Where: cle achieved an affected share of only 0.7%, saying
σ = Standard deviation that about 4 times less samples were affected than in
MV = Mean value the current lot.
®
Parameters Calculation of Outlier limits Explanation

The range is indicative for the Hairiness variation of
the entire lot.
In the example, the H values (100 m yarn samples)
ranged between 3.2 and 4.8.
The Affected share (see explanation below) is 0.4%.

Hairiness (H) Limits: In other words, in only 0.4% of the inspected samples
(-1.0, +1.0) MV – 1.0 outliers were detected (where one of the Hairiness
MV + 1.0 limits was exceeded).
cle achieved an affected share of 0.0%, indicating that
Where: over the whole test length there was never a Hairi-
MV = Mean value ness-value outside of the limits.
The affected share gives the percentage (%) of the
affected length compared to the total test length.
Concerning the calculation of this parameter, the total
test length is devided into several samples which are
Affected share analyzed for the corresponding criteria.
For example, 10% affected share for a particular crite-
ria means that 10% of the samples and therefore of
the total test length were affected by this particular
criteria (e.g. CV, Imperfections, Hairiness,…).
Presents the Uster Statistics 2013 percentile value for
USP13
the Affected share.
Best value of the same article and regarding a certain
criteria that has been achieved within the last 52
52 week best weeks. The 52 week best value is calculated as soon
as 5 tests of the same article are available and is to
be compared with the indicated affected share.
The above mentioned length of each sample within

Reference length the whole test length is called reference length. The
(Tool tip) value for the reference length is being displayed as
part of the tool tip.
In the example above (see table ‘Quality Outliers’)
showing ‘-‘ instead of a value just means that there
Interpretation “-“ was no data inspected that fits to the corresponding
criteria. In most cases ‘-‘ can therefore be interpreted
as ‘0’ or ‘0%’.
As common, the mean value describes the average
over all samples acquired, whereas the range is de-
scribing the registered minimum and maximum value.
Mean Value The mean value must not be interpreted to be exactly

in the middle of the minimum and the maximum value
of the indicated range. This is only true for perfect
symmetrical distributions or for other special distribu-
tions but not in the normal case.
®
6.7.4 Periodic Faults

The center of the bubbles in the matrix indicates the average size of the yarn fault
(mass and length). The size of the bubbles depends on the affected share and
regularity. One bubble represents one type of periodic fault. A new bubble is gen-
erated when the period or the yarn fault size (mass or length) is different.
Fig. 6.7.4 Periodic Faults
Periodic Fault ID2 is discribed as follollows:
Period (c):Repetition of Yarn fault 9.7 cm c
d d
Average size of Yarn fault (d):  32.6%/12 mm
32.6%
12 mm
Regularity: 100% corresponds to strict periodicity
No. of faults: Yarn faults cumulated and represented in a Periodic fault.

Affected length: No of faults x Period = 1934 x 9.7 cm = 0.188 km
100 % x Affected length 100 % x 0.188 km

Affected share: = 0.09%
Test length 200 km
®
6.7.5 Tailored Classes

Yarn type events without existing classes or events of overlapping classes can be
set up in Tailored classes.
Results of Tailored classes are displayed in tab ‘Test Run Management’ for
NSL/T, FD and FL yarn faults. Tailored classes have to be set in tab ‘Articles’. See
Chapter 6.14.5.
Tailored classes NSL/T
The example shows Tailored classes for

NSL/T events. Tailored classes are avail-
able for FD and FL events.
On NSL/T tab  Tailored NSL/T

On FD tab  Tailored FD
On FL tab  Tailored FL
6.7.6 Class sums

Results of Class sums are displayed in the tab ‘Test Run Management’ for
NSL/T, FD, and FL yarn faults.
Class sum limits have to be set in the tab ‘Setup’. See Chapter 6.17
Type depends on the selected tab.
6.7.7 Event report

Events are displayed independent for all yarn fault types:
Events are displayed independent of the tab selected and displays the reasons of
inspections and interruptions during a test.
Example:
- Pos.3
- Yarn fault event = N
- Event detection in class A4
- Mass = 899.9%, Length = 2 mm
- Time of event appearance
®
6.8 Reports
The presentation of the reports depends on the selection of the available report
templates.
Standard Reports
A
C
D
Fig. 6.8 Reports
A List of completed or aborted tests

B Predefined reports
C Display print preview of selected report
D Selection of separate Report language
Filter function see Chapter 6.3.1.
Report selection
To have the test results displayed on the screen act as follows:
1. Select an article from the list (A)
2. Select a Report template according to data needed (e.g. Outlier Summary)
The relevant results will be shown on the right window where the presentation can
be customized with the icons on top of the right window.
Icon Description
Print displayed report (Ctrl P).
Copy displayed report (Ctrl C).
Zoom in the report (Ctrl+).
Zoom out the report (Ctrl-).
100 % (Ctrl 1): Zoom the report to 100% of the normal site.
Page width (Ctrl 2): Zoom the report so that the width of the page
matches the width of the window.
One page (Ctrl 3): Zoom the report so that an entire page fits in the
window.
Two pages (Ctrl 4):

Zoom the report so that two pages fit in the window.
®
6.8.1 Report Templates

Detailed reports are available. Thick (NSL) and Thin (T) places can be selected for
three Classimat generations.
Fig. 6.8.1 Report Template
D Report language can be selected independent of the selected application lan-

guage.
CLASSIMAT 5 CLASSIMAT QUANTUM

Thick and Thin places Thick and Thin places
CLASSIMAT 3 CLASSIMAT 5 Thick and Thin places

Thick and Thin places and Foreign Matters
®
CLASSIMAT 5 CLASSIMAT 5
Periodic Faults Outlier Details
CLASSIMAT 5 CLASSIMAT 5
Outlier Summary Class Values per Position
®
6.9 Clearing Limits (Analysis)

CLASSIMAT 5 analyzes remaining yarn faults to estimate the clearing limit applied
and compares it to an USTER reference clearing limit. For each yarn fault type,
NSL/T, FD, VEG, FL and PP a Clearing Index is calculated based on its compari-
son.
B
D
C E
A
Fig. 6.9 Clearing Limits
List of Test Runs

B Yarn definition & test parameters
C View Option
D Yarn events with estimated clearing limit (blue)
E Clearing Index – color code representation
F Clearing Index – numerical representation
N S L
Clearing Index for NSL:
The yarn clearing for neps was

rather poor, therefore the clearing
limit for neps should be reviewed.
T
Numerical
Color code Implication
ranges
Orange 0 - 30 Poor or uncleared yarn – high number of outliers
Yellow 31 - 50 Moderate yarn clearing
Light green 51 - 70 Acceptable yarn clearing
Green 71 - 90 Good yarn clearing
Dark green 91 - 100 Excellent yarn clearing – lowest number of outliers
®
6.10 Yarn Body Comparison (Analysis)

Compares up to five different yarn bodies to their mean value or benchmarks and
identifies any significant changes.
C
A D
Fig. 6.10 Yarn Body Comparison
A List of Test Runs

B Reference selection
C Headline (automatic generated)
D Matrix – yarn body comparison
E Legend
The yarn comparison procedure described here is for NSL/T, is also valid for FD,
VEG and FL.
1. Tick the check boxes of the rele-
vant Test Runs (up to five are possi-
ble).
The Test Run number appear in the
Reference table, the shape of the
yarn bodies are displayed in the ma-
trix and the color code in the column
‘Legend’ refers to the yarn bodies in
the matrix.
The last entry in the column ‘Legend’
shows the respective reference (a).
2. Comparison - selected yarns
a
For a better visual comparison
among the selected yarns, mark a
Test Run (e.g. 37001) from
the Reference list. The yarn body is
now displayed green colored in the
matrix.
3. Comparison - mean values
Mark in
the Reference table. The mean value
of all selected yarns is displayed
green colored in the matrix.
®
4. Comparison - Mill Statistics

Mark ‘Mill Statistis’ in the Reference
table and select a predefined Mill
Statics (e.g. Mil Stat Nec20-40).
The yarn body of the Mill statistic is

displayed green colored in the ma-
trix. The yarns which fulfill the ‘Mill
Statistics’ definition, are green high-
lighted in the column ‘Legend’.
Mill Statistics have to be defined
in ‘Setup / Mill Statistics’ see Chapter
6.21.
®
5. Comparison - USTER STATISTICS
Mark in the
Reference table.
The article matches with USTER

® The article does not match with
®
STATISTICS, the yarn is listed as USTER STATISTICS, the following
follow: message appears:
®
To compare with USTER STATIS-
TICS, make sure that they are im-
ported and assigned to the article
prior to testing: 1
®
1. USTER STATISTICS have to be
®
imported in ‘Setup / USTER
STATISTICS’ (see Chapter 6.20).
®
2. USTER STATISTICS have to be
selected in ‘Yarn definition’. See
Chapter 6.5.1).
®
6.11 Quality Comparison (Analysis)

Compares the quality of up to five different yarns to identify the most suitable yarn
for the intended application.
E
A
Fig. 6.11 Quality Comparison
A List of Test Runs

B Headline
C Comparison results
D Expander button
E Detailed information
The quality comparison procedure:

1. Tick the check boxes of rel- Quality comparison overview
evant Test Runs (up to five are
possible). An overview of the
compared results is displayed
color-coded.
color code ranking

Dark green Best article
Green Second best article
Light green Third best article
Yellow Forth best article
Orange Fifth best article
2. By pressing button detailed
information for each parameter
are displayed.
®
Irregularity  yarn body comparison
191.9 = corresponds to the area of NSL and T outliers
NSL/T Outliers
Quality outliers
Foreign matter
16.3 = corresponds to the area of foreign matter
Vegetables
21.6 = corresponds to the area of vegetables
Foreign matter outliers
®
6.12 Longterm Analysis (Analysis)

Compares results over a period of time to identify trends and take necessary ac-
tion.
A
E
D
Fig. 6.12 Longterm Analysis
A List of Test Runs

B Reference selection
C Parameter catagories
D Sub Parameters
E Graphical or numerical
The Long term analysis:

1. Select articles via Filter function or
by ticking the check boxes of
relevant articles.
2. Mark one of the parameter in ‘Pa-

rameter catagories’, e.g. .
3. Tick checkbox of one or several

Sub Parameter.
4. Mark in
the Reference table
®
5. Long term analysis of selected parameters (e.g. Outliers for Tool tip shows
NSL/T and PF) comparing to mean value of selected tests Test Run,
for the chosen articles (mean value dotted lines). Date and
Value
Numerical display of selected parameters.
Graphical display of selected parameters is available either

time scaled or fix scaled.
Time scaled display
Fix scaled display
®
Comparison to Mill Statistics and USTER STATISTICS are provided as well, fol-
low the same procedure as for ‘Mean value’.
®
Zoom Function
Horizontal zoom in / out function
Vertical zoom in / out function
6.13 USTER® STATISTICS (Analysis)

®
USTER STATISTICS graphic display for CLASSIMAT 5
Fig. 6.13-a USTER® STATISTICS NSL/T Events
Fig. 6.13-b USTER® STATISTICS Outliers
®
6.14 Setting Inspection Limits (Articles)

Inspection limits can be set or modified in the tab ‘Articles’. A left mouse click on a
article on the left side opens a window with classification information. A left mouse
click in the area of a yarn fault type starts the editor to set up the inspection limits.
C D
A
E G
Fig. 6.14 Setting Inspections Limit
A List of articles
B PF inspection limits
C NSL/T inspection limits
D F/VEG inspection limits
E Tailored classes
F PP inspection limits
CLASSIMAT 5 provides two modes to set up inspection limits – ‘Normal’ and ‘Class
clearing’.
6.14.1 Editing Inspection Limits

Mode ‘Normal’
Place the set points by using the Polyline mode
1
3 2
Fig. 6.14.1-a Editing Inspection Limits
1. Set the mouse pointer to the required position and click the right mouse
button.
2. Move the mouse to ‘Add set point’ until it gets red and confirm with a left or
right mouse click.
3. Change a set point by setting the mouse pointer onto a set point. Hold the
left mouse button and move to the required place.
4. Coordinates of the set point are visible when moving the mouse pointer
onto a set point NSL1:6/3189 as shown I the picture below:
®
NSL1:6/3189 5
4
Fig. 6.14.1-b Set Point Coordinates
NSL1: First Set point of NSL inspection limits

6/ Horizontal scale: Length of fault 6 mm = 0.6 cm
3189 Vertical scale: Increase of yarn mass or diameter is 318%
5. The coordinates of all set points are listed in the right window. The numerical
values can be altered via keyboard by clicking on the figures accordingly.
Remove set points
Fig. 6.14.1-c Remove Set Points
1. Move mouse pointer to set point

2. Right mouse click on the set point
3. Confirm ‘Remove set point’
Mode ‘Classs clearing’

‘Class clearing’ enables to set the limits per class using the Class clearing mode.
Fig. 6.14.1 Class clearing
1. A right or left mouse click in the All classes above the designated class will
designated class will set the clear- be marked as to be cleared (grey).
ing limit.
2. In the same way a limit can be
moved or deleted.
®
6.14.2 Inspection Limits NSL/T / Slub

The inspection limit is defined as a line which separates disturbing faults from the
non-disturbing/remaining faults. The shape of the inspection limit is defined by
maximum 8 set points.
Set point parameters for NSL/T

Sensitivity (%) is a parameter for the inspection limits of
Sensitivity the corresponding type of fault. The sensitivity setting rais-
es (less sensitive) or lowers (more sensitive) the clearing
limit.
The reference length (cm) is a parameter for the inspec-
tion limits of the corresponding type of fault and shifts the
Reference length
inspection limit to the right (less sensitive) or to the left
(more sensitive).
Icon Description
Mode ‘Normal’: Set inspection limits for NSL/T using
the Polyline mode. The limits are determined by plac-
ing a maximum of 8 set points NSL1 to NSL8 and T1
to T8.
Setting procedure see Chapter 6.14.1
Mode ‘Class clearing’: Set inspection limits per class.
If ‘Normal Mode’ is selected, then can be toggled
between NSL/T, and Slub.
Set inspection limits for Slub yarns. The limits for

Slub yarns are determined by placing a maximum of
3 set points K+1, K+2, K+3.
NSL thick places

Inspect occurring thick places of various lengths.
Definition of NSL thick places

Faults Description
Thick places from 0.2 cm to < 1 cm  very short thick places
N-faults
(neps)
S-faults Thick places from 1 cm to < 8 cm  short thick places
L-faults Thick places from 8 cm to 200 cm  long thick places
®
Fig. 6.14.2-a NSL/T Normal Mode Fig. 6.14.2-b NSL/T Class Clearing
Inspection Limits T Thin Places

Inspect occurring thin places of various lengths.
Inspection Limits Slub Yarn
Fig. 6.14.2 Inspection Limit Slub Yarn
6.14.3 Periodic Fault Settings
Periodically consecutive occurring thick places can be detected. A cut takes place
if thick places in a regular distance and for a given number of periods are detect-
ed.
Settings: - Sensitivity in % (0% = Inspection inactive)
- Number of periods.
Information: Sensitivity = minimal yarn fault at 1 cm.
®
6.14.4 Inspection Limits F/VEG

Classification Matrix F/VEG
F/VEG classes
Fig. 6.14.5 F/VEG Matrix
Set point parameters F/VEG

Reflectance (%) is a parameter for the inspection limits
Reflectance of the relevant fault type. The reflectance setting raises
(less sensitive) or lowers (more sensitive) the clearing
limit.
Reference length (cm) is a parameter for the inspection
Reference length limits of the relevant fault type and shifts the inspection
limit to the right (less sensitive) or to the left (more sensi-
tive).
Icon Description
Set foreign matter dark limits.
The limits are determined by placing a maximum of 8 set
points FD1 to FD8.
No settings are possible. Active / inactive status - de-
pending on material displayed.
Set foreign matter light limits.
points FL1 to FL8.
Edit set points by using the Polyline mode.
Edit class limits by using the Class clearing mode.
®
6.14.4.1 Inspection Limits Dark Foreign Matter FD

Dark foreign fibers in light-colored yarn are detected.
Fig. 6.14.4.1 Inspection Limits FD
®
6.14.4.2 Vegetable VEG Classification

The vegetable detection can distinguish between organic (vegetable) and non-
organic foreign fibers. Since vegetable foreign fibers disappear during bleaching
process they can often be allowed to remain in the yarn. The result is a reduction
of foreign fiber cuts. The limit is set by the system and displayed.
Fig. 6.14.4.2 Inspection Limits VEG
Item Description
VEG classification is active only for cotton or cotton blends with
ACTIVE more than 30% cotton. Refer to ‘Articles’ / ‘Yarn definition’
Chapter 6.5.2.
Information
i Vegetables between the FD and VEG clearing limit are remaining
in the yarn. Vegetables above the VEG clearing limit are cut.
6.14.4.3 Inspection Limits Light Foreign Fibres FL

Light foreign fibers in dark-colored yarn are detected.
Fig. 6.14.4.3 Inspection Limits FL
®
6.14.5 Tailored Classes

Tailored class settings are applicable for NSL/T, FD and FL.
Fig. 6.14.5 Inspection Limits Tailored Classes
Limit setting
®
6.14.6 Inspection Limits PP

PP Detection
The Polypropylene PP inspection detects white or colored Polypropylene fibers.
Polypropylene fiber contaminations are well visible as white fault after dying of the
finish cloth, because the polypropylene fibers do not absorb cotton dyestuff.
Set point parameters for PP

Sensitivity (%) is a parameter for the inspection limits of the
Sensitivity
corresponding type of fault. The sensitivity setting raises
(less sensitive) or lowers (more sensitive) the clearing limit.
The reference length (cm) is a parameter for the inspection
limits of the corresponding type of fault and shifts the in-
Reference length
spection limit to the right (less sensitive) or to the left (more
sensitive).
Fig. 6.14.6 Inspection Limits PP
Item Description
Set polypropylene fiber limits.
PP points PP1 to PP8.
Setting procedure see  6.14.1 (Editing PP limits takes
place only in ‘Normal’ mode not in ‘Class Clearing’
mode).
PP settings are active only for cotton or cotton blends
ACTIVE with more than 30% cotton. Refer to ‘Articles’ / ‘Yarn
definition’ Chapter 6.5.2.
®
6.14.7 Special Settings
Cutting power
Normal: Yarns finer than Nec 20 are cut with reduced intensity.
High: All yarns are cut with high intensity.
Blow out intensity

The three modes for blow out intensity depend on the yarn count.
Off: Air pressure is switched off
Low: Air pressure is lower than in normal mode (e.g.
especially fine yarns with low tension)
Normal: Air pressure is used for the majority of the yarns to be inspected (default
setting).
High: Air pressure is higher than in normal mode (e.g.
very dusty yarns)
Yarn detector adjustment

YD sensitivity (normally set at 100%)
YD increment (normally set at 100%)
YD decrement (normally set at 100%)
Change settings only extraordinary situations!
®
6.14.8 Group Monitoring
Zero point monitoring
If the special monitoring functions are activated they react as follows:

 Zero point monitoring (ZPM)
If during automatic zero point adjustment the measuring zone was not empty, a
ZPM event is counted but no zero adjustment made. Clean measuring zone.
 Cut monitoring (CTM)
If the iMH repeatedly detects running yarn after a cut then a technical alarm is
triggered. Check cutting device.
Yarn jump monitoring
 Yarn jump monitoring (JPM)

A cut is triggered if the yarn jumps out of the measuring zone for a moment e.g.
because of a large yarn fault.
 Yarn jump alarm (JPA)
A cut and an alarm is triggered if the yarn jumps out of the measuring zone 3
times per 1 km. A textile alarm is displayed (reset alarm on CMT5-CCU).
 Possible settings for JPM and JPA:
JPM JPA Effect at yarn jump
- - Yarn jumps are registered and counted.

x - A cut follows a yarn jump
Cut 3 x JMP / 1 km. A textile alarm is displayed (reset alarm on
x x
CMT5-CCU).
®
Drum wrap
 Drum wrap monitoring (DWM) prevents the yarn from getting wrapped
around the drum with a cut.
 Drum wrap alarm (DWA) prevents the yarn from getting wrapped around
the guide drum with a cut and an alarm. At the same time a textile alarm is
activated and displayed (reset alarm on CMT5-CCU).
 Relation DVM and DWA:
DWM DWA Effect at danger of drum wrap
- - Drum wraps are registered and counted.

x - Cut at drum wrap
Cut, a textile alarm is displayed (reset alarm on CMT5-

x x
CCU).
Drum signal monitoring
 Drum signal monitoring (DSM)  not used for manual winders.

A technical alarm is activated if the CMT5 iMH does not receive a guide
drum signal after the winding position starts up. Check guide drum sensor.
®
6.15 System Settings (Setup)
A
B
Fig. 6.15 System Settings
A Adjustment per position (calibration cycles)

B Company Data
6.15.1 General Settings

1. Enter numbers of adjustments per position
2. Enter Company’s Name, Address and import Customer’s Logo (png- format).
The Logo is displayed on the reports.
6.15.2 Customer / Supplier
Click button to add new ‘Customer / Supplier’.

Registered ‘Customer / Supplier’ can be selected in ‘Test Run Setup’.
See Chapter 6.6
6.15.3 Natural fibers
Click button to add new ‘variety’

Registered ‘varieties’ can be selected in ‘Edit an Article’ for ‘Natural fibers’ (e.g. Silk
Linen, etc.). See Chapter 6.5.2.
6.15.4 Synthetic fibers
Click button to add new ‘brand’

Registered ‘brands’ can be selected in ‘Edit an Article’ for synthetic fibers (e.g. Pol-
yamid, Viscose, etc.). See Chapter 6.5.2.
®
6.16 CCU Configuration (Setup)
Fig. 6.16 CCU Configuration
A Machine configuration
B Winding position
The data shown in the section machine configuration (A) are transferred from the
CMT5-CCU to the CMT5-CU. The following Parameters are displayed.

IP address IP Address of connected CMT5-CCU.
CCU version Version of CMT5-CCU Software.
RPC version RPC version and build no.of installed software.
(Build no.)
Last connection time Time of the last successful connection.
Connection status Current connection state.
Machine type Machine type which is connected to the CMT5-CCU.
Current state of classimat group (group 1 on CMT5-
Classimat group status
CCU).
Clearer type Type of clearer which is connected.

Position / Label List of active and inactive winding positions.
No communication to the iMH (during startup of
Status
appplication).
Inactive Winding position is set inactive.
- Warm up time.
Adjusting / Running Calibration is in progress.
Adjusted Calibration process is successfully finished.
Alarm Alarm – for some reason the calibration failed.
®
Deactivation/Activation of winding positions
Deactivate Winding position is active.
Winding position is set inactive, the status field

Activate displays . Temporarily the winding position can be
deactivated during the calibration process. See
Chapter 6.6.1.
From a drop down menu a stop reason can be
Reason of deactivation
selected and assigned to the inactive positions.
®
6.17 Class Sums (Setup)

Class sums will be displayed during Test Run in the measurement window see
Chapter 6.6.2. After the measurement the results will be shown in the reports and
in ‘Test Run Management’. See Chapter 6.7.
Fig. 6.17 Class Sums

The original USTER “sum definitions” are write- and
rename protected. But they can be copied, deleted,
edited and saved by giving a new name.
Type Shows the type of yarn event.
Name of sums.
Name Customer’s sum may not contain the word Uster.
Sums can be copied, deleted and edited.
Full list of sum classes.
Sum definition
Sum definitions can be created with the button.
Starts the class sum editor and allows the following
entries:
1. Entering Sum name
2. Selecting type of yarn event
3. Defining new sum classes by a mouse click on the
required classes.
4. Clicking the button saves the sum

definitions and displays them in the tab Class
Sums.
Maximum 5 customized “sum definitions” can be

added.
Restores always all original USTER Class sums which
have been deleted previously.
®
6.18 User / Role Configuration (Setup)

®
Different users can be configured for USTER CLASSIMAT 5 including their
role and access level.
Fig. 6.18 User / Role Configuration
A User Overview
B Editing selected User
C Active User
Adding a new user:

1.
Click button, it adds a new
user to the list.
2. Enter Login name, assign a role

to the user (e.g. operator), set a
password and leave the check
box active.
3. Click button to apply or click After applying, the new user appears in
the Login selection menu. See Chapter
the button to discard the
6.2.3.2
changes.
®
6.18.1 User Overview

This window displays the current users of the system, including their role and their
status. With the icons at the top of the window users can be added or deleted.
Icon Description
Add a new user in the window ‘User Overview’. The
details of the new user name have to be defined in the
window ‘Edit selected User’
Delete a user.
After editing the selected user this button must be

pressed to close the procedure of adding a new user.
Discard all changes since the last save operation.
6.18.2 Edit selected User
Login Name Enables to enter the name of the user.
Assigned role Enables to select a role from the drop down menu.
This is NOT the Windows password but an alternative
®
password for USTER CLASSIMAT 5. Please avoid
Password
using the same password for CLASSIMAT 5 and the
Windows system for safety reasons.
Active A user can be set active or inactive.
®
6.18.3 Role / Access Rights
Head of laboratory
Uster-Service
Operator
Description Main Menu / Tab
Articles overview and Settings (read only) Articles Y

Edit existing article and save with new name Articles / ‘Save as’ Button’ N Y Y
Articles / Edit Settings and ‘Save’ But-
Modify existing article N Y Y
ton
Test Run overview and Test Run Settings (read

Test Run management Y
only)
Test Run management / ‘Import’ But-
Import a Test Run N Y Y
ton
Test Run management / ‘Export’ But-
Export a Test Run N Y Y
ton
Test Run management / ‘Delete’ But-
Delete a Test Run N Y Y
ton
Overwrite Test Run number by user Test Run / Test Run # N Y Y
Start a Test Run by user Test Run / Start measurement Y
Select Report Template and Test Reports / Report selection Y

Print displayed report Reports / ‘Print’ Button Y
View Users and Roles (read only) Setup / User / Role Configuration Y
Create/modify User, modify Role Setup / User / Role Configuration N Y Y
Show all Configurations Setup Y

Maintain positions (deactivate positions) Setup / CCU Configuration N Y Y
Configures Setup / System N Y Y
Define Class sums Setup / Class sums N Y Y
Import, export, add new, edit, copy and delete statis-
Setup / Mill Statistics N Y Y
tic
® ®
Import USTER STATISTICS Setup / USTER STATISTICS N Y Y
Start remote connection to CCU Control / Remote CCU N Y Y

Display service logbook Control / Service Log Y
®
6.19 Log book (Setup)

Process events are recorded in the Log book, if necessary the customer can be
®
asked to copy a selected event to the clipboard and to mail it to USTER
Service. On the other hand the complete Log book can be exported and send
®
to USTER Service as well.
Fig. 6.19 Logbook
6.20 USTER® STATISTICS (Setup)

Comparison to USTER® STATISTICS
Fig. 6.20 Setup USTER® STATISTICS

®
USTER STATISTICS can be imported by clicking the button.
®
6.21 Mill Statistics (Setup)

Comparison to internal ‘Mill’ results.
Fig. 6.21 Setup Mill Statistics
A List Mill Statistics profile

B Mill Statistics generation
1.
Click button to add new Mill Statistic
profile.
2. Complete the template according to the

Mill’s need:
- Define filter criteria, which tests
shall be part of the statistics
- Name the statistics
- Press button
Mill Statistics can be exported, imported,

copied, modified and deleted.
3. Statistics can be generated manually or

automatically after a Test Run.
To generate manually:
- Mark
- Select Statistic profile
- Click button to start the genera-
tion.
®
6.22 Measurements with USTER® CLASSIMAT 5

This chapter describes the handling of the CLASSIMAT 5 module. To operate the
winding machine refer to the user manual accordingly.
For a complete overview of a test sequence refer to  6.6.3
6.22.1 Positioning of the Yarn Package

Check the distance from the top of the package to the thread guide.
Recommended distance is one and a half times of the package height (H).
1.5 x H
Fig. 6.22.1 Positioning Yarn Package
6.22.2 Yarn Path

CLASSIMAT 5 Module ensures an optimized yarn feeding. Suitable guiding ele-
ments after the thread outlet and a reliable, trouble-free yarn draw-off have to
guarantee a steady thread line in the measuring slot.
Especially when testing bobbins with that typical large thread balloon, it is im-
portant to ensure an optimum thread line. If that is not the case, the yarn may oc-
casionally jump out of the measuring field area and that can result in false signals.
A maximum thread line deflection of 2° to 5° at the measuring head has to be real-

ized:
- Outlet angle (A) has to be adjusted on the winding machine.
- Feeding angle (B) can be adjusted to either 2° or 5°.
See Chapter Maintenance 7.4.5.
-
A
correct 2° - 5° incorrect
2° - 5°
no deflection of 90°
B
Fig. 6.22.2 Yarn Deflection at the CMT5 iMH
®
6.22.3 Yarn Position - Calibration Mode

While “Prepare calibration” the yarn is inserted in the eyelet (3).
2a 2b
Fig. 6.22.3 Yarn Position - Calibration Mode
1 Feed the yarn in the thread guide.

2 Push the yarn between the two tensioner disks (2a) backwards until the yarn is
behind the eyelet hook (2b).
3 Lay the yarn into the right eyelet (3).
4 Fix the yarn around the spindle.
5 Start winding machine
®
6.22.4 Yarn Position - Measurement Mode

After the calibration is done the status line shows: ‘Please insert yarn and start the
winding position’.
− At that stage move the yarn with a metallic tool (for instance an Allen Key or a
screw driver) from eyelet (3) into the measuring slot and eyelet (5).
− Start measurement.
Fig. 6.22.4 Yarn Position – Measurement Mode
WARNING
Do not use fingers to move yarn from one eyelet to the other eye-
let. The yarn is running with high speed and therefore severe inju-
ries on fingers can result from ignoring this warning.
®
6.22.5 Adjustment of Yarn Tensioner

Yarn tensioner is provided with two different springs.
Fine yarn: Spring light colour (nickel) ≤ 60 Nec.
Course yarn: Spring metallic colour > 60 Nec.
The used yarn count determines the force of the yarn tension (cN) which has to be
set on the tensioner. The force of the yarn tension should be between 1.2 cN/tex
and 2.0 cN/tex. The table below helps to determine the recommended force.
cN
2.0 cN/tex
1.2 cN/tex
32
tex
Nm
Ne
Fig. 6.22.5 Adjustment Yarn tensioner
The tensioner for a 20 tex yarn has to be set up with 32 cN (see example in dia-
gram above). The yarn is running in eyelet right side. Use the tensiometer to
measure the force. Adjust the force of 32 cN by turning the spring alignment (1)
clockwise / counterclockwise.
Note
When testing yarns, it is necessary, that at least one of the disks is
rotating. However, a constant speed is not required and it can
happen that for very short times both disks stop.
Always clean the tensioner with compressed air before adjusting

the tensioner and/or before starting a new test. See chapter
Maintenance 7.4.
®
6.23 Operation of the CMT5-CCU

The operation of the CMT5-CCU primarily contains setting parameters for the wind-
ing machine, calibration process and starting of a measurement. The operation of
the CMT5-CCU can be carried out as well from the CMT5-CU via ‘Remote CCU’.
See figure below.
Fig. 6.23 Remote CCU Operation
The operation of the CMT5-CCU is done via touch screen. The presentation of the
user interface looks similar on both Units.
6.23.1 Layout of the CMT5-CCU Screen

A
Display window
Fig. 6.23.1 Layout CMT5-CCU Screen
A Main menu D Tabs

B Function Keys E Status line
C Sub menu
Operation
Call-up the desired main menu, the sub-menu and the desired function or register
card with a manual touch.
Display window
The display window shows all the information for the selected menu and provides
an entry field and check box.
Status line
Shows information about the current status of the CLASSIMAT 5 installation such
as program version, GUI status, USB connection, date / time, and access right.
®
6.23.2 Main Menu

Displays
Viewing yarn fault events, yarn fault alarms and quality data,
log book.
Reports
Configuration of the printed reports, display of the clearer and
quality data, event and special reports.
Service
Call up of different service functions for checking the system.
Start-up
Basic settings of the installation.
6.23.3 Function Keys

Alarm
Display of textile and technical Alarms.
Login
Password entry.
Help
Information about Key functions and Abbreviations are availa-
ble.
Information
i Function keys are selectable at any time independent of the cur-
rent open menu.
®
6.23.4 General Icons

Control keys
O.K.; Confirm entry

Save changes
Reject entry
Changes aborted
Leave dialog
Function keys
Entry possible
Entry not possible

The necessary access right has not been granted.
Navigation keys
To the beginning of the list
Go up quickly
One line up
One line down
Go down quickly
To the end of the list
®
Check box
Entries not possible, requires password,
Display only.
Function deactivated, entry possible.
Function activated, but not saved.
Function activated.
Function deactivated, but not saved.
Radio button
Option inactive
At a time only one choice possible.
Option active
Alphanumeric entries
Write the desired text / number by clicking on the relevant characters, and then
confirm them with the OK key.
Moves the cursor to the beginning or the end of a line.
Moves cursor by one character either to the left or to the right.
Shift key for capital letters.
Caps lock for writing capital letters permanently.
Reject changes.
Backspace
Clear entry
®
Numeric entries
Reset to 0
+ 1 unit
- 1 unit
OK key to confirm entry
Reject entry
The input parameter and the valid value range are displayed.
Enter the desired value and confirm with the OK key.
List field
Press field again to close the list

without any modifications.
Current value is shown in red color.
Press the key with the desired value.
Toggle button
To toggle press field.
e.g. relative / absolute
®
Display extent of current or last shift / article
The data of the whole machine is displayed in the machine selection.
The spindle selection shows in the header the status, the group and the assigned
article. The data include the values of the selected winding position.
Login
Different user levels permit only authorized staff to modify settings and release ac-
tions.
No access right
Polykey not inserted / no password entered

− All displays are accessible.
− Functions which can only be modified with the "Operator", "Master" or "Service"
access right are displayed in grey.
[O] Operator level (Operator)
Password: 123 [Operator] = Password entered
Enables following functions.

− iMH reboot.
[M] Master (Level 2)
[Master] = Polykey inserted

Password: 1491 [Master] = Password entered
Polykey inserted or password entered.

− Enables alterations to settings
[S] Customer Service
®
Password: 6281 [Service] = Password entered
Enables following functions.

− Access to service functions is possible.
Reset access right

To reset a set access right
− Remove the master Polykey.
Press the key on the Login dialog.
Change passwords
To change a password
− Press the key on the Login dialog.
− Enter the new password for the user level to be changed two times and confirm.
Information
i Only the password of the active and lower access level can be changed. The
operator cannot change his password.
Forgotten passwords can only be reset by the Uster Service or an Initial start.
The access right necessary for a function is displayed with the following sym-
bols: for operator, for master and for customer service.
®
6.24 Menu Structure (CMT5-CCU)

Main menu Sub Menu Refer to Chapter
Data Display Summary  6.25.1
Yarn Faults  6.25.2
Textile Alarms  6.25.3
Special Counters  6.25.4
Q Data NSL/T / F / VEG Classes  6.25.5
Imperfections (IP)  6.25.6
NSL/T Scatter Plot  6.25.7
FD / FL or PP Scatter Plot  6.25.8
VEG Scatter Plot  6.25.9
Logbook  6.25.10
Main Menu Sub Menu Refer to Chapter

Reports Store a Report to an USB-Stick  6.27.1
Special Reports  6.27.2
Event Reports  6.27.3
Configuration  6.27.3.1

Service iMH  6.29.1
System Info  6.29.2
Special Functions  6.30

Start up System Settings - General  6.28.1
System Settings - Customer  6.28.2
System Settings - Hardware  6.28.3
Machine Settings - Machine  6.28.4
Machine Settings – Address Settings  6.28.5
Machine Settings – Display iMH  6.28.6
Options  6.28.7
®
6.25 Main Menu – Data Display (CMT5-CCU)

6.25.1 Summary
Graphic display of the events per winding position.
Fig. 6.25.1 Summary
Red vertical line = selected winding position

Black horizontal line = average value of group
Graphic display of the events per winding position.
Category Feature
Length km
Yarn faults YF, YF, YJ, N, S, L, T, Cp, Cm CCP, CCm, CY, PF, FD, FL, PP,
VEG
Operation
1 Select category and feature.
2 Select current or last shift.
3 Select relative or absolute display.
4 To see the current numeric values touch the desired winding position or select with
key.
5 Up to eight functions can be stored as a favorite by pressing key. A Favorite
can be removed by selecting the function and then pressing key.
®
6.25.2 Yarn Faults

Display of all yarn faults of the machine or a winding position over the selected pe-
riod.
1 - 12
Fig. 6.25.2 Yarn faults
Setting
• Values for the machine or for a winding position
• Period: current, current / last shift or current / last lot
The "current" counters are reset with

• Shift change
• Article change
Length wound length of the machine, group or winding position

• YF Sum of all yarn faults
• YB Natural yarn breaks
Warning
The relative values are not reliable because the configured length / time are not
reached. The unity for the relative values can be configured. See chapter 6.28.1.
®
6.25.3 Textile Alarms

Display of all yarn faults of the machine, a group or a winding position over the se-
lected period.
Fig. 6.25.3 Textile alarms
Setting
• Values for the machine, for a group or for a winding position
• Period: current, current / last shift or current / last article
The "current" counter is reset with

• Shift change
• Article change
• Clear counters of a group
Warning
reached. The unity for the relative values can be configured. See chapter 6.28.1
®
6.25.4 Special Counters

Display of cuts triggered by one of the special monitoring functions or by the wind-
ing position over the selected period.
1 - 12
Fig 6-11-4 Special counters
Category Feature
DWM Drum wrap monitoring
DWM reg Drum wrap registration
DWA Drum wrap alarm
DSM Drum signal monitoring
ZPM Zero Point monitoring
SPC Special cuts
U Upper yarn cuts
A Machine-associated additional cuts
JPM Yarn jump monitoring
JPM reg Yarn jump registration
JPA Yarn jump alarm
Setting
• Values for the machine, for a group or for a winding position
• Period: current, current / last shift or current / last article
The "current" counters are reset with

• Shift change
• Article change
• Clear counters of a group
Warning
®
6.25.5 Q Data – NSL/T / FD / FL / VEG Classes

Display of the classifications:
• of the whole machine without clearing limit
• of a group with clearing limit
• of a winding position with clearing limit
1 - 12
Fig. 6.25.5 Q Data – NSL/T / FD FL / VEG Classes
Clearing limit
Remaining or
cut yarn faults
Total yarn faults

Display of cuts or remaining faults can be configured. See chapter 6.28.1
Settings
• Machine, group, winding position
• absolute, relative per 100 km
• Period: current, current / last shift or current / last test parameters
Warning
Information
i The data of the winding positions are deleted at power failure.
®
6.25.6 Q Data – Imperfection (IP)

Display of the last measurement over the evaluation length with date and time of:
• Neps / 1000 m of all classes per winding position
• Thick places / 1000 m of all classes per winding position
• Thin places / 1000 m of all classes per winding position
• Time of record
• No data available at present.
Display of the group mean value MV of all imperfection classes of the running shift.
GR 1
Fig. 6.25.6 Q Data - Imperfection (IP)
The result of the Imperfection classes will be marked in color in case of set alarm
limits for certain classes.
• green Alarm limit set but no alarm
• red Alarm, the set limit has been exceeded
The numbers of IP events are always converted to a length of 1000 m independent

of the selected evaluation length.
Information
i The data of the winding positions are deleted at power failure.
®
6.25.7 Q Data – NSL/T

Display of the yarn body and the event dots.
For each group / winding position the last events NSL/T, J are displayed as indi-
vidual dots on the classification matrix.
GR 1
Fig. 6.25.7 Q Data - NSLT / scatter plot
Settings
• Selection of group or winding position
• NSL/T
• Density: 25%, 50%, 75% or 100% of the memorized events are displayed.
Clearing limit
Red dots are cut yarn faults.
Green dots are remaining events.
Yarn body variation
Yarn body
Cuts will increase extremely if the clearing limit is laid within the green area.
Displayed values per channel

km Winding length represented in the scatter plot
/100km Expected number of cuts / 100 km
Information
i All dots are deleted at power failure.
®
6.25.8 Q Data – FD / FL or PP Scatter Plot

Display of the Dense area and the event dots.
For each group / winding position the last events FD, FL or PP are displayed as in-
dividual dots on the classification matrix.
GR 1
Fig. 6.25.8 Q Data - NSL/T / J scatter plot
Settings
• FD / FL or PP
Clearing limit
Red dots are cut yarn faults.
Blue dots are remaining events.
Dense area

Information
®
6.25.9 Q Data – VEG Scatter Plot

Display of the Dense area and the event dots.
For each group / winding position the last VEG events are displayed as individual
dots on the classification matrix.
GR 1
Fig. 6.25.9 Q Data – VEG scatter plot
Settings
• VEG
VEG clearing limit

Brown dots are remaining vegetables.
Dense area

Information
®
6.25.10 Logbook
The logbook registers the last 100 setting alterations as well as Yarn faults and
quality alarms and it’s acknowledge. Every entry is registered with date and time.
Selection of Logbook
Fig. 6.25.10 Logbook
Event types
Information
Textile Alarm
Quality Alarm
Warning
Warning acknowledged
Warning disappears automatically
Technical Alarm
Alarm acknowledged
Technical alarm disappears automatically
®
6.26 Main Menu – Alarm (CMT5-CCU)

6.26.1 Technical Alarms and Warnings
Displays the technical alarms which have occurred during operation. Each individ-
ual alarm is displayed with date and time and registered in the Service Logbook.
Fig. 6.26.1 Technical alarms
Deleting a technical alarm or technical warning

• Remedy the disturbance causing the alarm
• Select the alarm / warning and acknowledge with <Acknowledge alarm>.
• In case of an alarm on successive winding positions: press the <Acknowledge
SP x> key to delete the alarm on a specific winding position.
Alarm types
Warning
Technical Alarm
®
6.27 Main Menu – Reports (CMT5-CCU)

Report output containing settings and production data of a group over a certain
time period.
The report can be either printed on the external printer or stored to an USB-stick
plugged to the CMT5-CCU. If the report is stored to an USB-stick, depending on
the extent of the report one or more graphic files (format *.png) are created. Each
graphic file represents a DIN A4 page which can be viewed or printed on a PC.
Report variants:
• Special reports
Predefined reports giving information on the installation settings. See chapter
6.27.2.
• Event report
Selectable for the whole machine, per group or per winding position. Continu-
ous display of all yarn fault and textile alarm events. See chapter 6.27.3
6.27.1 Procedure to Store a Report to an USB-Stick

1 Insert the USB-stick to the CMT5-CCU
2 Press the key of the required report and confirm.

3 To store the report press the <USB> key.
4 Wait until the "Done!" message appears.

5 Remove memory device or call up further reports
Report file
The report files will be stored to the subdirectory "UsterReports". The file name is
automatically created and structured as follows:
Rep_MachName_yyyymmdd_hhmmss_Report name_0.png
Rep = Report
MachName = Machine name.
Yyyymmdd = Date year, month, day
hhmmss = Time hour, minute, second
Report name
Setup = Report Structure
Service = Service
LBCient = Logbook
LBService = Service Logbook
0 = Page 1, 1 = Page 2, etc.
png = Portable Network Graphics
®
6.27.2 Special Reports
Fig. 6.27.2 Special reports
The content of following reports is printed out immediately:
Report Content
Test Parameter Parameters (clearing limits, alarm limits, Q parameters)
Start-up Report of Machine data, available Options, Network config-
uration and Shift change times
Service Summarized report of all important installation and setting
data
Event report Report of the last 10, 25, 50, 100 or all selected entries
Logbook Report of the last 10, 25, 50, 100 or all logbook entries
Service logbook Report of the last 10, 25, 50, 100 or all logbook entries
®
6.27.3 Event Report

6.27.3.1 Configuration – Event Report
Fig. 6.27.3.1 Configuration - Event report
Procedure:
1 Select desired range (machine, group or winding position).
2 Select group or range of winding positions.
3 Printout:
Normal* = display and printout
NO = display only
Paper feed on alarm* = to wrap the print out around the bobbin.
4 Switch event groups on or off as desired.
Information
i
• Only active with an external printer.
• Other: Special cuts, cops change, cone change and yarn breaks
• Independent of the settings events selected with the function "iMH LED
display" is also displayed in the event report See chapter 6.30.2 .
®
6.27.3.2 Print/Display – Event Report

The selected events are printed out and/or displayed with date, time and winding
position information. Yarn faults are also displayed showing the size/intensity in %
and length in mm, as well as their classification.
Fig. 6.27.3.2 Print/Display - Event report
The data display is updated every ten seconds if the display is on the first line.
The events which should be displayed have to be selected in the menu Configura-
tion – Event report. See chapter 6.27.3.1.
Information
i All entries are deleted at power failure.
®
6.28 Main Menu – Start up (CMT5-CCU)

6.28.1 System Settings – General
Fig. 6.28.1 System Settings - General
Language
Language changes become effective immediately without saving.
Settings: German, English, French, Italian, Spanish, Portuguese, Turkish, Chinese,
Vietnamese
Count system
Settings: Nm, Nec, New, Tex
Classification display
This setting determines the meaning of the upper class value in the display Q Data
– Classification NSL/T / FD / FL / VEG
Settings: Remaining events / Total events or
Cuts / Total events
Values relative
Settings: /10 km, /100 km or /1000 km of the wound length since article start.
6.28.2 System Settings – Customer
Fig. 6.28.2 System Settings - Customer
The complete mill address has to be entered. The address will appear in all printed
reports
®
6.28.3 System Settings – Hardware
Fig. 6.28.3 System Settings - Hardware
Network
• IP address
Address of the CMT5-CCU in the network. The address must be assigned by
the network administrator.
xxx.xxx.xxx.xxx xxx = 0 to 255
• Subnet mask
Network configuration
System clock
Date and time are set by the CMT5-CU.
Display
• Screensaver
• The brightness of the monitor lighting is reduced after the set time.
Setting: 1 to 60 min 0 min = switched off
• At the first touch the selected action will not be carried out, only the monitor light
will be activated.
• Brightness
The brightness keys control the lighting of the monitor.
• On low set brightness the different to reduced brightness is hardly visible.
®
6.28.4 Machine Settings – Machine
12
Fig. 6.28.4 Machine settings - Machine
Machine type
The system provides special functions for the set machine type. ---- is a default set-
ting and prevents the winding positions from starting up. This is to ensure that the
user makes (enters) the machine type settings.
Settings:
Select the corresponding machine type from the list.
---- = no Machine type selected
Machine name
The machine name is a customer-specific entry with up to a max. of 10 figures. The
machine name entry is optional.
Spindles
Entry of the number of winding positions.
Spindle numbering
Direction of spindle numbering
Setting: "left  right" or "left  right"
The graph at the display – Summery and – iMH are adapted to the num-
bering direction.
®
6.28.5 Machine Settings – Address Settings iMH (Service)

Addressing at start-up or after replacing the iCSA
Each iMH must have an individual address in order to be able to exchange infor-
mation with the CMT5-CCU.
The address must be determined with this function. The address will be stored on
the clearer spindle adapter iCSA.
12
Fig. 6.28.5 Machine settings – Address settings iMH
Procedure:
1 Enter the address range of the iMH to be readdressed by calling up the iMH ad-
dress setting function.
2 Start addressing process and confirm with <X>. Status switches to running.
3 Press the first iMH button of the address range for 2 sec.
4 Continue pressing (2 sec) rest of iMH buttons in series.
Each address which becomes active increases the Active address counter by 1.
When all iMH’s of the address range have been given an address, the State
changes from running to ---. Addressing is finished.
5 Exit menu with
6 Check address
Start addressing test with the key. The LEDs of the iMH of all
the winding positions have to flash sequentially
®
6.28.6 Machine Settings – Display iMH Types
10
Fig. 6.28.6 Machine settings – Display iMH types
The installed iMH’s are automatically recognized and displayed per group. The
display is not valid until the iMH is switched on for the first time.
®
6.28.7 Options
Information
i Deactivated Options. Do not transmit data to CMT5-CU.
®
6.29 Main Menu – Service (CMT5-CCU)

Support with troubleshooting. The functions / displays described in the following
are intended for the service technician. The user can also gain access in order to
be able to provide the service technician with important information. The service
functions have no direct influence on the yarn inspection.
Access to some of the service functions/displays is only possible via the "Customer
Service" access level.
Following service functions / displays are available:
State of iMH
System Info
Special Function Yarn detector
Special Function Test function
Special functions iMH LED display
Special-Function SW Update
®
6.29.1 iMH
Displays the current state of each iMH as well as the individual parameters regard-
ing communication, configuration and ADMV.
Gr 1 12
12
Fig. 6.29.1 Service – iMH
Statistic of the communication between iMH and CMT5-CCU.
iMH data regarding hardware, software and application.
Only visible for Uster Service
Fehler! Verweisquelle konnte nicht gefunden werden. Yarn-specific average values and the
number of start-ups (max. 200) per group and winding position in production.
Data regarding hard and software of the machine interface
Individual or a range of iMH’s can be deactivated giving a reason. Winding posi-

tions with deactivated iMH no longer start up. All alarm functions are switched off.
Possible reasons are:
• SP defective
• iMH defective
• preventive maintenance
• other reasons
12
If an iMH reset is triggered, the iMH cuts. Then the iMH software is checked and
started. The article parameters are reloaded. All winding position related measur-
ing values are reinitialized. After a second cut the winding position is ready for op-
eration again.
An iMH reset should be triggered when
• adjustment was carried out with wrong yarn.
• the winding position doesn’t start up.
®
6.29.2 System Info

Versions
Display of installed program version.
Miscellaneous
Display of date and time of system starts, CMT5-CCU Board information
Display of CMT5-CCU parameters
GUI connection
Display of GUI connection state.
This value is set automatically with the selection of the winding machine and
should remain unaltered.
Special Function – Yarn detector
Displays the iMH type, YD sensitivity, YD increment and YD decrement for each
group. YD delay is the time during which the yarn detector remains blocked after
the yarn is laid in.
Setting range: 0 to 1000 (1 step = 4 ms)
This value is set automatically with the selection of the winding machine and
should remain unaltered.
®
6.30 Special Functions (CMT5-CCU)

6.30.1 Special Functions – Test Functions
6.30.1.1 Touch-Screen
The touch screen has to be recalibrated if the cursor arrow fails to return to the po-
sition which you touch with your finger.
Test touch
Procedure:
1 Tap the <test touch> key.
2 Press the touch screen on different places. The cursor arrow has to move to the
positions which have been pressed.
3 Quit test with key .
Information
i The calibration will automatically be rejected if the configuration is not made
within 60 seconds.
Calibrate touch
Procedure:
1 Tap the <calibrate touch> key.
2 Tap on the displayed positions 1 to 3 exactly on the symbol.
Finally, the display “calibration finished” appears.
3 Confirm with or reject with .
6.30.1.2 Reboot CMT5-CCU
Warmstart
If a warm start is activated the CMT5-CCU reacts in the same way as when the
mains voltage is switched off and on again.
The following data are thereby deleted: Scatter plot, single spindle classification
(class alarm), IPI classification, and messages in the event report.
When a cold start is triggered all acquired production data are deleted.
When an initial start is triggered not only the settings but also all acquired data are
deleted. The settings are reset at the factory default settings.
®
Warm start, cold start, and initial start must be carried out only when necessary
and with due caution.
Check address of all iMH
Start addressing test with the key. The LEDs of the iMH of all
the winding positions have to flash sequentially for three seconds.
6.30.2 Special Functions – iMH LED Display

The purpose of this function is to allow certain events to be displayed on the iMH
LED. On some winding machines there is the possibility of stopping the winding
position when the selected event occurs (test mode).
The iMH LED display function can be assigned to the whole machine, one group or
several winding positions.
When the programmed Event occurs:

• The iMH cuts
• iMH LED flashes according to the selection
• The Event will be listed in the event report.
• Red winding position lamp lights up continuously.
Restarting winding position:
• Press the start button on the winding position.
• After a splicing cycle the winding position starts up again.
Procedure:
1 Select , or .
2 Enter range and cut type for the display variant or SYD/DYD and con-
firm.
11 11
3 All selected iMH-LED functions will be listed.
11
State display of the static SYD and dynamic DYD yarn detector.
No yarn in the measuring zone  LED
SYD Stationary yarn in the measuring zone  LED
Non or stationary yarn in the measuring zone  LED
DYD Running yarn  LED
®
With the function SYD / DYD the winding position will not be stopped.
Change or delete function:

4 Select line, press key "Change" or "Delete".
5 Make changes and confirm action.
6.30.3 Special Functions – SW Update

The procedure for a data backup and software update are described in the operat-
ing instruction. We recommend calling an Uster service engineer to carry out soft-
ware updates.
®
6.31 Save Screen Contents (CMT5-CCU)
The CMT5-CCU offers the possibility to make screen shots from the actual screen
and save the content on a USB-stick.
Procedure:
1 Insert the USB-stick to the USB connector.
2 Press on the logo on the right hand bottom of the screen.
3 Press "Save screen contents to USB".
A Portable Network Graphics (png) file with the screen content is stored to the
subdirectory "UsterScreens" of an inserted USB-stick.
The file name is automatically created and structured as follows:
Screen_Machine name_yyyymmdd_hhmmss.png
4 Wait until the “Done!” message appears. The USB-stick can now be removed.
The saved screen content can be edited on a PC.
Information
i •
•
It is possible that the saving is not successful with all type of UBS memory
sticks.
There is no message if the USB memory stick is full.
®
®
Operating Instructions Maintenance 7
Contents
Page
7 Maintenance 3
7.2 Maintenance schedule 3

7.2.1 Weekly checks 4
7.3 Maintenance on the Sensor 5

7.3.1 Cleaning of the Measuring Zone 5
7.3.2 Cleaning Tools 6
7.3.3 Cleaning Solvent 7
7.3.4 Cleaning Procedure 8
7.3.5 Maintenance on the Cutting Device 9
7.3.6 Replacement of Yarn Guides 10
7.4 Maintenance on the Yarn Tensioner 12

7.4.1 Cleaning procedure Yarn Tensioner 12
7.4.2 Checking Tensioner Disks 13
7.4.3 Checking Safety Screw on Spring Alignment 13
7.4.4 Checking Jet 14
7.4.5 Yarn Deflection 2° / 5° 15
7.5 Replacement of Battery 16
®
7 Maintenance Operating Instructions

®
7 Maintenance

®
The USTER CLASSIMAT 5 is an electronic classing system which measures the
running yarn with a high accuracy. In order to guarantee the correct operation of
the product and, therefore, a constant quality control of the produced yarn it is re-
quired to check the sensors of the monitoring system regularly.
®
Regular inspection of the USTER CLASSIMAT 5 installation at recommended in-
tervals will ensure the reliability of the classing system to the user.
The work described in this chapter is to be carried out by trained maintenance per-
®
sonnel of the customer or by an USTER service technician.
7.2 Maintenance schedule

®
The design and construction of the USTER CLASSIMAT 5 installation has been
aimed in particular at minimum maintenance requirements.
Note
The cleaning intervals depend very much on the degree of the
contamination in the yarn.
Perform at least weekly maintenance as described hereafter.
Note
If yarn with a high content of honey dew or other kind of dirt con-
tamination, or if the installation is operated in a contaminated envi-
ronment, then the maintenance intervals must be shortened ac-
cordingly.
®
7.2.1 Weekly checks
Checks Procedure
Cutting device - When the equipment is in still stand mode then insert
double thread into the measuring zone and cut the
yarn by pressing the reset button on the CMT5 iMH.
For this check a customer’s thread can be used.
- The double thread must be cut cleanly by the knife.
- Check the exact reset position of the knife.
- Check for dust and deposits
If necessary, the cutting device must be cleaned or the

knife replaced. See also Chapter 7.3.5
Yarn guide - Check the measuring heads for missing or defective

ceramic eyelets (yarn guide).
If necessary, ceramic eyelets or yarn guide plates

should be replaced immediately. See also Chapter 7.3.6
Yarn path - The correct laying-in of the yarn has to be checked.

- The yarn should be running on the base of the three
ceramic eyelets.
Cable mounting - After replacing a CMT5 iMH, make sure that the ca-
bles do not worn
- contact with moving parts of the machine or with
running yarn.
- Worn cables result in malfunctions and failures.
Blowing device - Check air pressure and blowing effect during a test
run.
- The maintenance unit should be checked and
cleaned as required.
- Check clean air direction of air
Tensioner disk - Check tensioner disks

- Check air guidance
If necessary, tensioner disks should be replaced imme-
diately. See Chapter 7.4
®
7.3 Maintenance on the Sensor

Capacitive sensor
Under normal circumstances a cleaning of the capacitive measuring zone is not
required. The cleaning is carried out by the running yarn. Remaining contamina-
tions of the measuring zone are compensated by the electronic circuits.
Foreign matter sensor

Deposits of dirt in the foreign matter measuring zone interfere with the foreign mat-
ter detection function. Compared to clean measuring zones, dirty foreign matter
measuring zones display much higher foreign matter classifications. The soiling
can be caused by gassed yarns, synthetic yarns treated with spinning aids or syn-
thetic blended yarns etc.
7.3.1 Cleaning of the Measuring Zone

We recommend cleaning the measuring zone:
• if there is strong evidence that the measuring zone is contaminated,
• if some individual clearers have high or low foreign fiber counts or foreign fiber
cuts,
• if individual clearers have increased cuts in basic clearing,
• if the winding position does not start up.
Dirty measuring zones must be cleaned according to the following instructions.
®
7.3.2 Cleaning Tools
WARNUNG
Caution: Hard metallic tools
The cleaning of the measuring zone with hard metallic tools such as
screw drivers, knifes, scissors, etc. may damage the measuring
zones mechanically and electrically as well the ceramic eyelets.
Tools for clogged measuring zones
Cleaner for contaminated

measuring zone *
Cleaning brush*
Tools to clean dirty measuring zones
Pipe cleaner *
Cotton sticks
Cotton yarn bundle of fab-

ric strip
* Available in the cleaning set for each delivery.
®
7.3.3 Cleaning Solvent
WARNUNG
Caution: Cleaning solvents which are not allowed
Do always clean with brush or pipe cleaner before using solvents.
Cleaning of the measuring zones with cleaning solvents such as al-

cohol, ethanol and nitro derivatives can cause irreversible damage of
the clearer.
When using cleaning solvent, disconnect power from CMT5 iMH.
An optimum cleaning solvent:

• can remove the contaminations,
• does not destroy the plastic parts of the measuring zone,
• does not destroy the metal case,
• evaporates very quickly after cleaning
• leaves no residue.
Recommended cleaning solvent
Cleaning liquid Contents: Water with a few drops of detergent

Sales organizations: Department store
Application: Mainly for paraffin cotton. Removes deposited
micro dust and honeydew very well.
The measuring zone must be dried after cleaning with a

cloth or yarn.
Lighter fluid Product name: Zippo

Contents: Naphtha, Petroleum distillate, petroleum ben-
zene
Sales organizations: Kiosks, drugstores
Application: Mainly for dyed yarn
Caution: flammable
Keep away this cleaning solvent from fires or ignition sys-
tems.
Do not smoke. Keep away from children.
Caution: May endanger the health of the operator
Do not swallow solvent. Do not inhale vapor
Notice hints on the box of the product
Window cleaning agent Contents: Water with a few drops of detergent

Sales organizations: Department store
Application: Mainly for paraffin cotton. Removes deposited
micro dust and honey dew very well.
Cleaning agent must not contain any alcohol

The measuring zone must be dried after cleaning with a
cloth or yarn.
®
7.3.4 Cleaning Procedure

If the measuring zones are to be cleaned without removing the CMT5 ’s from the
machine, then the installation must be switched off.
1 Sprinkle cleaning liquid to the cleaning tool.

Shake off excess liquid.
2 Remove yarn guide, yarn guide plate out and

eyelet. See Chapter 7.3.6.
3 Move moistened pipe cleaner 10 times back

and forth through the measuring zone. Make
sure that the bottom of the measuring zone
also gets cleaned.
4 Use a dry pipe cleaner or cotton bud to con-

tinue cleaning and also to dry the area. The
measuring zone must be completely dry.
Do not use compressed air to dry the

measuring zone.
5 Make a check with the help of a magnifying

glass that the measuring zone is now clean.
®
7.3.5 Maintenance on the Cutting Device

The knife in the CMT5 iMH must be replaced if
• the schedule check shows that a double thread is not cut completely,
• one winding position shows repeatedly ‘Cutter alarm’ on the CMT5-CCU.
CAUTION
Caution: Knife
The knife must only be replaced if the CMT5 iMH is disconnected.
• Use a T10 (Torx) screwdriver to unscrew or tighten the fastening screws.
T10
Cover
Knife
Plunger
T10
Fig. 7.3.5 Knife replacement
Procedure:
1 Remove cover screw, Torx T10.
2 Remove dust and fibers with vacuum cleaner.
3 Cutter which is worn out has to be removed by lifting from plunger.
4 New cutter has to be moved to the correct position on the plunger.
5 Fasten cover.
6 Carry out cutter check.
®
7.3.6 Replacement of Yarn Guides

If a ceramic eyelet of a CMT5 iMH is missing or damaged, it has to be replaced
immediately.
CAUTION
Caution: Screws, yarn guides
Use only screws from the original equipment manufacturer! Order

these screws via the local service station.
All screws at the CMT5 iMH are TORX type screws. Use the TORX
screwdrivers of the correct size. The size is indicated by Tx.
Before turn in a TORX screw, rotate the screw counterclockwise up

to a full rotation until the screw matches with the thread (hearable or
noticeable) now tighten carefully the screw clockwise.
Position of the ceramic eyelets

Ceramic eyelet at yarn input side
Guiding elements
Ceramic eyelet at yarn output side
Guiding element
The ceramic eyelets are positioned at the correct place by means of the guiding el-
ements.
Yarn output side

Eyelet (1) Yarn guide
Eyelets (2)
Yarn guide plate out (3)
T8
Fig. 7.3.6-a Yarn output side
Replacement procedure:
In order to replace the ceramic eyelet, the ‘Yarn guide’ has to be removed.
In order to replace the eyelets (2) the complete ‘Yarn guide plate out’ (3) has to be
replaced.
®
Yarn input side
Yarn guide
Knife
Anvil
Cover Eyelet
T8
T10
Fig. 7.3.6-b Yarn input side
Replacement procedure:
In order to replace the ceramic eyelet, the cover and the yarn guide has to be re-
moved.
®
7.4 Maintenance on the Yarn Tensioner

7.4.1 Cleaning procedure Yarn Tensioner
To clean tensioner use compressed air by means of the safety air gun (1) provided.
WARNING
Dirt particles coming loose when you are working with compressed
air.
Danger of injury for eyes and unprotected skin areas during clean-
ing work with compressed air.
Do not use compressed air:

- to clean human body parts or clothes
- if the parts are heavily polluted (pre-cleaning, e.g. with
vacuum cleaner!).
Always wear the safety goggles provided and ear protectors (not
provided) during cleaning work with compressed air.
Fig. 7.4.1 Cleaning tensioner
Note
Clean the tensioner always before adjusting the tensioner and
before starting a new test.
CAUTION
Do not use compressed air to clean the measuring zone of the
CMT5 iMH.
®
7.4.2 Checking Tensioner Disks

Check tensioner disks for wearing, grooves or bendings, if necessary replace the
disks. To check the disks for bending illuminate the disks with a torch, there must
be no gab visible. Another way to check the planarity is to put the disk on a table
with a straight surface, also here no gap may be visible between disk and table.
Assembling order of the disks see fig. 7.4.2
1
2 3
4
5
4
6
Fig. 7.4.2 Assembling tensioner disks
7
8
9
1 Shaft
2 Steel washer
3 Rubber washer
4 Tensioner disk
5 Eyelet with hook
6 Disk
7a Spring for yarn count ≤ 60 Nec  0.5x11x22.4mm
7b Spring for yarn count > 60 Nec  0.42x11x22.4mm
8 Safety screw
9 Spring alignment
7.4.3 Checking Safety Screw on Spring Alignment

Occasionally the safety screw (2) of the spring alignment (3) has to be retightened
or if necessary it has to be replaced.
Fig. 7.4.3 Checking safety screw
®
7.4.4 Checking Jet

The three holes of the Jet (1) must be free of dirt and the air blast must be directed
towards the center of the yarn tensioner.
Clean with vacuum cleaner first and only afterwards use compressed air.
After cleaning of the Jet check the air blast direction which is directed to the center
of the tensioner disks.
1
Fig. 7.4.4-a Tensioner front view Fig. 7.4.4-b Tensioner side view
®
7.4.5 Yarn Deflection 2° / 5°

Depending on the yarn it may be helpful to change the yarn deflection from 2° to 5°
or vice versa, in order to avoid strong fluff accumulation in the yarn tensioner.
When changing the yarn deflection, then the Jet must be adjusted as well, to en-
sure, that the air blast is directed to the center of the yarn tensioner
The adjustment has to be carried out with the Guidance Tool provided.
edge for 2° angle adjustment

2° 5°
edge for 5° angle adjustment
Fig. 7.4.5-a Guidance Tool for Jet adjustment
Adjustment procedure
1. Loosen a bit screws (1), (2) and (3) (comply this order).
2. Push tool (6) onto the shaft of the yarn tensioner as far as it will go (6a).
3. Position edge of tool (2° or 5°) together with Jet and Link to the edge of the
support (7). See Fig. 7.4.5-b for 2° and Fig. 7.4.5-c for 5°.
4. Align Tool (6) with Jet (4a), Link (5b) and Shaft (8c) see Fig. 7.4.5-d.
5. Tool, Jet, Link, and Shaft must be hold with the edge of 2° or 5° to the support
(7), as described under steps 2-4 and tighten with screws (3), (2) and (1) (com-
ply this order).
1) Screw M3 Positioning 2° Positioning 5°

4 4
2) Screw M5
5 5
3) Screw M5
4) Jet
5) Link 1 1
6) Guidance 2
Tool 2 6
6
7) Support 3 6a 3 6a
8) Shaft
7 7
Fig. 7.4.5-b Tool positioning 2° Fig. 7.4.5-c Tool positioning 5°
4a
5b
8c
8
6
Fig. 7.4.5-d Alignment of Tool, Jet, Link and Shaft with Support
®
Checking of the eyelet hook position

After the adjustment of the air jet or after replacement of the tensioner disks check
the eyelet hook position. The correct position of the hook is in front not at the back.
See picture below.
incorrect
correct
Fig. 7.4.5-f Eyelet hook position
7.5 Replacement of Battery

CMT5-CCU
If the battery is empty, the warning ‘Replace battery!’ is displayed at the CMT5-
®
CCU. Don’t switch off the CMT5-CCU and call USTER Service.
®
Operating Instructions Troubleshooting 8
Contents
Page
8 Troubleshooting 3
8.1.1 Personnel Qualification 3
8.1.2 Safety Information 3
8.1.3 General Information 3
8.2 Faultfinding and Troubleshooting 4
8.2.1 Troubleshooting Procedure 4
8.2.2 Indications at the CMT5-CCU 6
8.2.3 Non-indicated Disturbances 8
8.3 Indications at the CMT5-CU 9
8.3.1 Error Message Displayed in the Status Bar 9
8.4 Replacement of Installation Components 11
8.4.1 CMT5-CCU 11
8.4.2 iCSA Quadgroup 11
8.4.3 CMT5 iMH 12
8.4.4 CMT5-CU 12

8 Troubleshooting Operating Instructions


8 Troubleshooting

The work described in this chapter is to be carried out only by authorized persons
who meet the requirements listed in the section ‘Personnel Qualification’ below.
8.1.1 Personnel Qualification

Authorized are persons with:
• Basic electrotechnical or electromechanical training
• Basic mechanical training
• Who have read and understood the safety regulations contained in Chapter 2.
8.1.2 Safety Information
CAUTION
Electrical circuit boards must only be serviced or repaired by
USTER® service technicians.
Components carrying voltages are accessible on opening the
housing of an electrical installation unit. Connection points can
also carry voltages.
It has to be ensured that only fuses of the specified type and rating
are used as replacements.
Using repaired fuses or short-circuiting the fuse holder is not al-

lowed!
8.1.3 General Information

Defective installation components are to be returned in suitable packing to the local
service center for repair, see Chapter 10.
Information
To prevent a loss of data, you should wait at least 30 seconds after
an entry or change before you switch off the CMT5-CCU. After
switching off the CMT5-CCU, wait at least 30 seconds before you
switch it on again.

8.2 Faultfinding and Troubleshooting

8.2.1 Troubleshooting Procedure
Introduction
Technical faults that occur on a USTER® CLASSIMAT 5 installation are indicated
at:
• CMT5 iMH see ‘Indications at the CMT5 iMH’

• CMT5-CCU see ‘Indications at the CMT5-CCU’
• CMT5-CU see ‘Indications at the CMT5-CC’
Aside from indicated faults, there are faults which are neither indicated nor dis-
played. These are faults that result in a total failure of the installation or in malfunc-
®
tioning of the winding tests, for example, in this case contact USTER Service.
Procedure for indicated Faults

If a fault is indicated at the CMT5-CCU, CMT5 iMH or alarm indicator, proceed as
follows:
1. Select the display of technical alarms at the central unit.

2. Acknowledge the alarm message by pressing the Acknowledge alarm key.
The alarm message disappears.
3. If the same alarm message reappears after a short time, look for the indicated
text in the first column of the table in the Chapter 8.2.2 (arranged in alphabeti-
cal order).
4. The table column Possible cause / explanation provides further information
about the indicated fault.
5. Follow the troubleshooting procedures proposed in the table column
Measures.
6. If an installation component is to be replaced, proceed according to the instruc-
tions in Chapter 8.4 ‘Replacement of installation modules’.
7. If the proposed measures are not successful, contact USTER® Service.
Note
®
Settings can only be made with the USTER Polykey plugged in or
with the password 1491 Master level.

Indications at the CMT5 iMH

Indications at the CMT5 iMH you find in Chapter 4.5 ‘Operating and Display –
CMT5 iMH’
Indications at the Operation Panel

There are different indicators at the central unit. These indicate textile and tech-
nical alarms and other operating conditions. A fault is indicated at the CMT5-CCU
by:
• POWER LED green (Operating status)
• ALARM LED red
• STATUS LED yellow
• Alarm displayed on the screen
• Service Logbook
Functions of the CMT5-CCU LED's
ALARM LED blinks:

Technical alarm occurred for one winding position or for the installation.
STATUS LED blinks:

Technical warning occurred for one winding position or for the installation.
POWER LED on: Supply voltage present

POWER LED off: No supply voltage
Alarm display
Service logbook

8.2.2 Indications at the CMT5-CCU
Displayed text Possible cause / explanation Measures

Blocked sensor / Clean measur- This alarm is given if the CMT5 iMH  Remove yarn bundle out of the
ing head measuring zone is blocked by material measuring zone.
(cotton balls).
Checksum error in CMT5 iMH program  Replace CMT5 iMH.

in hardware configuration
in application configuration
in calibration configuration
Communication error – Communication error between CMT5 iMH  Replace iCSA
and iCSA.  Replace CMT5 iMH
iMH <-> iCSA
Cutter alarm A Cutter alarm is triggered if the dynamic  Replace knife.
yarn detector is still switched on after a  Replace CMT5 iMH.
certain time in spite of the cut.
The knife did not cut the yarn.
Cutter alarm Defect on the cutter circuit.  Check cutting magnet con-
Poor contact to the cutting magnet. nector.
- Capacitor voltage failure
 Replace CMT5 iMH
- Input voltage failure  Contact USTER® Service.
- Poor cut capacitor
- Cut capacity remains
Error zero point Zero point fault of a CMT5 iMH. The  Clean CMT5 iMH and
CMT5 iMH cannot set the zero point. acknowledge alarm.
The measuring zone may be blocked.  Check mounting of the CMT5
iMH.
 Replace CMT5 iMH.
Failure 12V The CMT5 iMH monitors the +12 V sup-  Replace iCSA Quadgroup.
ply. The alarm indicates that the 12V  Replace CMT5 iMH.
supply is too low or not available.
Failure 5V The CMT5 iMH monitors the +5 V supply.  Replace iCSA Quadgroup.
The alarm indicates that the 5V supply is  Replace CMT5 iMH.
too low or not available.
iMH download required, This alarm is triggered when an CMT5 Acknowledge the message to start
acknowledge to start iMH has no software or an incompatible the download.
software version loaded.
iMH has timeout The CMT5-CCU transmits to the commu-  Check CMT5 iMH connections.
nication bus but receives no answer from  Check fuses and voltages at
the CMT5 iMH. The fault occurs if the CMT5-CCU.
CMT5 iMH is without current or if the
connection is interrupted. A defective
CMT5 iMH can also be the cause.
The CMT5-CCU starts correctly and the
menu operation is functioning properly.
The CMT5-CCU shows the fault message
CMT5 iMH has timeout.
There is probably no power supplied to
the CMT5 iMH.
If the whole machine is affected, the prob-
lem must be in the cabling or the CMT5-
CCU.
iMH RS485 blocked The CMT5-CCU cannot transmit. The  Unplug bus elements until fault


fault occurs if there is a short circuit on no longer occurs.
the clearer communication bus. In most  Locate and eliminate short
cases, more than one winding position is circuit.
affected.
 Replace defective CMT5 iMH.
iMH RS485 disturbance Fault on the clearer communication bus.  Check communication bus.
Several CMT5 iMH's have the same ad-  Readdress CMT5 iMH's
dress.  Replace CMT5 iMH
Noisy sensor This alarm is given if the static yarn de-  Reset alarm message.
tector is frequently switching on and off  Clean measuring zone.
with the winding position running or at a
 Check measuring head instal-
standstill.
lation and yarn path.
The CMT5 iMH has calibrated the zero
point with yarn present in the measuring
zone.
Accumulated fibers have fallen out of the
measuring zone.
The measuring head could be improperly
installed.
Overload – Winding speed too The CMT5 iMH is overloaded  Reduce winding speed
high
Too many iMH reboots Limit: 3/h Short brownout of the +5 V supply.  +5 V supply of the iCSA faulty.
Software error  Cable or connector defect.
 Replace CMT5 iMH if alarm
occurs often.
Wrong CMT5 iMH  Contact USTER® Service

Warning

Replace battery! The battery of the CMT5-CCU is almost  Contact USTER® Service.
empty.
iMH download active This warning is shown during the down-  Do not switch off unit and wait
load of the application software to the until message is no longer
CMT5 iMH's. shown.
Alarm goes off automatically After down- See also Chapter 5:
load is completed the message ‘Done!’ is CMT5 iMH software download
shown.
Sensor F dirty Warning given if the sensor is too dirty.  Clean measuring zone.
See Chapter 7: Maintenance.
Storing database This message is displayed for approx. 10  Do not switch off unit and wait
seconds after a lot change while the da- until message is no longer
tabase is being stored. If the unit is shown.
switched off during this procedure, the
data will not be updated from the last lot
change or shift change or they may be
stored twice.
8.2.3 Non-indicated Disturbances
Symptom Possible cause / explanation Measures

High or low number of F-readings The CMT5 iMH is not correctly installed.  Check measuring head instal-
at a winding position. The yarn is not running at the measur- lation.
ing zone base.  Check yarn guide and yarn
The F sensor is dirty. path.
 Clean the measuring zone.
Increased number of cuts or the Measuring zone for basic clearing is  Clean measuring zone.
winding position will not start. The dirty. See Chapter 7: Maintenance.
iMH is cutting during the start of
the winding position
CMT5-CCU will not start (no indi- The power to one of the following com-  Check power supply.
cation on the screen) after it is ponents is probably missing:  Check fuses of CMT5-CCU.
connected to the mains. • CMT5-CCU
• Central power supply
• CMT5 iMH power supply
The red iMH LED flashes every 3 Test in Progress.  Start a Test.
seconds once even a few minutes In the display the Status has to be
after the installation has been Test running and not Winding
switched on. position is inactive.
The red iMH LED arrow flashes 2 The CMT5 iMH is deactivated.  Activate CMT5 iMH.
times every 3 sec.  Communication to the CMT5-
CCU interrupted.
 Check cable.
The red iMH LED arrow flashes 3 • The address setting has probably  Check address, if necessary
times every 3 sec. not been made or readdress CMT5 iMH.
• iCSA is defective

8.3 Indications at the CMT5-CU
Fig. 8.3 CMT5-CU communication error status A

A Displayed Error Message
8.3.1 Error Message Displayed in the Status Bar

CU communication status: Measures to be taken
Error
HostUnreachable Check connection CMT5-CCU to CMT5-CU
FailedTimeSynchronisation CMT5-CU is the master regarding time setting.
CMT5-CU transfers date and time to the CMT5-
CCU.
RpcVersionMismatch Check match of version CMT5-CCU and CMT5-
CU
®
Inform Uster Service about both versions.

CU communication status: Measures to be taken

Error
MissingClassimatOption  Classimat Option is not enabled on CMT5-CCU.
MissingExpertOption  Expert Option is not enabled on CMT5-CCU.
MissingAdvancedOption  Advanced classes Option is not enabled CMT5-
CCU.
Check settings in CMT5-CCU
NoPosition No position is defined in classimat group on

CMT5-CCU.
ClearerTypeNotSupported Too many positions are defined in clasimat group
on CMT5-CCU.
NoLicense License is missing or wrong license is installed.

8.4 Replacement of Installation Components

8.4.1 CMT5-CCU
Procedure:
1. Save setting data:
Store settings to an USB Memory Stick if this is still possible. See Chapter 7.
2. Stop all winding positions and then switch off machine at main switch.
3. Disconnect CMT5-CCU from the mains
4. Unplug signal connections at CMT5-CCU.
5. Remove CMT5-CCU.
6. Connect and install new CMT5-CCU.
®
7. Put winding machine and USTER CLASSIMAT 5 installation into operation.
8. Enter all settings according to specifications or load it from USB.
Information
If a different software version is installed in the new CMT5-CCU,
the application software must be downloaded to the CMT5 iMH‘s.
See Chapter 5 ‘CMT5 iMH Software download’
8.4.2 iCSA Quadgroup

Procedure:
1. Disconnect CMT5-CCU from the mains.
2. Unplug the communication bus cable, blower cables and all CMT5 iMH's.
3. New iCSA: Check and, if necessary, correct coding (switch position must be
on ‘F’).
4. Replace iCSA.
5. Plug in all previous removed cables in the same order.
6. Connect CMT5-CCU to the mains again.
7. Carry out function – Machine settings – Address CMT5 iMH.

8. Put winding positions into operation.

8.4.3 CMT5 iMH
Information
The CMT5 iMH must not be unplugged or plugged when powered.
Procedure:
1. Switch off winding position.
2. Disconnect CMT5 iMH from iCSA.
3. Remove defective CMT5 iMH.
4. Install and plug in new CMT5 iMH.
Information
A download of the application software is also required if the CMT5
iMH is being used for the first time.
See Chapter 5: iMH Software download
5. New iMH is ready for operation.

6. Winding position can be started.
8.4.4 CMT5-CU
There are no components of CMT5-CU to be replaced by the user of the
CLASIMAT 5 system.

Operating Instructions Decommissioning, Storage 9
Contents
Page
9 Decommissioning, Storage 3
9.1.1 Storage Period 3
9.1.2 Authorized Personnel 3
9.1.3 Safety Regulations 3
9.2 Decommissioning 4
9.3 Storage 4
9.4 Commissioning 4
9.5 Putting the System into Operation again 4

9 Decommissioning, Storage Operating Instructions


Operating Instructions Decommissioning, Storage 9
9 Decommissioning, Storage

This chapter describes the measures that must be taken by the owner if he intends
®
to put the USTER CLASSIMAT 5 installation out of service and into storage for a
period of more than 3 months.
9.1.1 Storage Period

«Out-of-service» period means in these operating instructions the space of time
between periods of use (min. 3 months). It should not be interpreted to mean pos-
sible downtime due to interruptions of testing (e.g. work holidays).
9.1.2 Authorized Personnel

Putting the unit out of service without disassembling
The personnel authorized to put the system into operation is also authorized to put
the system out of service. (See Safety regulations in Chapter 2.5.1.).
Putting the unit out of service with disassembling

Only trained maintenance personnel of the user or else the local service center are
authorized to disassemble and reassemble the installation.
9.1.3 Safety Regulations
DANGER
Dangerous voltage.
Before starting to disassemble the installation, the CMT5-CCU and

the CMT5-CU must be disconnected from the mains voltage. Ob-
serve also the ‘Safety regulations’ in Chapter 2.
WARNING
Improper disconnection of the compressed air.
Before starting to disassemble the pneumatic components, first

disconnect air supply and then disconnect all air hoses of the
CLASSIMAT 5 Modules.
Pneumatic components must only be disconnected by authorized

persons!

9 Decommissioning, Storage Operating Instructions
9.2 Decommissioning
Preparation
To eliminate any danger for the personnel involved, make sure that all parts of the
installation have been disconnected from the mains voltage before starting any
disassembly work.
• All installation components connected to the mains voltage have to be discon-

nected from the mains.
− CMT5-CCU: pull out the power cable.
− Before disconnecting the CMT5-CU carry out a Data backup and a correct
shut down.
Procedure for the disassembly:

• Unplug and remove all connecting cables between all components of the
®
USTER CLASSIMAT 5 installation.
• Unplug and remove all air hose connections from the CLASSIMAT 5 Modules
• Remove all CLASSIMAT 5 Modules from the winding machines and store them
in suitable packing. Pay attention to the tensioners, disassemble them and put
them in the original packaging or use an equivalent packaging.
9.3 Storage
Storage
The installation part must be stored
− in a suitable packing
− in a dry and dust-free location
Storage conditions
Temperature 5-55 °C
Rel. humidity 20% to 90% noncondensing
9.4 Commissioning
®
For the assembly of the stored USTER CLASSIMAT 5 installation, proceed in re-
verse order of the disassembly.
Authorized personnel
See ‘Safety Regulations’ in Chapter 2.5.1.
9.5 Putting the System into Operation again

Follow the instructions in Chapter 5 to put the system into operation again.

Operating Instructions Packaging, Transport 10
Contents
Page
10 Packaging, Transport 3
10.2 Packaging 3
10.3 Transport 3

10 Packaging, Transport Operating Instructions


Operating Instructions Packaging, Transport 10
10 Packaging, Transport

The USTER® CLASSIMAT 5 installation or individual parts of the installation are to
be transported in suitable packaging. The ‘Storage conditions’ described in Chap-
ter 9.3 must also be observed during the transportation.
10.2 Packaging
Always use suitable packaging to store or transport the CLASSIMAT 5 installation
or any of its parts to ensure optimum protection against damage.
Original packaging
If the original packaging is no longer available:
• Installation components with an enclosure (e.g. iMH, tensioners) have to be
packed so that the parts are protected against mechanical damage.
10.3 Transport
Always transport the USTER® CLASSIMAT 5 installation:
• using suitable packaging
• without violating the storage conditions (Chapter 9.3)
• protect against slipping.
Note
Loads over 25 kg:
May be transported only in pairs, or else transport aids must be
used.

10 Packaging, Transport Operating Instructions

Operating Instructions Disposal 11
Contents
Page
11 Disposal 3
11.2 Disposal Regulations 3
11.3 Disposal of Installation Components 3
11.4 Mandatory Notification 4

11 Disposal Operating Instructions


Operating Instructions Disposal 11
11 Disposal

®
The owner should recycle or dispose of USTER CLASSIMAT 5 installations in
compliance with applicable legal regulations. The proper dismantling of the
®
USTER CLASSIMAT 5 installation and practical separation of materials requires
experience in the field of mechanical work and knowledge in the classification of
waste materials.
If there are any uncertainties about proper disposal in order to avoid endangering
people or the environment,
• Uster Technologies AG will provide the necessary information
• Uster Technologies AG will take care of the disposal for a reasonable fee.
11.2 Disposal Regulations

®
The disposal of USTER CLASSIMAT 5 installation components must be carried
out in compliance with national and regional laws and regulations.
11.3 Disposal of Installation Components

®
The USTER CLASSIMAT 5 installation components have to be dismantled for
proper disposal. This is to be done by the customer‘s personnel.
WARNING
Dangerous voltage
Before starting to disassemble the installation, make sure that all

parts of the installation have been disconnected from the mains
power supply. The life of the personnel involved will otherwise be
endangered.
Capacitors inside the components may still be charged after all

voltage sources have been disconnected.
The disassembled components are to be sorted according to the type of material

and taken separately to the respective collecting or recycling locations.
Particular care must be taken for the correct disposal of the following components:
Packing material: Cardboard, plastic foam
Housing: zinc die-casting, sheet metal and aluminum
Printed circuit boards: Electronic waste
Cables Electronic waste
Air hose Plastic waste
Batteries: Special waste
Screen: Special waste

11 Disposal Operating Instructions
11.4 Mandatory Notification

®
When taking an USTER CLASSIMAT 5 installation out of service for disposal, the
manufacturer (Uster Technologies AG) or the respective service center must be in-
formed accordingly.

Operating Instructions Spare Parts 12
Contents
Page
12 Spare Parts 3
12.1 Safety Information 3
12.2 Ordering Information 3
12.3 Available Spare Parts 4
12.4 Accessories 8

12 Spare Parts Operating Instructions


12 Spare Parts
12.1 Safety Information
WARNING
Using non-original spare parts.
The use of non-original spare parts may cause physical injury and
damage to material.
Use only original spare parts from the spare parts catalog of Uster
Technologies AG.
Non-compliance with this requirement will void any warranties

provided by Uster Technologies AG.
12.2 Ordering Information

To prevent incorrect deliveries, it must be ensured when ordering spare parts that
the order contains the necessary information such as:
®
• Product name, for example USTER CLASSIMAT 5.
• Material number and description of spare part (if not available please send a
photo or sketch).
• Correct address and contact person
• Serial number, if applicable
To order spare parts end-users are requested to contact the Uster Service Agent in
their own country.
The address can be found under

http://www.uster.com/en/about-uster/uster-worldwide/
Choose Country; select Service then press the button ‘Search’.

12.3 Available Spare Parts
Illustration DESIGNATION Mat. No.
CMT5-CCU MMI 24 V DC (19") 318101-58400
CABLE POWER/COMM. CCU - QUAD 304001-03200

GROUP
VALVE CABLE 318103-03000
NETZKABEL CH 3-POLIG 6A / 250VAC 243350-00250
iCSA QUAD GROUP NEUTRAL CPL 318101-01000
CMT5 iMH C15F30 CPL 318150-00020
CMT5 iMH C20F30 CPL 318150-00050

YARN GUIDE PLATE OUT 316000-00411
YARN GUIDE PLATE OUT CPL 318101-00900
YARN GUIDE PLATE IN 316000-00400
EYELET OUT 316000-00390
EYELET IN 316000-00380
BN4851 SENK-I6R 2,5 VJR 6 - 8.8 153327-02006
BN11288 GF SENK-I6R 2,5 VJR 10 153749-10007
SCREW CRESACOAT I6R M3X12 BN90905 153749-00010

DISTANCE DISK 304010-02310
KNIFE COMPLETE 304000-00575
TENSIONER CPL 318101-00700
3) RUBBER WASHER 318102-00270
4) TENSIONER DISK SET (2 PCS) 318101-00150
7a) SPRING 0.5x11x22.4mm (≤ 60 Nec) 318102-00310
7b) SPRING 0.42x11x22.4mm (> 60 Nec) 318102-00440
8) SAFETY SCREW BN1073 M4x5 - PA 153735-04005
2 WAY ELECTRIC SOLENOID VALVE 318102-00160
JET 318102-00170
CMT-Q THREAD GUIDE 304100-02350
JET GUIDANCE (TOOL) 318102-00350

CLIMATE SENSOR CPL 316002-01020
FUSE 250V 1.0 AT SLOW 155796-41000
FUSE 250V 2.5 AT SLOW 155796-42500
BLOW GUN WITH SPIRAL HOSE SET 318102-00380
SAFETY GLASSES (GOGGLES) 318102-00390

12.4 Accessories
Illustration Designation Mat. No.
YARN FAULT CARD WS/SW A4 237 809-60200
YARN FAULT CARD WS/SW A5 237 809-60100
PIPE CLEANER (80 PIECES) 242207-00320
CLEANING PLATE 242208-00000
CLEANING BRUSH 242207-00100
®
SCREWDRIVER TORX SCREWS T8 304000-06011
®
SCREWDRIVER TORX SCREWS T10 304000-06012
SCREWDRIVER TORX® SCREWS T25 400112-01620

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USTER CLASSIMAT 5 ®

THE YARN CLASSIFICATION SYSTEM

Version 1.0 / Mat. No.318 104-40020

Head office Switzerland

© Copyright 2012 by Uster Technologies AG. All rights reserved.

2 (6) 09.12 USTER® CLASSIMAT 5

0 Keywords, Terms, Abbreviations

0.1.2 Terms used with the USTER® CLASSIMAT 5

S-faults Thick places from 1 cm to < 8 cm  short thick places

L-faults Thick places from 8 cm to 200 cm  long thick places

Parameters used for NSL/T and F/VEG

Parameters used for PP

4 (6) 09.12 USTER® CLASSIMAT 5

‘Chapter’ - symbol (in a cross-reference):

CV Coefficient of variation of yarn evenness

0.4 Version History

Chapter Edition Description of change Date of change Carried out by

6 (6) 09.12 USTER® CLASSIMAT 5

1.1 Legal Regulations 3

1.2 Original Language 3

1.4 Installation Overview 4

1.5 Technical Data 6

USTER® CLASSIMAT 5 09.12 1 (10)

© Copyright 2012 by Uster Technologies AG. All rights reserved.

2 (10) 09.12 USTER® CLASSIMAT 5

1.1 Legal Regulations

Unless allowed explicitly by the license agreement, no part of this documentation

1.2 Original Language

The original language of these operating instructions is English.

USTER® CLASSIMAT 5 09.12 3 (10)

1.4 Installation Overview

Up to 12 winding positions may be connected to a CLASSIMAT 5 system.

4 (10) 09.12 USTER® CLASSIMAT 5

1.4.2 Identification of the Product

USTER® CLASSIMAT 5 09.12 5 (10)

1.5 Technical Data

1.5.2 Electrical Connection

1.5.3 Compressed Air

1.5.4 Ambient Conditions

Storage with the original Packing intact

6 (10) 09.12 USTER® CLASSIMAT 5

Three classification standards • CLASSIMAT 5

USTER® CLASSIMAT 5 09.12 7 (10)

Climate measurement: Sensor for measurement of humidity and temper-

Classification of thick and thin Capacitive measurement

Measuring Head Type

Yarn Count Range and Measuring Head Types

8 (10) 09.12 USTER® CLASSIMAT 5

1.6.2 Scope of Delivery

• CMT5-CCU with installed software

USTER® CLASSIMAT 5 09.12 9 (10)

10 (10) 09.12 USTER® CLASSIMAT 5

2.1 General Information 3

2.2 References and Symbols 4

2.3 Basic Safety Information 5

2.4 General Safety Rules 6

2.6 State of Technology 9

© Copyright 2012 by Uster Technologies AG. All rights reserved.

2.1 General Information

2.1.2 Observance of the Safety Regulations

Cleaning the equipment is only permitted at standstill of all moving parts.

2.2 References and Symbols

i Text marked with this symbol contains practical information and is