MACHINES FEATURES CONTROLLER SM5500+ - Rev.0

ATHENA4 - MACHINE’S FEATURES & CONTROLLER SM5500+ Rev.
ATHENA4™
FABRIC DYEING MACHINE
MACHINE’S FEATURES & CONTROLLER
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ATHENA4 - MACHINE’S FEATURES & CONTROLLER SM5500+ Rev. 0
Contents `
1. MACHINE TECHNICAL SPECIFICATIONS ...................................................................... 5
1.1. MACHINE VESSEL ...................................................................................................... 6
1.1.1. DOUBLE SOFT FLOATINGTM (DSF) DYEING SYSTEM ......................................... 7
1.1.2. VARIABLE SPEED OPEN PLAITING SYSTEM WITH LIQUOR BY PASS (OPLB) ....... 7
1.1.3. STORAGE CHAMBERS ........................................................................................ 8
1.1.4. PTFE SHEET ........................................................................................................ 8
1.1.5. CYCLOCLEAN® .................................................................................................... 8
1.1.6. STANDARD MAIN VESSEL COMPONENTS .......................................................... 8
1.2. LIQUOR CIRCULATION MAIN PUMP.......................................................................... 9
1.3. FLOW BALANCING DEVICE (FBD) .............................................................................. 9
1.4. HEAT EXCHANGER ..................................................................................................... 9
1.4.1. HEAT EXCHANGER INLET-OUTLET VALVES ...................................................... 10
1.5. ADDITION TANK ...................................................................................................... 10
1.5.1. STANDARD ADDITION TANK COMPONENTS ................................................... 10
1.6. SECOND ADDITION TANK ........................................................................................ 11
1.6.1. SECOND ADDITION TANK COMPONENTS ........................................................ 11
1.7. CONTINUOUS FLOW DOSING SYSTEM (CFD) .......................................................... 11
1.8. UNLOADING SYSTEM FOR SINGLE AND DOUBLE ROPE OPERATION ...................... 12
1.8.1. EXTENDED LENGTH UNLOADING ROLLER WITH TWIN REELS PER CHAMBER 12
1.8.2. SEPARATING GUIDE ......................................................................................... 12
1.8.3. SPLASH GUARD ................................................................................................ 12
1.9. FRONT PLATFORM .................................................................................................. 12
1.10. SEAM DETECTION MANAGEMENT .......................................................................... 13
1.11. TO KNOW LIQUOR RATIO SYSTEM (TKLR) ............................................................... 13
1.12. SCLAVOS DRY SALT TRANSFER & FINE DOSING SYSTEM (DSFD) [OPTIONAL] ......... 13
1.13. AQUACHRON CONTINUOUS WASHING SYSTEM .................................................... 15
1.13.1. AQUACHRON 4G (patented) ............................................................................ 15
1.13.2. AQUACHRON FLX (patented) ........................................................................... 15
1.13.3. AQUACHRON CALCULATOR ............................................................................. 15
1.14. AUTOMATIC SETTINGS ADJUSTMENT (ASA) ........................................................... 16
1.15. MONITORING THE CONSUMPTIONS OF UTILITIES .................................................. 17
1.16. GENERAL SPECIFICATIONS OF THE REQUIRED UTILITIES ........................................ 17
2. CONTROLLER SCLAVOS SEDOMAT 5500+ TECHNICAL SPECIFICATIONS ..................... 17
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2.1. MACHINE CONTROL SYSTEM .................................................................................. 18

2.2. CONTROLLER/ADDITION TANKS CONTROL PANEL ................................................. 19
2.3. AUXILIARY CONTROL PANEL ................................................................................... 19
2.4. FULLY AUTOMATION BY SCLAVOS SEDOMAT 5500+ .............................................. 19
3. CONTROLLER SCLAVOS SEDOMAT 5500+ FUNCTIONS .............................................. 21
3.1. MAIN FUNCTIONS ................................................................................................... 22
3.1.1. FILLING ............................................................................................................. 22
3.1.2. DRAINING ........................................................................................................ 23
3.1.3. AQUACHRON 4G™ RINSING ............................................................................ 23
3.1.4. AQUACHRON 4G ™ FLX.................................................................................... 24
3.1.5. HEAT/COOL ...................................................................................................... 24
3.1.6. HOLD TIME....................................................................................................... 25
3.1.7. TKLR FUNCTIONS ............................................................................................. 25
3.2. PARALLEL FUNCTIONS ............................................................................................. 26
3.2.1. PREPARE T1 (T2) .............................................................................................. 27
3.2.2. FILL ADD T1 (T2) .............................................................................................. 27
3.2.3. DOSING T1 (T2) ................................................................................................ 28
3.2.4. TRANSFER T1 (T2) ............................................................................................ 28
3.2.5. RECIRCULATION T1 (T2)................................................................................... 28
3.2.6. HEAT ADD T1 (T2) ............................................................................................ 29
3.2.7. CONTROL OFF .................................................................................................. 29
3.2.8. (UN)LOAD ........................................................................................................ 29
3.2.9. AQUACHRON CTRL .......................................................................................... 30
3.2.10. CYCLOCLEAN® .................................................................................................. 31
3.2.11. SALT PREPARE (Optional) ................................................................................ 31
3.2.12. SALT DOSING (Optional) .................................................................................. 31
3.2.13. SALT PUMP CLEAN (Optional) ......................................................................... 32
3.3. DATA FUNCTIONS ................................................................................................... 33
3.3.1. PUMP SPEED .................................................................................................... 33
3.3.2. REEL SPEED ...................................................................................................... 33
3.3.3. VAT FUNCTION ................................................................................................ 34
3.4. SPECIAL FUNCTIONS................................................................................................ 35
3.4.1. PROGRAM START............................................................................................. 35
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3.4.2. PROGRAM END ................................................................................................ 35

3.4.3. PROMPT (FUNCTION STOP) ............................................................................. 35
3.4.4. FUNCTIONS FOR SEDOMASTER/CHEM.DISPENSER ......................................... 38
3.4.5. RESTART PROGRAM AFTER SUDDEN STOP ..................................................... 39
4. CONTROLLER HANDLING......................................................................................... 39
4.1. FRONT PANEL KEYS ................................................................................................. 41
4.2. STATUS AREA .......................................................................................................... 42
4.3. MAIN SCREEN AREA ................................................................................................ 44
4.4. PROGRAM VIEW...................................................................................................... 45
4.5. ADD TANKS SCREEN ................................................................................................ 46
4.6. CONTROLLER SALT FINE DOSING SYSTEM SCREEN (Optional) ................................ 48
4.7. PROGRAM HISTORY AND EVENTS SCREEN ............................................................. 49
5. CREATING A PROGRAM FOR ATHENA4TM ............................................................... 52
5.1. HOW TO LOAD A NEW BATCH ................................................................................ 52
5.2. FROM PROCESS DIAGRAM TO STRUCTURED PROGRAM ........................................ 55
5.3. EXAMPLE OF MAKING A CONTROLLER’S PROGRAM (COTTON 100%).................... 57
6. CONTROLLER FINE TUNING – MANUAL MODE ......................................................... 61
6.1. NUMERICAL INFOS – TUNE VALUES ........................................................................ 61
6.2. MANUAL MODE DESCRIPTION ................................................................................ 61
6.2.1. ELECTRICAL PANEL........................................................................................... 62
6.2.2. OPERATOR PANEL ............................................................................................ 63
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1. MACHINE TECHNICAL SPECIFICATIONS

Sclavos Fabric Dyeing Machine Athena4TM Type H
Machine Type: 150H 250H 500H 750H 1000H 1250H 1500H
Number of Chambers: 1 1 2 3 4 5 6
Maximum Capacity per
150kg 250kg
Chamber:
Capacity Range at LR
90-150 150-250 300-500 450-750 600-1000 750-1250 900-1500
5.8:1 (kg):
Operational
135°C
Temperature (max):
Sclavos Fabric Dyeing Machine Athena4TM Type Hx300
Machine Type: 300H/1 600H/2 900H/3 1200H/4 1500H/5 1800H/6
Number of Chambers: 1 2 3 4 5 6
Maximum Capacity
300kg
per Chamber:
Capacity Range at LR
180-300 360-600 540-900 720-1200 900-1500 1080-1800
5.8:1 (kg):
Operational
135°C
Temperature (max):
Athena4TM operates with minimal water usage throughout all the process cycles.
Water Usage Ratio is the ratio between the total water used and the total fabric
quantity processed throughout the total process.
Water Usage Ratio can be calculated at the production planning stage when
Water Usage Ratio: following information is known: Fabric type and weight, dyestuffs classification-
quantity (% on fabric), salt concentration and processes used.
Athena4TM does not follow conventional methods of rope dyeing, but in
conventional terminology is able to run at a liquor ratio of 4 to 5.5:1, depending on
fabric type.
Fabric Types: Suitable for dyeing knitted and woven fabrics, even the more sensitive ones.
Most of fabrics with linear weights from 0.15 Kg/Lm up to 0.65 Kg/Lm can be
loaded according to the nominal machine capacity, provided that those have been
equally distributed in the machine’s chambers. Linear weights from 0.15 Kg/Lm up
to 0.32 Kg/Lm (*for Athena4TM Type x300 it’s from 0.19 Kg/Lm up to 0.37 Kg/Lm
Maximum Capacity (at respectively) are recommended to run in “double rope” operation for full loading.
single & multi rope Linear weights less than 0.15 Kg/Lm (*for Athena4TM Type x300 it’s 0.19 Kg/Lm
operation): respectively) can run in multi rope operation. Other linear weights can run in both,
multi rope or “single rope” according to Dyer’s choice. Fabrics out of the above
limits, or with strong peculiarities, probably should run with slightly reduced
loading. (Kg/Lm = weight in Kg of fabric length of one meter). In general, we
recommend maximum length per rope 800m.
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Heat Exchanger is designed and manufactured in accordance with the rules and
regulations as specified by the American Society of Mechanical Engineers (ASME)
and the Tubular Exchanger Manufacturers Association (TEMA), fulfil the additional
requirements of PED2014/68/EU and certified accordingly. Tested at a static
Heat Exchanger
hydraulic pressure of 14.6bar.
Construction:
Maximum standard operating saturated steam temperature is 185°C. Maximum
standard operating saturated steam pressure is 10bar.
All pressure parts in contact with the process liquor are manufactured from high
quality corrosion and acid resistant stainless-steel material type 316 or 316L.
Main vessel is designed and manufactured in accordance with the rules and
regulations as specified by the American Society of Mechanical Engineers (ASME),
fulfil the additional requirements of PED2014/68/EU and certified accordingly. Final
testing is performed at a static hydraulic pressure of 4bar.
Pressure Vessel
Maximum continuous operating temperature is 135°C.
Construction:
(corresponding pressure is 2.12 bar)
Maximum design temperature is 141.9°C at 2.8bar.
Main vessel and all parts in contact with the process liquor are manufactured from
high quality corrosion and acid resistant stainless-steel material type 316 or 316L.
Each machine provides many features that ensure the gentle fabric handling which
combined with the unique Aquachron (4G or FLX) continuous washing process
removes efficiently the very low lint quantities that are generated during the
process. As a result, there is no need of filter screen, which usually collect lint and
Filterless Operation:
build yarns that gives more contamination in machine’s parts and fabric as well.
Additionally, the liquor circulation remains steady, without any throttling from the
lint accumulation on the filter screen, resulting to ideal dyeing and washing
conditions throughout complete process.
1.1. MACHINE VESSEL

➢ 1 (one) stainless steel dyeing vessel mounted on stainless steel feet with an individual
turret for each chamber. Each turret is equipped with an access door incorporating sight
glass and illumination for observation of the fabric running, an automatically safety
locking mechanism and a hand release pressure safety valve.
➢ 1 (one) low power main drive system (Approx. 20% less energy requirement) with AC
motor and gearbox combination per chamber, controlled by AC inverter, for speeds
between 0 – 340 m/min driving:
➢ 1 (one) drive reel with anti-slip bars per chamber with individual drive shafts and easily
replaceable mechanical seals supplied with cooling/lubricating flush for extended seal
life.
➢ 1 (one) Sclavos catch basket mechanism per chamber for automatic self-correction of
fabric overfeeds without operator intervention or opening/depressurising the machine,
including micro switch and remote activation pneumatic piston.
➢ 1 (one) inspection door sealed and bolted at the side of the main vessel for maintenance
purposes.
➢ 1 (one) vacuum relief valve CV01 for vessel protection.
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➢ 1 (one) mechanical quick actuating pressure relief safety valve VPR01 for vessel
protection to prevent excess pressure build-up within the machine set at 2.8 bar. It
conforms to European (PED) specifications and it is properly certified. (PED: Pressure
Equipment Directive of EU)
➢ 2 (two) safety pressure switches PA01&PA02 for the activation of depressurisation valves
and automation interlocks. Set at 2.6 & 2.7 bar in parallel connection, in order to give
two additional protection levels.
➢ 1 (one) pressure indication gauge PI02 for indicating the vessel pressure. Gauge scale 0-
6 bar.
➢ Analogue level transmitter for continuous measuring the liquor height inside the kier.
1.1.1. DOUBLE SOFT FLOATINGTM (DSF) DYEING SYSTEM

➢ 1 (one) patented ‘Double Soft Floating’™ System per chamber. Each system comprises
of two nozzles of different design, slightly inclined and connected with a big radius
elbow, in order to achieve a large intensive zone. The first nozzle achieves the initial
fabric penetration and as the fabric moves and relaxes after the first contact, then it
arrives to the second nozzle area. Due to the design of the second nozzle, it can create a
liquor “stream” that contact the fabric in a way to form a liquor “cushion” and achieves:
a. “Floating effect” on fabric rope, which eliminates any abrasion between
fabric and dyeing tube wall. It prevents any fabric speed reduction and
protects the fabric surface. Thus, a very efficient handling for medium to
heavy weight fabrics is obtained.
b. Reposition of the fabric folds and further liquor to fabric penetration, which
improves levelling and results to fabric relaxation. Moreover, fabric tension
and fiber distortion are eliminated.
c. Higher fabric speed at a very low liquor pressure at nozzles.
d. Less fiber loss, 1-2%, compared to any single nozzle machine.
➢ The design of DSF System with two nozzles and the big sectional area of the transport
tube (approx. 140mm) permits to run different fabric weights, widths and types without
any manual modification or other changes to the nozzles. Additionally, it permits the
circulation of high liquor flowrates in order to reduce the bath recirculation time and
thus to achieve a perfect distribution of dyestuffs, chemicals and temperature in the
dyebath. The liquor flow distribution between the two nozzles is automatically optimized
for each batch according to the batch parameters. Thus, DSF System incorporated with
the other machine systems can run batches of different loads and succeed a perfect
shade matching.
1.1.2. VARIABLE SPEED OPEN PLAITING SYSTEM WITH

LIQUOR BY PASS (OPLB)
The variable speed Open Plaiting system with Liquor by pass is placed at the exit of each DSF
system and ensures proper plaiting of the fabric inside the fabric storage chamber (J-box).
Each system consists of two parts: The moving part and the stationary part.
The moving part oscillates horizontally with variable frequency, which follows the fabric
speed and gives direction change to the fabric.
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The stationary part is a specific design “elbow”, of equal width to the J box width, with fully
perforated and properly polished back.
As the fabric with the liquor goes out from the moving part, both touches the back of the
“elbow” and the greatest part of the liquor goes out through the perforation, in the space
between the back of the J-box and the machine’s shell. Due to the large size of the
perforated area, there is no liquor stream falling inside the j box with the fabric. Thus, fabric
plaiting is not disturbed, because there is no source for tangles.
During the touch of the fabric on the perforated back of the “elbow”, the fabric “opens” and
its folds are repositioned. The back of the “elbow” guides the fabric in the center plane of
the J-box. Thus, the “open” fabric is distributed and covers all the - box area, eliminating
further tangle sources.
1.1.3. STORAGE CHAMBERS
1 (one) individual unit construction 'J' box per chamber highly perforated and polished.
Installed with an all-around free space to ensure efficient flow of dyestuffs and chemicals
and to allow rapid bath circulation times.
1.1.4. PTFE SHEET
1 (one) PTFE (Teflon) sheet covers the bottom in each J-box, in order to aid in the tensionless
movement of fabric from the rear to the front of the machine.
1.1.5. CYCLOCLEAN®
1 (one) Cycloclean® System with a new design hydro-dynamically driven revolving head. New
head gives more and better distributed jets that cover all the internal machine’s surfaces
and cleaning of them becomes more efficient. It must be used during final stages/soaping
off of the process cycle leading to savings in time, water, steam, electricity and chemicals.
Cycloclean® is controlled by the process controller and can be integrated within the process
cycle.
Enables boil-outs to be performed at low liquor levels thereby providing significant savings
in time, water, steam, electricity, and chemicals. Cycloclean® is efficient even in low
temperatures. Additionally, it reduces boil-out times.
Cycloclean®III will provide an increase in productivity of at least 3%.
1.1.6. STANDARD MAIN VESSEL COMPONENTS
➢ 2 (two) pneumatic double acting (air to open - air to close) valves VF1 and VF2 for filling,
designed for unrestricted flow of filling water and to be unaffected by high line pressure
or water hammer (suitable materials selection in contact with water, such as 316
stainless steel, EPDM).
➢ 1 (one) electromagnetic flowmeter installed at the main filling pipeline, for precise water
usage monitoring and water flow control during Aquachron™ and filling.
➢ 1 (one) analogue pneumatic valve for filling water flow regulation, designed for
unrestricted flow of filling water and to be unaffected by high line pressure or water
hammer (suitable materials selection in contact with effluent water, such as 316 stainless
steel, PTFE, EPDM-HT).
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➢ 1 (one) analogue pneumatic valve for Aquachron drain flow regulation, designed for
unrestricted flow control of the drained water. (Suitable materials selection in contact
with effluent water, such as 316 stainless steel, PTFE, EPDM-HT).
➢ 1 (one) double acting pneumatic drain valve VD1 (suitable materials selection in contact
with effluent water, such as 316 stainless steel, EPDM-HT).
➢ 1 (one) temperature sensor fitted within the liquor circulation line for control of the bath
liquor temperature.
➢ 1 (one) analogue level sensor for continuous measurement of main vessel levels.
1.2. LIQUOR CIRCULATION MAIN PUMP
High efficiency low energy pump system P1 (approximately 50% less power requirement
than conventional systems) fitted with easily accessible mechanical seal providing high
volume, low pressure liquor circulation with approximately one bath circulation every 30-45
seconds.
Horizontally fitted pump & motor, mounted on sturdy base, and depending on power, are
coupled directly or through pulleys and belts. Stainless steel cover protects the main pump
assembly properly.
Main pump motor is driven through AC frequency inverter. It achieves a stepless regulation
of the pump delivery (through speed change) and assures smooth pump running, less
hydraulic losses (eliminates foaming) and lower energy consumption.
1.3. FLOW BALANCING DEVICE (FBD)
FBD is a unique development of Sclavos which eliminates any interference on machine’s

operation caused by supply’s fluctuations of factory’s utilities networks.
FBD “isolates” machine’s performance from the Dyehouse water supplies and their pressure
fluctuations accordingly.
As a result, machine’s efficiency is considerably increased.
FBD consists of following parts:
a. Balancing Chamber. This device is the absorber of any water supply’s pressure
fluctuations.
b. Low Energy Flow Control Pump. This pump supplies absolutely steady water flow
rate into the machine.
1.4. HEAT EXCHANGER
Shell and tube type heat exchanger external to the main vessel for the combined indirect
heating or cooling of the dye bath liquor.
➢ 1 (one) inlet manifold for mounting the proportional steam and cooling water inlet
valves.
➢ 1 (one) outlet manifold for mounting the condensate return and cooling return valves.
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Designed for an average rate of temperature rise of 5°C/min (*for Athena4TM Type x300
it’s 5°C/min respectively) between 20°C and 135°C at a steam pressure of 8 bar. Designed
for an average rate of cooling of 3°C/min (*for Athena4TM Type x300 it’s 2,5°C/min
respectively) between 135°C and 75°C with a maximum cooling water temperature of
20°C.
(Figures are calculated for a full load working at a liquor ratio of 1:5.)
1.4.1. HEAT EXCHANGER INLET-OUTLET VALVES
➢ 2 (two) proportional modulating control valves VH & VC for regulation of the steam and
cooling water inlet to the heat exchanger for precise control over heating and cooling
gradients and stable temperatures whilst maintaining temperature on hold.
➢ 2 (two) on-off valves, one for condensation return and one for cooling water return.
➢ 1 (one) Steam isolation valve for protection of the modulating control valve.
➢ 1 (one) vent and 1 (one) drain valve for draining the shell side part during the change
from cool to heat.
1.5. ADDITION TANK

➢ 1 (one) stainless steel Addition Tank system (approx. capacity: (Lt) = (0.5-0.6) x max.
machine fabric capacity.
➢ Fine mesh removable filter with extended handle to enable the operator to remove filter
without having to place the hands in the solution.
➢ Addition tank rim spray for filling or rinsing the tank with fresh water.
➢ Steam heating element for heating of the tank contents through direct injection of steam
and temperature sensor for temperature control.
➢ Piping to and from the machine to enable liquor runback from machine to addition tank,
transfer and dosing from addition tank to machine and draining of the side tank.
➢ Addition tank transfer and dosing high-efficiency pump P2 complete with mechanical
seal and splash guard.
➢ Mixer for the agitation and perfect dilution of the dyestuff paste and other uses
(Chemicals, etc).
➢ Add tank stainless steel cover.
➢ Removable stainless-steel table that helps the operator to place the salt bag and pure it
inside.
1.5.1. STANDARD ADDITION TANK COMPONENTS
➢ 1 (one) stainless steel pneumatic transfer/dosing valve VACFD for transferring and dosing
the liquor from addition tank to main vessel.
➢ 1 (one) stainless steel pneumatic valve from addition tank to high pressure pump.
➢ 1 (one) stainless steel pneumatic addition tank fill-rinse valve VAF/R.
➢ 1 (one) stainless steel pneumatic addition tank drain valve VAD.
➢ 1 (one) stainless steel pneumatic runback valve VTVA for runback of liquor from the main
vessel to the addition tank.
➢ 1 (one) stainless steel pneumatic valve for the automatic adds tank heating.
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➢ 1 (one) combined bubble regulator and pressure to current transducer for continuous
analogue measurement of the addition tank level.
1.6. SECOND ADDITION TANK

➢ 1 (one) stainless steel Addition Tank system (approx. capacity: (Lt) = (0.5-0.6) x max.
machine fabric capacity.
➢ Fine mesh removable filter with extended handle to enable the operator to remove filter
without having to place the hands in the solution.
➢ Addition tank rim spray for filling or rinsing the tank with fresh water.
➢ Steam heating element for heating of the tank contents through direct injection of steam
and temperature sensor for temperature control.
➢ Piping to and from the machine to enable liquor runback from machine to addition tank,
transfer and dosing from addition tank to machine, and draining of the side tank.
➢ Mixer for the agitation and perfect dilution of the dyestuff paste and other uses
(Chemicals, etc).
➢ Add tank stainless steel cover.
➢ The two addition tanks are identical and can function separately or coupled. They share
one common high efficiency pump, which enables simultaneous dosing from the two
coupled tanks at maximum delivery up to 150 lt/min per chamber (approx.).
1.6.1. SECOND ADDITION TANK COMPONENTS
➢ 1 (one) stainless steel pneumatic valve from addition tank to high pressure pump.
➢ 1 (one) stainless steel pneumatic addition tank fill-rinse valve VAF/R.
➢ 1 (one) stainless steel pneumatic runback valve VTVA for runback of liquor from the main
vessel to the addition tank.
➢ 1 (one) combined bubble regulator and pressure to current transducer for continuous
analogue measurement of the addition tank capacity.
➢ 1 (one) stainless steel pneumatic valve for the automatic adds tank heating.
1.7. CONTINUOUS FLOW DOSING SYSTEM (CFD)
CFD is achieved through infinitely variable pump motor frequency adjusted by AC inverter
automatically from the machine controller. The transfer/dosing valve remains open and the
pump ON during the whole dosing time, resulting into continuous dosing. CFD is the
continuous adjustable flow of chemicals and dyestuff solutions into the dyeing machine.
All the conventional ‘dosing’ systems result in interrupted flow dosing, leading to increased
dosing and migration times to reach homogeneity.
Compared to a conventional dosing system, Sclavos CFD results to productivity increase of
approximately 5-6%.
The dosing function can be adjusted according to the dyer’s needs by choosing the dosing
time as well as the dosing curve.
Apart from the basic linear dosing curve, a variety of progressive and digressive dosing
curves can be chosen.
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1.8. UNLOADING SYSTEM FOR SINGLE AND DOUBLE ROPE

OPERATION1
UNLOADING SYSTEM consists of the following equipment:
1.8.1. EXTENDED LENGTH UNLOADING ROLLER WITH

TWIN REELS PER CHAMBER
Depending on the machine size, the machine is equipped from one or two extended length
rollers, mounted on stainless steel suspension arms and equipped with one or two ac
inverter driven motor-reducer(s).
Each machine chamber is served by twin reels with silicone rubber bars, fixed on the roller.
In the case of “Double Rope Operation” per chamber, the two ropes are separated during
unloading, one in each reel. Thus, there is enough space between the ropes, so they can be
unloaded in separate trolleys.
In the case of “Single Rope Operation”, fabric is unloaded through one of the twin reels.
Operator can regulate the unloading speed, so perfect rope separation can be achieved
easily.
1.8.2. SEPARATING GUIDE
It serves mainly the “Double Rope Operation”, where the separation between the two ropes
is achieved during unloading. The design and construction of the guide creates “channels”
that not only separate the ropes but drive them to the twin reels perfectly.
In the case of the “Single Rope Operation”, one of the two “channels” per chamber is in use.
1.8.3. SPLASH GUARD
Properly designed stainless steel splash guard protects not only against the water spreading
during unloading, but also helps the operator to guide the fabrics efficiently through the
separating guide channels to the twin reels.
1.9. FRONT PLATFORM

➢ Front platform with stainless steel handrail and fabric loading guide rings fabricated from
stainless steel in order to maintain appearance and to avoid contamination and abrasion
of fabric.
➢ Slip safe grates for the floor and steps.
➢ Stair can be placed left or right.
1
Not applicable for 150H size machines.
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1.10. SEAM DETECTION MANAGEMENT

Seam Detector II is an electronic devise provided with the proper number of sensors. It
receives all the seam signals, calculates also and give other information such as cycle time,
cycle number etc. and prepares all the necessary information for the below operations:
➢ Scans all chambers simultaneously with high accuracy. Has the ability to detect seams
per selected chamber. Gives full information for any chamber selected. Will give an alarm
should fabric stop e.g. seam breaks. Has optional lot history
➢ STOP MACHINE CONTROL. Programmable for specific or general chamber selection.
1.11. TO KNOW LIQUOR RATIO SYSTEM (TKLR)
One of the most significant factors that affect directly batch-to-batch reproducibility and
“first time right”, is the accurate calculation of the quantity of liquor being in the machine
throughout the process.
TKLR controls the LR accurately at any step of the process without human intervention,
through specific programmed functions which are supported from other machine’s features.
1.12. SCLAVOS DRY SALT TRANSFER & FINE DOSING SYSTEM

(DSFD) [OPTIONAL2]
Sclavos Dry Salt Transfer & Fine Dosing system is a peripheral apparatus specially designed
to dilute, deliver and dose dry salt into the dyeing machine without additional fresh water,
thus leaving the Liquor Ratio unaffected.
System Operations
➢ Dry Salt Fast transfer with a delivery up to 50Kg per minute (depending the bulk density
of the salt).
➢ Dry Salt Dosing using “Linear”, “Progressive 2” and “Progressive 3” Dosing Curves
automatically adjusting the speed of the screw conveyor.
➢ Dry Salt hopper capacity up to 250Kg of salt. In case of fast transfer for higher salt
quantities, the operator refills the hopper during the fast transfer, in order to fulfil the
required quantity.
➢ In the case of dosing, the salt transfer flowrate is automatically adjusted depending the
selected dosing curve in the relevant program function.
➢ At a convenient point and prior to salt transfer step, the operator fills the hopper with
the appropriate quantity of salt and confirms that the salt is ready to be transferred or
dosed.
➢ When the machine proceeds to the step, which requires the salt, automatically starts the
programmed operation without any human intervention.
➢ When the hopper becomes empty of salt, the operation stops automatically.
2
DSFD is optionally installed. Thus, all descriptions regarding it (from the Mechanical aspect of view as long
as from the Controller’s Functions’ aspect of view) are only applicable to machines that contain it as extra
equipment.
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Benefits
➢ No operator presence is required during operation of the system (except refill is

required).
➢ Fine dosing capability with “Linear”, “Progressive 2” or “Progressive 3” Dosing Curves.
➢ No involvement of the machine addition tanks in salt dilution is required, so faster
process is obtained. Therefore, machine’s addition tanks can be used for other chemicals
preparations.
➢ Depending of the machine size and process salt requirements, salt fast transfer time for
the complete required quantity is at least half of any other salt transfer application.
➢ No need of fresh water for salt dilution, so there is no LR change during the critical dyeing
step.
Components
➢ All the parts in contact with salt are made from 316/316L stainless steel.
➢ Salt hopper with salt capacity up to 250Kg.
▪ Stainless steel screen on the upper part, in order to protect the entrance of other
impurities.
▪ Compressed air vibrator to improve the salt flow.
▪ Stainless steel cover above the screen for protection against the entrance of solid or
liquids inside the hopper.
▪ Proximity switch with build-up protection to sense the presence of salt inside the
hopper.
➢ Sclavos design Hydro-Feeder with impellers, casing and electrical motor, protected with
stainless steel splash guard.
▪ Piping and automatic valves for the liquor and salt dilution liquor circulation.
▪ Motor is driving the Hydro-Feeder through pulleys and belt, so it has a perfect
protection against any possible leakage of the hydro-feeder seal.
▪ Rigid bearing housing of the hydro-feeder assembly for trouble free and long-life
operation.
➢ Dry salt Screw conveyor assembly connected with the lower part of the salt hopper. It
brings the dry salt to the hydro-feeder entrance.
▪ Dry salt exit nozzle is protected properly, for operational and human safety.
▪ Motor-reducer assembly, directly connected with the screw.
▪ Motor-reducer operation is driven from a frequency inverter, which is controlled
from the software.
Stainless steel rigid frame for the positioning and basement of all the above.
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1.13. AQUACHRON CONTINUOUS WASHING SYSTEM
1.13.1. AQUACHRON 4G (patented)
It is a further development of the established Sclavos continuous washing system, which

allows the entire process from loading to unloading to be performed without stopping either
the liquor or the fabric circulation. Thus, the fabric never stops moving for Drain or Fill
operations.
Process is Fully Controlled by advanced software developed by Sclavos which adjusts water
flow, temperature, level of liquor in the vessel and heating-cooling gradient as well if
needed.
System is able to wash effectively at low Temperature of 80°C without soaping agent,
obtaining excellent wash fastness.
FBD of Athena4TM machine improves efficiency of the system due to precisely steady
incoming flowrate.
The result of the above is a non-stop process without drops or fills. It provides savings of
up to 30% in time, up to 12% in water, up to 30% in electric energy and up to 20% in steam,
compared with modern conventional machines.
1.13.2. AQUACHRON FLX (patented)
Due to FBD feature, a further development of Aquachron system has been done. This version
is called Aquachron FLX.
Aquachron FLX operates under following conditions:
Low freshwater flowrate.
Low fabric speed.
Low nozzle pressure.
Low main Pump speed.
Result is Up to 15% less water consumption, up to 15% less steam consumption, up to 12%
less electric energy consumption, whereas total process time is increased by 5%, compared
with Aquachron 4G figures.
Proper operation of the system is fully controlled by specific software, while hardware
remains same as in Aquachron 4G.
1.13.3. AQUACHRON CALCULATOR
It is a software which is created from Sclavos IT and is based on algorithms and mathematical
calculations developed by Sclavos R&D dept. Giving the below data:
- Machine size
- Total Fabric weight
- Total (%) Dyestuffs
- Salt Concentration (gr/lt)
- Washing Class
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- Dyeing Temperature, and

- Your CHOICE: 4G or FLEX
It is calculated all the washing profile with all the details needed for the function
programming and getting in advance the total required water (Lt/Fabric Kg) and time in
minutes.
Provided that all given Data are correct and dyeing process has been performed inside the
well-known and accepted industrial tolerances (e.g. pH value, etc.), Sclavos guarantee the
achievement of washing test results, according the used dyestuff specifications.
Thus, there is no “rule of thumb” estimations of how to wash and succeed the washing test
results. All are pre-calculated without any excess consumption in water, time and energy.
1.14. AUTOMATIC SETTINGS ADJUSTMENT (ASA)

Athena™4 with Auto Settings Adjustment is at the cutting edge of technology and the only
available “self-thinking system”, providing global Interactive Control.
The machine is now able, without human interference, to monitor, control and interact with
process parameters.
Auto Settings Adjustment will:
➢ adjust the optimal settings for each individual batch,
➢ calculate accurately and adjust automatically the process Liquor Ratio,
➢ monitor and automatically self-adjust the time, water and steam supplies,
➢ adjust automatically the speed, revolution and flowrate,
➢ control and optimise automatically the process time,
➢ eliminate human intervention and practically disappears faults, which becomes from
operators.
➢ serve single or double rope operation
Inputs needed for Auto Settings activation are:
- Fabric Load
- Fabric weight per linear meter
And further parameters for washing (according the Aquachron Calculator):
- Liters per Kg of fabric
- Temperature / heating / cooling rates.
- Washing profile.
Athena™4 with Auto Settings Adjustment incorporated will constantly achieve the
application of an efficient Variable Loading System (VL), with benefits as below:
▪ absolute repeatability between batches ranging 60-100% of full loading,
▪ shade matching between batches ranging 60-100% of full loading
▪ identical LR between batches ranging 60-100% of full loading
▪ similar cost per fabric kg between batches ranging 60-100% of full loading
▪ constant chemicals’ and dyestuffs’ consumption per kg of fabric
▪ similar water and steam consumption per kg of fabric
Important Note:
As it is declared in the Maintenance section and mentioned here as well:
▪ Operation at minimum Liquor Ratio level demands auto adjustment settings.
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▪ Avoid running the pump at maximum speed manually.

These factors are important for the life prolongation of the machine’s Main Pump’s
mechanical seals.
1.15. MONITORING THE CONSUMPTIONS OF UTILITIES

Athena™4 machine is equipped with proper hardware components and special software
algorithms that can monitor and record for every batch, the following utilities consumptions:
➢ Total water used per batch. The machine counts every liter of fresh water entering
in the machine. Fresh water is coming from filling function or even from the
additional tanks as well. It is presented at the machine’s Controller.
➢ Total electrical energy per batch. Electrical energy meter placed at the central
electrical supply, counts and records every consumed kWh that is presented at the
machine’s Controller.
➢ Steam consumption for every batch. Special developed algorithms and correction
factors can give and present the total steam used within very good accuracy margins.
It is presented on the Controller at the end of the batch.
1.16. GENERAL SPECIFICATIONS OF THE REQUIRED UTILITIES

ELECTRICAL POWER SUPPLY:
3 - Phase - From 380 Volt up to 460 Volt at 50 or 60 Hz Plus PE (Protective Earth)
COMPRESSED AIR:
Dry, Clean and Oil free at Pressures: min 6 bars and max 7 bars.
STEAM to Heat Exchanger:
Saturated Steam at Pressures: min 6 bars and max 10 bars.
COOLING Water to Heat Exchanger:
SOFT, Cold – max 300C – Debris free (Filtered), Pressures: min 2.5 bars – max 6 bars. It is
preferable that the pressure fluctuations to be not more than +/- 0.5 bars.
PROCESS WATER:
Quality according to the Dyeing process requirements, Debris free (Filtered), Pressures:
min 1.5 bars – max 6 bars.
2. CONTROLLER SCLAVOS SEDOMAT 5500+ TECHNICAL

SPECIFICATIONS
The Sclavos automation philosophy is based on:

1. A user-friendly operator – machine interface under windows environment with icons for
a simple and intuitive operation.
2. A simple programming language for creating/editing dye programs, and,
3. A strong software structure with efficient algorithms that govern and control every
machine function is the core of the system.
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The fully automated system includes:
▪ A Sclavos-Sedomat 5500+ controller based at Windows CE® operating system, with 12.1”
TFT color display 800x600 pixels, touch screen placed in a separate stainless-steel cabinet
with intuitive user interface, including touch screen soft buttons easily adopted by
operators. These touch screen buttons allow the convenient operation of the addition
tanks manual functions from one single point. The cabinet incorporates all the necessary
light control indicators for a safe machine operation.
▪ Double stainless-steel cabinet with temperature-controlled ventilation, housing all the
necessary electrical, electronic and electropneumatic components for full and safe
machine operation, at two separate sections: one for the low voltage control
components and the other for the high-voltage power components.
▪ One auxiliary control panel placed on the top of the machine, easily accessible, in order
to minimize operator movements during the machine operation
All major functions have software interlocks, which prohibit the operator from inadvertently
damaging the machine or himself e.g. the pump will not start unless water is sensed in the
machine.
The electric cabinet and components leave the factory tested and pre-connected. Only
minimum workmanship, power and air connections are necessary at the customer site for
starting the machine in order to minimize time and expense in commissioning.
2.1. MACHINE CONTROL SYSTEM

➢ 1 (one or two, depending on machine size) stainless steel electrical cabinet for the
protection and housing of all-electronic, electrical and pneumatic components
comprising of:
➢ Remote Input/Output units with PROFIBUS DP interface including digital as well
as analogue inputs and outputs (I/O boards).
➢ Internal mounting for all electric relays, contactors, fuses, frequency inverters,
switches and other electrical and electronic equipment, for full and safe control
of the machine
➢ AC digital frequency inverter for fully variable main reel drive speed
➢ AC digital frequency inverter for fully variable plaiter speed, synchronised to the
main reel drive
➢ AC digital frequency inverter for fully variable main pump speed
➢ AC digital frequency inverter for fully variable continuous flow dosing
➢ AC digital frequency inverter for fully variable unloading reel(s) speed.
➢ Manual override feature on electro-pneumatic valves
➢ Seam detector main unit for the automatic and easy search of the fabric seams.
➢ Electro-pneumatic valves, gauges, manometers, filters, I/P and P/I Converters for the
full and safe control of the machine functions
➢ Stainless steel trucking for all exterior wiring and pneumatic tubing.
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2.2. CONTROLLER/ADDITION TANKS CONTROL PANEL
Sclavos Sedomat 5500+ controller with 12.1” TFT color touch screen and internal PLC, placed
in a separate stainless-steel enclosure:
➢ All touch screen soft buttons for manual control of the addition tanks
➢ All illuminated lights and switches have been placed on the enclosure for a safe
machine operation
➢ Sealed and properly ventilated control panel
2.3. AUXILIARY CONTROL PANEL

➢ Digital temperature display
➢ Alarm/Operator call beacon and buzzer
➢ All illuminated buttons and switches for the remote control of the drive functions.
➢ Sealed control panel.
2.4. FULLY AUTOMATION BY SCLAVOS SEDOMAT 5500+
➢ SCLAVOS Sedomat 5500+ Microprocessor based at Windows CE® operating system,

with 12.1” TFT color display 800x600 pixels, touch screen and internal PLC with
PROFIBUS DP worldwide accepted standard field bus for the connection of
automation components like remote PLC I/O boards, frequency inverters etc.
➢ Windows CE® is a robust operating system tailored for industrial applications. This
system is suitable for machine control against any computer virus and Trojans.
➢ Windows user interface with icons for a simple and intuitive programming operation.
➢ Animated VGA mimic of the machine, which improves the process overview.
➢ Graphical user interface for user friendly and simple operation.
➢ Touch screen soft buttons for manual control of the addition tanks.
➢ Practically unlimited number of dyeing programs.
➢ Parallel functions, subprograms and addition programs.
➢ Compatible with SM5000 & 5500 dye programs.
➢ Graphic display showing the dye cycle, the Liquor Ratio, the actual dosing curve,
water consumption.
➢ Local monitoring functions, storage of process data (e.g. temp curve) accurate
information of the Liquor Ratio and water consumption throughout the process.
➢ All alarms and pre-defined operator messages in text format.
➢ Several system text languages and character sets (e.g. Spanish, Chinese) are
supported.
➢ USB interface for inexpensive devices, like memory keys, for copy/save dye
programs, batch history (curves) and machine backup data.
➢ Internet technology (integrated web server) for remote access from any PC in the
plant network via Microsoft Internet Explorer.
➢ Ethernet TCP/IP network for link to SedoMaster Central system.
Page 19|64
Main vessel full automation functions:
I. Filling by monitoring the exact liters of water by electromagnetic flow meter. The
indirect calculation based on the fabric load and the LR is standard
II. Filling to a programmable water temperature (when hot water is available)
III. Draining to pump level plus drain time.
IV. Heating and cooling control of a gradient to a target temperature and time and
temperature control on a hold via PID control loop.
V. Aquachron (4G or FLX) controlling the flow rate of the water, the level inside the
machine, the desired temperature, the cool down rate and the hold time, according
the predefined water consumption for each step, providing Total Interactive Control
(TIC)
VI. Precise Water Calculation of the bath liquor through specific functions during
programming.
Addition tank full automation functions:
I. Filling of exact litres of fresh water or run back of exact litres from the machine.
Continuous Flow Dosing over a programmed time on ten selectable curves:
1) 4 Digressive Curves
2) 1 Linear Curve
3) 5 Progressive Curves
Using closed loop feed-back system for precise control of chemical injection.
II. Fast transfer for chemicals from addition tank to machine vessel.
III. Rinsing of addition tank through to the machine and rinsing to drain after final
transfer.
IV. Addition tank prepare signal.
V. Heating control and temperature control on a hold time.
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3. CONTROLLER SCLAVOS SEDOMAT 5500+ FUNCTIONS

In order to create the basic program steps, the dyer must be fully aware of the functions and
parameters of the Athena4TM SCLAVOS 5500+ Controller. The list of functions is presented
below3:
MAIN PARALLEL DATA SPECIAL

Filling Prepare Tank Pump Speed Prog. Start
Draining Control Off Reel Speed Prog. End

Aquachron 4GTM Rinsing Fill Add Tank VAT Dyeing Operator Call
Heat / Cool Dosing Tank Label Function
Hold Time Transfer Tank Jump
Save L.R. AQUACHRON CTRL Next Batch
Recall L.R. Cycloclean Prepare Prod.
Recirculation Tank Wait Prod.
Heat Tank Check Prod.
(Un)Load
Salt Prepare (Optional)
Salt Transfer (Optional)
Salt Pump Clean (Optional)
It must be mentioned here that the Main, Data and Special functions are inserted in the first
column. As far as the Parallel functions are concerned, these are inserted in the remaining
three parallel columns.
Optional functions, like Salt functions, are operational when the suitable equipment is
installed on the machine.
3
In the machine screen, the special functions are not available. However, they are presented here in order to
show a complete list of the available categorized functions.
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ATHENA 4 - MACHINE’S FEATURES & CONTROLLER SM5500+ Rev. 0
In general, Main Functions govern the step by step progress of the process, while the parallel
functions run alongside them. Care must be taken, however, when programming machine
functions, as they may delay the start of the next main function. For example, if a main
function ‘Hold Time’ is programmed for 5 minutes, and on the same step the machine
function ‘Cycloclean®’ is programmed for 10 minutes, the controller will remain on that step
for 10 minutes because of the Cycloclean® function.
3.1. MAIN FUNCTIONS
Figure 1: Example of Main Functions list
3.1.1. FILLING
Performs the filling of the machine.
Important Note:
In order to prolong the main pumps’ mechanical seals’ life, the dyer should consider the
below:
1. Machine should never run with foam inside the bath.
2. Operation at minimum Liquor Ratio level demands auto adjustment settings.
3. Avoid running the pump at maximum speed.
(See Maintenance Chapter)
Page 22|64
Programmable Parameters:
WATER TYPE (Text)

LITERS (Liters)
The desired volume of water should be programmed in liters.
Wt.LIQ.RATE (Value)
Filling by water liquor ratio.
WATER TEMPERATURE (°C)
This parameter is used in case of a mix water type filling valves.
3.1.2. DRAINING
This function starts the draining of the machine.
DRAIN TIME (mins)

DRAIN TYPE (Text)
The preferable drain valve should be selected (if there are more than one).
3.1.3. AQUACHRON 4G™ RINSING

By controlling the flow of the incoming water and the drain rate, Aquachron 4GTM Rinsing
can maintain a steady liquor level throughout the rinsing process, while also controlling
the desired level of temperature .
The operation of Aquachron 4GTM Rinsing is controlled by two functions:
The “Aquachron 4GTM Rinsing” and the “AQUACHRON CTRL” function.
WASH TEMPERATURE (value)

The set temperature that is maintained throughout the whole Aquachron 4GTM
Rinsing.
GRADIENT/MIN (value)
Gradient of Cooling/Heating throughout the Aquachron 4GTM Rinsing.
LT/MIN/CHAMBER (value)
The parameter that determines the flow of water per chamber during the
Aquachron 4GTM Rinsing. It can be either set by the user or calculated
automatically by using the algorithm option. It should be noted that, in case of
simultaneous cooling/heating and rinsing, the algorithm option should be used for
optimal performance.
LT/KG (value)
This parameter is used in order to calculate the liters of water that will be
consumed during the Aquachron 4GTM Rinsing operation.
The dyer can modify all parameters while creating the “Aquachron 4GTM Rinsing”
commands.
Page 23|64
Figure 2: AQUACHRON 4G™ RINSING parameters
a. AQUACHRON CALCULATOR
Sclavos Dyeing Technology team has developed the Aquachron Calculator software, which
helps the user to calculate with precision the parameters of the Aquachron 4GTM Rinsing
(or the Aquachron 4G™ FLX) operation.
3.1.4. AQUACHRON 4G ™ FLX

Aquachron 4G™ FLX is a second available option of Sclavos’ continuous rinsing system, obtaining
up to 15% less water consumption, up to 15% less steam consumption, up to 12% less electric
energy consumption, whereas total process time is increased by 5% compared to Aquachron
4GTM Rinsing.
Proper operation of the system is fully controlled by specific software, while hardware
configuration remains same as in Aquachron 4GTM Rinsing.
3.1.5. HEAT/COOL
Performs the normal Heating-Cooling operation of the bath through the Heat Exchanger
System.
Page 24|64
TEMPERATURE (°C)
GRAD/MIN (°C/min)
3.1.6. HOLD TIME

TIME (mins)
CYCLES (value)
Second option. Instead of Hold Time by minutes, there can be a set of cycles
number.
3.1.7. TKLR FUNCTIONS
a. SAVE L:R
When the SAVE L:R function is activated, the machine starts the calculation of the liquor
inside the main vessel and memorizes it.
TNK1 FILL L:R (value)

TNK2 FILL L:R (value)
During the SAVE L:R function, and in order to maintain the same LR for
Pretreatment and Dyeing phase, the operator can select an amount of LR that will
be runback in each tank. This water will not be calculated while memorizing the
Water level and it will be transferred back to the main vessel when the SAVE L:R
function is executed.
b. RECALL L:R
Performs the bath’s recall level to the memorized liquor ratio.
WATER TYPE (text)

Set according to the factory supplies.
AQUACHRON DRAIN TYPE (text)
Set according to the factory supplies.
WATER TEMPERATURE (°C)
This parameter is used in case of a mixing filling valve(s).
Page 25|64
3.2. PARALLEL FUNCTIONS
Figure 3: Example of Parallel Functions list
Page 26|64
3.2.1. PREPARE T1 (T2)

Function that warns the operator in order to Prepare the Chemicals/Dyestuff for insertion
to the side tanks.
Figure 4: The “Tank Prepare Buttons” indicated with the numbers 1,2 according to the Tank where the preparation is made.
If they are blinking yellow, the operator must add the chemicals. When he adds the chemicals and press on the corresponding
button, it turns yellow and the controller acknowledges that the chemicals have been successfully added in the tank(s).
MESSAGE (Text)
The chemical name that needs to be prepared must be selected.
MAX TIME (min)
The maximum preparation time before alarm warning must be entered.
3.2.2. FILL ADD T1 (T2)

Performs the Filling of the Addition Side Tank(s).
WATER (Text)
Two choices to select: Cold and Runback water.
LEVEL (Liters)
The desired filling level quantity should be set in liters.
LEVEL ALG (Value)
Filling the add tanks by algorithm.
Page 27|64
3.2.3. DOSING T1 (T2)

Performs the dosing of the chemicals and the dyestuffs from the additional side tank(s) to
the machine.
DOSING TIME (mins)

The Dosing Time is set in minutes.
DOSING CURVE (Text)
Selection of the dosing curve. There are 10 available curves: Linear, 5 Progressive
(1 to 5) and 4 Degressive (1 to 4) [see drawing with curves and table below]
CYCLES DOSING (value)
Second option for dosing the ingredients of the side tanks, by cycles number.
DOS1+DOS2 (Text)
The above parameter is available only when setting the DOSING T1 function.
With this parameter the simultaneous dosing from both side tanks is available. The
simultaneous dosing is set only for Tank 1.
Figure 5: Graphical presentation of the dosing curves
3.2.4. TRANSFER T1 (T2)

Transfers the contents of the additional side tank(s) to the machine’s vessel.
None
3.2.5. RECIRCULATION T1 (T2)

It performs the recirculation of the bath liquid into the additional tank(s) and transfers it
back to the machine.
Page 28|64
TEMPERATURE (°C)
TIME (min)
3.2.6. HEAT ADD T1 (T2)

Heats up the Add Side Tank(s) contents
TEMPERATURE (°C)
TIME (mins)
3.2.7. CONTROL OFF

The execution of this function sets the temperature control OFF.
Programmable Parameters: None
3.2.8. (UN)LOAD
The function is a call for the operator to proceed for the fabric’s loading or unloading.
When the Load/Unload is complete the program moves to the next step by pressing the
soft key NEXT STEP on the controller wizard screen or the NEXT STEP physical button
located on the operator panel.
None
Page 29|64
Figure 6: In order to reveal the "Next Step" button, the operator must press the Operator Key button (see Chapter 4.1) and
then in the submenu he can press the "Next Step" in order to move forward with the program
3.2.9. AQUACHRON CTRL

Aquachron CTRL function must always be programmed parallelly to the Aquachron 4G
Rinsing (or the Aquachron 4G FLX) function.
WASH LEVEL (LU/CHAMB.4G) (value)

The set water level throughout the Aquachron 4GTM Rinsing operation.
WATER TYPE (text)
AQC DRAIN TYPE (value)
The preferable drain valve should be selected (if there are more than one)
Page 30|64
Figure 7: AQUACHRON CTRL parameters
3.2.10. CYCLOCLEAN®
Performs the cleaning of the internal part of the machine’s vessel.
TIME (mins)
3.2.11. SALT PREPARE (Optional)

The function activates the alarm light and the siren in order to call the operator for the salt
preparation.
None
3.2.12. SALT DOSING (Optional)

Executes the salt dosing. When the salt is dosed, a clean cycle of the salt pipeline is
activated.
DOS TIME (mins)

CURVE (text)
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The user must select the desired salt dosing curve among the below options:
FAST
LINEAR
PROGRESSIVE 2
PROGRESSIVE 3
Figure 8: Salt Dosing function parameters, and dosing curve options
Programmable Batch Parameters:
In order to make the optimum calculations of the salt dosing parameters the Dry Salt Fine
Dosing system uses 2 batch parameters that need to be set while a batch is loaded in the
controller4. These parameters are:
SALT (gr/lt)
Set point of the salt amount in gr/lt.
BULK DENSITY (value)
This is the bulk salt’s density. Every quality of salt has a different density that is
important for the above calculation. This need to be set according the salt’s
specifications.
3.2.13. SALT PUMP CLEAN (Optional)

For a set time, the function activates the cleaning of the salt pump by recirculation of the
machine’s bath.
TIME (mins)
4
See Chapter 5.1.1
Page 32|64
3.3. DATA FUNCTIONS
Figure 9: Data functions
3.3.1. PUMP SPEED

Defines the Main Pump motor speed.
SPEED % (value)
PROCESS (Text)
There are two choices: “Normal” and “Pretreatment”.
The choice ‘Normal’ is used when the fabric is completely wet. ‘Pretreatment’
choice is used during the dry fabric loading and up to the step where the fabric has
become completely wet.
3.3.2. REEL SPEED

Sets the reel speed in m/min (yd/min).
METERS/MIN (m/min)
Programmable Batch Parameters:
FABR.DENSITY (text)
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While loading a batch in the controller, one of the Batch Parameters that needs to
be inserted is the one called Fabric Density5 and it is self-explanatory as it refers to
how dense the fabric that will be loaded is. This option is there in order the machine
to adjust the Reel Speed accordingly depending on the Density of the fabric. This
Batch Parameter has two selectable options, “NORMAL” and “HIGH”
3.3.3. VAT FUNCTION

This function was created especially for “VAT” dyeing process. The purpose of this function
is to avoid the air intake into the machine during the reduction of “VAT” dyes.
VAT ACTIVE (Text)

There are two choices: “ON” and “OFF”.
Notes:
▪ During this function, main functions like” HEAT/COOL” can be executed
without any problem except the main Drain function. The side tank filling
with machine water (Runback) is allowed.
▪ If the VAT choice is activated, you can see at the graphic animation
screen(s) on SM5500+ the indication “VAT” with RED as below:
5
See Chapter 5.1.1
Page 34|64
3.4. SPECIAL FUNCTIONS
Figure 10: Special Functions list. The chemical dispensing/Sedomaster functions described above, are part of the Special
Functions list.
3.4.1. PROGRAM START

Program Start must be programmed at the start of all Main Programs.
.
3.4.2. PROGRAM END

Program End must be programmed at the end of all Main Programs.
.
3.4.3. PROMPT (FUNCTION STOP)

Prompts are messages to the operators warning him that he must perform a manual
function.
Programmable parameters:
Kind of Stop Remarks

SAMPLE See Below
SEAMS 1 BY 1
CHECK pH
CHECK SALT
CHECK PEROXIDE
Page 35|64
CHECK SPEED
MACHINE CLEAN
REPLACE FILTER
CHECK HARDNESS
(UN)LOAD
SEAMS DETECTION See Below
CHECK CLARITY
CHECK REDUCTION
An Alarm signal is given, and a message is displayed on the controller screen. After the
operator has performed the required task, he has several options as to how the process
will continue:
a. SAMPLE
During the command “SAMPLE”, the Seam Detector device is automatically activated in
order to automatically stop to the fabric’s seam.
b. SEAMS DETECTION
Function “Seam Detection” should be used for the unloading of the fabric using the
detection of all seams simultaneously until all seams are found..
c. GO TO THE NEXT LINE

Having completed the manual intervention, the “Enter” button must be pushed in order
to proceed to the next step of the program.
d. GO TO LABEL
All the Labels used within the dyeing program are being displayed. The operator has the
option to select the required label and jump from the present program step to another
step, within the same program, which has been ‘marked’ by a Label function from where
the program will continue to run.
e. EXECUTE ADDITIONAL PROGRAM

This option is selected in cases in which an additional program is about to be executed.
The operator has the option to select the required additional program, which has
been previously created and exists to the controller’s memory.
f. LABEL
Label functions provide ‘tags’ within the program in order to jump to, whenever a
process modification is required.
ADDITION
LABEL TYPE REPAIR
LABEL
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Example
STEP MAIN FUNCTION PARALLEL 1 PARALLEL 2 PARALLEL 3
LABEL FUNCTION
34
LABEL: ADDITION
FILL ADD T1
PREPARE T1 WATER: RUNBACK
35 MESSAGE: ALKALI LEVEL: ADD 1
MAX TIME : 5 LEVEL(ALG)
LEVEL ALG: 3
HOLD TIME
36 TIME: 30
CYCLES: 5
DOSING T1
DOS TIME: 3
37 DOS CURVE: LINEAR
CYCLE DOSING: 5
DOS1+DOS2: NO
HOLD TIME
38 TIME: 30
CYCLES: 5
PROMT
39 KIND OF STOP:
SAMPLE
In the above example it is possible to jump back from step 39 to 34 and repeat the process
between steps 35 and 39 if, after the sample has been taken at step 39, it is found that an
addition is required.
This is done by selecting GO TO LABEL on the controller. All the Labels used in the
program will be displayed. Choose the Label where the program is to jump to.
g. RETURN
The Return command must be programmed at the end of all Subprograms or Addition
Programs.
h. SUBPROGRAM
Performs the call and execution of a subprogram.
PROGRAM NR (value)
The subprogram number should be entered.
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3.4.4. FUNCTIONS FOR SEDOMASTER/CHEM.DISPENSER

The activation of these functions will be performed by the person, which will establish the
software communication between the “Sedomaster” and the dispensing station.
These functions are described as Data functions.
There are three (3) functions / commands:

➢ PREPARE PRODUCTS
➢ WAIT FOR PRODUCTS
➢ CHECK PRODUCTS
When the above three functions are being used at any point of the dye program (and taking
under consideration that a dispensing system is installed), the following steps must be
programmed in this way:
Main Window Parallel 1 or 2 or 3
(Main function) Prepare tank 1 or 2

Prepare products
Wait products
Check products
Transfer or Dosing
More specifically for each function of the above:
a. PREPARE PRODUCTS
When the command “Prepare products” is activated, the machine through “Sedomaster”
asks for the dyestuffs from the dispensing system.
PREPARE NR (value)
Specifies the number of the preparation (1 to 99)
TANK NR (value)
Specifies the tank in which the requested dye stuff material will be transferred (1
to 5)
b. WAIT FOR PRODUCTS

When the command “Wait for products” is activated, the machine through “Sedomaster”,
asks from the dispensing system to respond whether the specific dyestuff exists in its list
or not and whether it is available or not.
PREPARE NR (value)
Specifies the number of the preparation (1 to 99). The number must be the same
as the one that was declared with the function “prepare products”.
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c. CHECK PRODUCTS
At this point the machine waits for a final reconfirmation. When the dispenser performs
the transfer of the dyestuff, “Sedomaster” is informed and the function is reset.
If the chemical dispenser cannot deliver the requested dyestuff, then “Sedomaster”
activates an alarm which informs the operator to input the relative dyestuff manually,
while the button “tank OK” is blinking. The dye program remains at this step till the
operator inputs the dyestuff and confirms this with the press of the Tank OK button.
PREPARE NR (value)
Specifies the number of the preparation (1 to 99). The number must be the same
as the one that was declared with the function “prepare products”.
3.4.5. RESTART PROGRAM AFTER SUDDEN STOP

After a sudden STOP like a drop voltage or an ALARM with STOP action, the program can
be restarted with two possibilities:
a) Restart Functions: The program will

restart the marked functions as well as the
programmed set values, ignoring any
previous countdown of the time or the
quantity.
b) Continue Functions: The function that was
active before the program was interrupted,
will continue with the current actual values.
Figure 11: Restart interrupted process window The interrupted function will be completed,
and then the program will continue.
4. CONTROLLER HANDLING
When switching the Athena4TM machine on with the main power switch6, the controller
will also be activated and it will be necessary to wait for a few seconds while the controller
initializes, and the machine graph (see page below) appears on the screen.
This is the main screen of the controller and will be referred as the “Main Screen”
throughout this manual. The Main Screen presents a graphic with the machine’s drawing
including some touch screen buttons, with which you can switch to several animation
screens, like graphic display showing the fabric dye cycle, the liquor ratio, the water
consumption, the flow into pipes and the status of the valves.
6
See sub-chapter 6.2
Page 39|64
Further information is displayed at the top of the screen in the so-called “Status Area”.
The Status Area is constantly updated while the machine is in process and gives the
following information:
➢ Status of the program.

➢ Batch identification.
➢ Number and name of the program being executed.
➢ Alarms and operator messages.
➢ Process values like actual and theoretical machine temperature, remaining time for the
active step, total water consumption, L.R recording.
Some screenshots of the controller’s interface are shown below:
Figure 12: SM5500+ ATHENA4™ Main Machine Screen
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Figure 13: SM5500+ ATHENA4™ Cycle Time Screen
4.1. FRONT PANEL KEYS
Figure 14: Controller's Front Panel Keys
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1 Batch Menu Key

2 Management Key
3 Context Key
4 F1 Hot Key. It can be assigned to any dialog. In order to assign a new dialog to this key,
open a dialog and then press the F1 key for 5 seconds. From now, the F1 key will be assigned
to that dialog.
5 F2 Hot Key. Like F1 Hot Key.
6 Start Program Key.
7 Stop Program Key.
8 Program View Key. When pressed it shows the screen with all the Program Functions’
sequence for the actual loaded Batch.
9 Machine Drawing Key. When pressed it shows a more detailed screen of the machine’s
activity.
10 Functions View Key. When pressed it shows the current active functions and allows
to intervene to these functions. Moreover, this Key allows to manually start a function.
11 Logging View Key. When pressed it can show the recorded graphs and events stored
in the controller’s memory.
12 Operator Key. Simulates the buttons on a panel. When pressed it gives the ability to
the operator to increase/decrease the Reel Speed, go to next step in a program etc.
13 Service View Key. When pressed, the Service View menu opens up.
14 Machine Drawing Key. When pressed it shows the previously opened screen.
4.2. STATUS AREA
Figure 15: Controller's Status Area
1 Graphical indication of the Batch status. There are four different indication that can be
shown here according to the Batch status:
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When Batch is Running

When Batch is Stopped
When Batch is Halted
When Batch is in Manual Operation
2 The area marked with number 2 in the photo above is split into two minor ones. The
upper and the lower:
➢ In the upper area can be found the Batch Identification, which in fact is the Batch
Name given when a new Batch is loaded.
➢ In the lower area can be found the Program name and its corresponding number.
When a batch is running, the Process Name and number and the Running
Treatment Name and number are showing in this area consecutively.
3 In this field, Local Messages, PLC Messages and Stop Declarations are appearing during
a Batch.
4 Alarm showing area.
5 Current water temperature (oC).
6 Target temperature of a Heating or Cooling function (oC).
7 Actual Countdown of the command that is currently activated during a process. If more
than 1 commands are simultaneously activated, the countdown shows for the one with the
maximum time remaining only (minutes).
8 Actual measuring of the water liters that have been consumed since the start of the
batch. (liters x10)
9 The latest saved measurement of Liquor Ratio.
10 Clock.
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4.3. MAIN SCREEN AREA
Figure 16: Controller's Main Screen
1 Reel Speed indication (m/min)

2 Main Reel graphical indication. When the Main Reel is activated, the graphic is turned
green, when it is deactivated, it is turned grey as it is shown in the photo.
3 Pump Speed indication (%)
4 Pump graphical indication. When the Pump is activated, the graphic is turned green as
it is shown in the photo, when it is deactivated, it is turned grey.
5 Unloading Reel graphical indication. When the Unloading Reel is activated, the graphic
is turned green, when it is deactivated, it is turned grey as it is shown in the photo.
6 Heat Exchanger graphical indication. When the Heat Exchanger is activated, it turns
either blue when it is in a cooling process, or orange when it is in a heating process. When
it is deactivated it is turned grey.
7 Heated water’s temperature indication (oC). This is the indication of the water’s
temperature measurement right after the Heat Exchanger. Thus, it is the temperature of
the water that it is sprayed on the fabric through the nozzles.
8 Indication of the current water L.R inside the Main Vessel.
9 Indication of the current water litters inside the Main Vessel.
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4.4. PROGRAM VIEW

When a batch is loaded, or when the Program View Key7 is pressed the below screen
appears:
Figure 17: Controller's Program View
The 5500+ Controller features 4 columns, which mean 3 parallel functions can be run along
with the main one. The sequence of these function eventually creates a whole process.
A program consists of a sequence of functions that are executed. Most functions include
parameters. For example, the function heating includes the parameters temperature, time
and gradient. The functions and the parameters are represented by an icon, a large icon
for the function and smaller icons for the function parameters.
When the function is not in the magnified area (meaning it’s not manually pressed in order
to get to its sub-menu), only the first function parameter is shown.
The program is divided in four columns. The left column always controls the main process.
The other three parallel ones usually control parallel processes e.g. tank units, preparation
units, dosing units, etc.
When the functions are synchronous, the program is executed line by line but and all
functions on the same program line are executed simultaneously. But functions can also
be asynchronous. That means the next function is already started although the main
function is not finished. Determination of which of the functions are synchronous or
asynchronous is made by the Department of Sclavos which is responsible for the
Controller’s software.
When a function is finished, then the next line is executed. For some functions, an
acknowledgement that the previous function is done, is not required, so the Controller will
7
See Chapter 4.1
Page 45|64
not wait to execute it. This way, it is possible that in the same window, several functions
are active at the same time. (e.g. During Filling, the operator can be called to add the
chemicals to a side tank)
Each window has a position pointer that points to the function that is being executed or
pointing to the function that will be executed next. These position pointers are of magenta
color.
Finally, a program always contains special functions that control the flow of it. These
functions do not perform any action on the machine and their color is always green. Such
functions are:
4.5. ADD TANKS SCREEN

By pressing on the Additional Tanks graphic illustration on the Controller’s Main Screen as
it is shown on Chapter 2.4, the Controller opens the Add Tanks Screen as shown below:
Figure 18: Controller’s Add Tanks Screen
1 Add Tank Runback buttons.

Once the button is pressed, water through machine runback fills the add tank.
The output resets if FILL ADD, or DOSING, or TRANSFER, or RECIRCULATION, or
Aquachron 4GTM Rinsing functions start running, or the button is pressed again, or
the add tank level reaches the maximum level, or the machine temperature gets
above the safety one (interlock).
2 Add Tank Heat buttons
Once the button is pressed the additional tank’s heating output comes on.
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The output resets if DOSING starts running, or the button is pressed again, or the
additional tanks’ level is under the middle level (set in tune value), or the add tank
temperature is above 95oC.
3 Add Tank Transfer buttons
Once the button is pressed the additional tanks transfer and the additional tanks’
pump outputs activate.
The output is reset if any side tank functions in AUTO mode are activated, or the
button is pressed again, or the main pump is not running.
4 Add Tank Drain manual buttons
Once the button is pressed the additional tanks drain and the additional tanks’ pump
outputs activate.
The output resets if DOSING, TRANSFER, RECIRCULATION, HEAT ADD functions are
running, or the button is pressed again, or the additional tank transfer button is
pressed, or the additional tanks’ minimum level plus the drain time (set in tune
value) is reached or the button is pressed again.
5 Add tank mixer buttons
Once the button is pressed the add mixer output comes on.
The output is reset when the button is pressed again, or the “mixer” add level is
reached, or the mixer overload input comes on.
6 Adds Tank Ready buttons
This gives the signal that the preparation is ready. See PREPARE ADDS parallel
function description.
7 Add Tank Fill/Rinse button (Touch Screen Button)
Once the button is pressed the add fill/rinse output comes on.
The output resets if FILL ADD, or DOSING, or TRANSFER, or RECIRCULATION parallel
functions are running, or the button is pressed again, or the add level reached the
maximum point.
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4.6. CONTROLLER SALT FINE DOSING SYSTEM SCREEN

(Optional)
While on Add Tanks Screen, as shown on Chapter 2.5, by pressing on the Salt Fine Dosing
System graphic illustration, the Controller opens the Salt Fine Dosing System Screen as
shown below:
Figure 19: Controller's Salt Fine Dosing System Screen
1 Salt tank ready button

This gives the signal that the salt preparation is ready.
See PREPARE SALT parallel function description.
2 Salt Final Dose button
The operation described at SALT PREPARE function.
3 Salt Screw Start – Stop button
Sets the salt screw and the salt vibrator outputs ON.
Reset is performed if the salt pump is not running, or the SALT TRANSFER function
is running, or the machine temperature is above the interlock temperature, or any
alarm related to salt system comes on. As this is a manual mode, start the speed set
at 100%.
4 Salt Empty Tank light (Animated Screen)
Provides the signal that the salt tank has been emptied.
5 Salt Quantity
It’s the indication of the salt amount in grams per liter that was set in the Batch
Parameters during the Batch Loading.
6 Dosing Screw Percentage (%)
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Depending on the salt dosing curve it has been selected, the percentage of the Salt
Screw operation is indicated here. It cannot be changed manually.
7 Salt Pump Start – Stop button
Sets the salt pump and the salt inlet- outlet outputs ON.
Reset is performed if the main pump is not running, or the SALT TRANSFER function
is running, or the machine temperature is above the interlock temperature or any
alarm related to salt system comes on.
4.7. PROGRAM HISTORY AND EVENTS SCREEN

Sedomat 5500+ gives its operator the opportunity to go through past batches history in
order to help in finding any mistakes or events that took place and possibly affected in a
negative way the batch.
In order to get to the history screen the operator needs to press the Logging View Key8.
When the button is pressed the menu below appears:
Figure 10: History Screen
1 Batch Number Indication

2 Program Number Indication
3 Program Name Indication
4 Time when the batch was loaded Indication
8
See Chapter 4.1
Page 49|64
5 Production Number Indication

6 Buttons to browse up and down to the Batch Parameters options
7 Logging View Button
8 Show Curve with Events Button
9 Select Logging Button
On the above screen, by pressing the Select Logging Button (no. 9) the below dialog box
opens where the preferred batch can be selected from the list of the ones that are
memorized in the Controller’s internal memory.
Figure 21: History Batch Selection
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Finally, when a batch is selected, it is graphically represented as below:
Figure 22: Batch Curve Screen
1 Date and Time on the cursor’s point

2 Curve Name
3 Curve Indication
4 Cursor
5 Show Batch Information
6 Show Curve with Events
7 View Total Curve
8 Zoom Button
9 Browse Left/Right Buttons
In this screen the operator can find the whole graph of the Batch process that was selected
and, also, the step-by-step details on the lower part of the screen.
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5. CREATING A PROGRAM FOR ATHENA4TM

Sedomat 5500+ separates the Programs into three (3) program groups :
➢ PROCESS (Main Programs).

➢ TREATMENT (Sub Programs).
➢ ADDITION (Addition Programs).
Regarding the difference of the aforementioned kinds of program groups, please refer to
the SM5500+ User manual.
5.1. HOW TO LOAD A NEW BATCH

By pressing the Batch Menu Key9 the controller gets into the Batch information sub-menu:
Figure 23: Batch Sub-Menu
Here, the operator must select the first option: “Load current batch” which will lead him in
the below screen:
9
See Chapter 4.1
Page 52|64
Figure 24: Load Current Batch Sub-Menu
The information that need to be inserted here are the Batch Number and by pressing on
the Program List field, a local process from the total ones stored in the Controller’s
memory must be also selected.
After these two parameters have been filled successfully, the operator needs to press on
the “Batch param.” button on the lower left of the appearing window. By pressing on this
button, the below screen will appear:
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Figure 25: Batch Parameters Sub-Menu
Here, the appearing Batch parameters need to be filled accordingly:

➢ Fabr. Weight (kgs) is referring to the total batch weight.
➢ Liquor Ratio is referring to the filling Liquor Ratio
➢ Length gr/lm refers to the GLM of the fabric or else the grams per linear meter of
it.
➢ AQC LU/Ch refers to the Aquachron level of water during the Aquachron 4GTM
Rinsing process. This will be explained in the Aquachron Chapter.
➢ Double Rope refers to the option that the operator must load the fabric as single
or double rope. So, the option “NO” refers to single rope operation and “YES” to
double rope operation.
➢ Fabric Density obviously refers to the density of the fabric that is being loaded in
the machine. Two options here, Normal and High. Depending on the selection, the
machine will adjust properly the cycle time for better quality results.
➢ Salt (gr/l) refers to the amount of salt in grams per liter that will be used in the
dyeing process.
➢ Bulk Density refers to the salt’s density which in every change of salt’s quality in
the dyehouse needs to be measured and the right value to be set in this window.
After inputting the right values, the operator needs to press “OK” which will lead him to the
previous screen and from there he needs to select the “Load local”. This way the process
will be loaded in the screen and it will be ready to start after the “Start Program key” 10 is
pressed.
10
See Chapter 4.1
Page 54|64
5.2. FROM PROCESS DIAGRAM TO STRUCTURED

PROGRAM
The procedure displayed below, is an actual process for 100% Cotton Fabric, run on an
Athena4TM (500 kg) machine, and will be used as an example throughout this section to
explain how to structure a program.
Both the bleaching and the dyeing cycle are according to the customer’s existing processes.
By using Aquachron 4GTM Rinsing, it is recommended not to do any alterations on the
process or the desired L.R, in order to achieve significant savings both in time and water.
The recipe used is the following:
Remazol Yellow RR 1.11%
Remazol Red RR 0.16%
Remazol Blue RR 0.73%
Glauber Salt 30 gr/lt
Soda Ash 5 gr/lt
Caustic Flakes 1 gr/lt
This is a typical process for cotton 100% fabric (Pre-bleaching, dyeing, and rinsing with
open width 210 cm and 160 GSM).
Athena4TM
Total
Lit/min/ Delay Time Temp Water °C/
Cot Medium 2,0% (Pre bleach - React 60°C) Ch/ers Lit/kg time
Ch/er (min) (min) (°C) (Lit) min
(min)
ACTUAL BATCH (KG) 500 2 0 0 30
Fill L:R 1: 5.5 5.5 3 3 30 2750
Heat 30>60°C -Trans Recycl [A], [B] - Load 10 13 60 0 5
Dose linear (Runback 1:0,2) [C] 3 16 60 0
Save L:R while Runback T1 & T2 5.0 1 17 60 0
Heat 60>98ºC 13 30 98 0 3
PREBLEACH
Hold time 30 60 98 0
Cool 98>80ºC 6 66 80 0 3
Aquachron 4G 80°C 130 2 4 8 73 80 2000
Aquachron 4G 80°C>55°C 120 2 4 8 82 55 2000 3
Check/Correct pH 10 92 55 0
Hold time - Check/Correct H2O2 - Transfer [E] 0.10 11 103 55 50
Recall L:R 1 104 55 0
Heat 55>60°C -Trans Auxiliaries [F] - Salt DSFD 2 105 60 0 3
Hold time 10 115 60 0
Dose Dyes Linear 20 min 0.40 20 135 60 200
DYEING
Hold time 15 150 60 0

Dose Alkali Progress3 45 min 0.40 45 195 60 200
Hold time 45 240 60 0
Sample 3 243 60 0
Aquachron 4G at 60°C 179 2 4.3 6 249 60 2150 0
Check/Correct pH Trans (Fresh 1:0,2) [I] 0.2 12 261 60 100
WASHING
Aquachron 4G 60>80°C 128 2 5.1 10 271 80 2550 2

Aquachron 4G 80°C 135 2 10.5 19 291 80 5250 0
Aquachron 4G 80>60°C 108 2 4.3 10 301 60 2150 2
Unload 10 311 60 0
Drain 2 313 0 0
PROGRAM RETURN
TOTAL 38.8 313 19400
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100
90
80
70
DYES ALKALI
60 Peroxide
Per. Killer
Acid
50 Acid SALT
Dyeing Aux
40 Bleaching Aux
& Caustic
30
20
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
There are some points, worth mentioning, for this specific batch:
According to the fabric characteristics, the automatic settings will adjust the reel speed to
296 m/min and the pump to 90%. The cycle time shall be 2.7 minutes.
During the various steps of Aquachron 4GTM Rinsing the water quantity inside the machine
was adjusted at 400lt/chamber and the flow of fresh water was:
Step 8: 130 lt./min/chamber

In order to structure the rinsing processes during pre-bleaching, you need to keep in mind
the operating temperature of the peroxide killer and of course the temperature at which
dyeing starts. In the example used in this section, the peroxide killer, which is an enzyme,
can be used effectively between 40⁰C and 60⁰C.
Since the dyeing temperature was 60°C, we performed Aquachron 4GTM Rinsing down to
55⁰C (step 9) and then added the enzyme.
At the end of dyeing, the rinsing process starts. The rinsing time and amount of water
used for rinsing are always adjusted according to the depth of shade and therefore, the
concentration of the electrolyte in the bath. With the help of Aquachron Calculator
software, we calculate the step and water consumption during Rinsing Process.
After soaping, in the conventional process, we would use drain-fill method. In Athena4TM
we use Aquachron 4GTM Rinsing, a continuous process that frees us from the need to
drain-fill and its negative effect on the fabric as well as time/energy consumption.
In contrast to the conventional method, Aquachron 4GTM Rinsing process has the
following advantages:
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➢ Faster processes due to more efficient rinsing effect and elimination of drain, fill,
heating and cooling time.
➢ Less water consumption due to the continuous rinsing process in low Liquor Ratio, at
the optimum temperature for each Aquachron 4GTM Rinsing step, ensuring better
water utilization.
➢ Better fabric quality, due to absence of stoppages for drain-fill, which results to
temperature shock effects.
➢ Precise calculation of water consumption.
➢ No need for special adjustments, as the system is automatically set and controlled.
➢ Less energy consumption.
At the same time the use of CYCLOCLEAN® is recommended in order to keep the internal
parts of the machine clean.
5.3. EXAMPLE OF MAKING A CONTROLLER’S PROGRAM

(COTTON 100%)
STEP MAIN FUNCTION PARALLEL 1 PARALLEL 2 PARALLEL 3
1 PROG_START
PUMP SPEED
REEL SPEED
2 PUMP SPΕED (%): 70
METERS/MIN : 100
PROCESS: PRE-TREAT
FILLING FILL ADD T1 FILL ADD T2

WATER TYPE: COLD PREPARE T1 WATER: RUNBACK WATER: RUNBACK
3 LITERS: FILL ALG(ALG) MESSAGE: WETTING LEVEL: ADD 1 LEVEL: ADD 2
Wt.LIQ.RATE: 0.0 MAX TIME : 5 LEVEL(ALG) LEVEL(ALG)
WATER TEMP: 40(⁰C) LEVEL ALG: 3 LEVEL ALG: 2
HEAT/COOL PREPARE T2
4 TEMPERATURE: 60(⁰C) TRANSFER T1 (UN)LOAD MESSAGE: PEROXIDE
GRAD/MIN: 0 MAX TIME: 5
PUMP SPEED
REEL SPEED
PUMP SPΕED (%):
5 METERS/MIN:
PUMP SPΕED(ALG)
REEL SPEED(ALG)
PROCESS: NORMAL
DOSING T2
DOS TIME: 3
6 DOS CURVE: LINEAR
CYCLE DOSING: 5
DOS1+DOS2: NO
SAVE L:R
8 TNK1 FILL LR: 4
TNK2 FILL LR: 4
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HEAT/COOL
10 TEMPERATURE: 98(⁰C)
GRAD/MIN: 3
HOLD TIME
11 TIME: 30
CYCLES: 5
HEAT/COOL
12 TEMPERATURE: 80(⁰C)
GRAD/MIN: 3
AQCHR CTRL
AQUACHRON 4G FILL ADD T2
WATER TYPE: PROCESS
TEMPERATURE: 80(⁰C) WATER: COLD PREPARE T2
WASHING LU:AQCHR
13 GRAD/MIN: 0 LEVEL: ADD 2 MESSAGE: ACID
LEVEL(ALG)
LT/min/champ: 130 LEVEL(ALG) MAX TIME: 5
AQ.DR.TYPE: CLEAN
LITRES/Kgr: 4 LEVEL ALG: 3
DRAIN
AQUACHRON 4G AQCHR CTRL
FILL ADD T1
TEMPERATURE: 55(⁰C) WATER TYPE: PROCESS
WATER: COLD PREPARE T1
GRAD/MIN: 3 WASHING LU:AQCHR
14 LEVEL: ADD 2 MESSAGE: PEROXIDE
LT/min/champ: AQCHR LEVEL(ALG)
LEVEL(ALG) MAX TIME: 5
FLOW(ALG) AQ.DR.TYPE: CLEAN
LEVEL ALG: 3
LITRES/Kgr: 4 DRAIN
15 TRANSFER T2
OPERATORCALL OPERATORCALL OPERATORCALL OPERATORCALL

16
MESSAGE: CHECK pH MESSAGE: CHECK pH MESSAGE: CHECK pH MESSAGE: CHECK pH
HOLD TIME
17 TIME: 10 TRANSFER T1
CYCLES: 5

18 MESSAGE: CHECK MESSAGE: CHECK MESSAGE: CHECK MESSAGE: CHECK
PEPROX PEPROX PEPROX PEPROX
RECALL L:R
WATER TYPE: PROCESS
19 AQ.DR.TYPE: CLEAN
DRAIN
WATER TEMPER :20(⁰C)
FILL ADD T2
PREPARE T2
HEAT/COOL WATER: COLD
MESSAGE: DYEING
20 TEMPERATURE: 60(⁰C) LEVEL: ADD 2
AUXIL
GRAD/MIN: 3 LEVEL(ALG)
MAX TIME: 5
LEVEL ALG: 3
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21 TRANSFER T2
FILL ADD T1
RECIRCUL T2 WATER: COLD PREPARE T1
22 TIME: 5 LEVEL: ADD 2 MESSAGE: DYESTUFFS
RINSE? YES LEVEL(ALG) MAX TIME: 5
LEVEL ALG: 4

23
MESSAGE: CHECK pH MESSAGE: CHECK pH MESSAGE: CHECK pH MESSAGE: CHECK pH
HOLD TIME
24 TIME: 10
CYCLES: 5
DOSING T1
DOS TIME: 20
25 DOS CURVE: LINEAR
CYCLE DOSING: 5
DOS1+DOS2: NO
FILL ADD T2
HOLD TIME WATER: COLD PREPARE T2
26 TIME: 15 LEVEL: ADD 2 MESSAGE: ALKALI
CYCLES: 5 LEVEL(ALG) MAX TIME: 5
LEVEL ALG: 4
DOSING T2
DOS TIME: 45
27 DOS CURVE:PROGRES 3
CYCLE DOSING: 5
DOS1+DOS2: NO
HOLD TIME
28 TIME: 45
CYCLES: 5

29
MESSAGE: SAMPLE MESSAGE: SAMPLE MESSAGE: SAMPLE MESSAGE: SAMPLE
AQCHR CTRL
AQUACHRON 4G FILL ADD T2
WATER TYPE: PROCESS
TEMPERATURE: 60(⁰C) WATER: COLD PREPARE T2
WASHING LU:AQCHR
30 GRAD/MIN: 0 LEVEL: ADD 2 MESSAGE: ACID
LEVEL(ALG)
LT/min/champ: 179 LEVEL(ALG) MAX TIME: 5
AQ.DR.TYPE: CLEAN
LITRES/Kgr: 4.3 LEVEL ALG: 2
DRAIN
31 TRANSFER T2
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32
LITRES/Kgr: 5.1 DRAIN
AQCHR CTRL
AQUACHRON 4G
WATER TYPE: PROCESS
TEMPERATURE: 80(⁰C)
WASHING LU:AQCHR
33 GRAD/MIN: 0
LEVEL(ALG)
LT/min/champ: 135
AQ.DR.TYPE: CLEAN
LITRES/Kgr: 10.5
DRAIN
34
LITRES/Kgr: 4.3 DRAIN
35 (UN)LOAD
DRAINING
TIME: 2
36
DRAIN TYPE: CLEAN
DRAIN
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6. CONTROLLER FINE TUNING – MANUAL MODE
6.1. NUMERICAL INFOS – TUNE VALUES
Figure 26:Numerical Infos-Tune Values Screens
As shown in the photos above, the Numerical Infos and the Tune Values menus contain
lots of information regarding the machine’s safety and fine tuning. It should only be
touched with the assistance of SCLAVOS S.A. “Automation & Customer Service
Department” and only in case it is needed as most of the values are critical for the safety
of the personnel and the machine functionality.
So, the Technician of the Dyehouse, in order to make necessary changes on this part,
should contact Sclavos through the support email: support@sclavos.eu
6.2. MANUAL MODE DESCRIPTION
Many buttons regarding the manual operation of the Athena4TM machine have been
replaced by “touch screen key buttons” taking the advantages of the touch screen
controller SM5500+. However, some others have still been left for manual control and can
be found at the operator panel as well as on the electrical panel.
Page 61|64
6.2.1. ELECTRICAL PANEL
Figure 27: Electrical Panel
1 Power Supply button

The operator must press this power supply button, in order to supply the electronic
units with 24Voltage DC current.
2 Main Power Switch
Page 62|64
6.2.2. OPERATOR PANEL
Figure 28: Operator Panel
1 Main Pump Start manual button (BMPSR)

Sets the main pump output ON if the pump protect level is covered. If the program
is running the pump speed takes the value from the program. If a program is not
running or the machine is in manual mode, pump speed takes the value 100%.
2 Main Pump Stop manual switch (SMPST)
Resets the main pump output both for manual and auto mode, for as long as the
input is on.
3 Main Drive (Reel) Forward manual button (BMDFSR)
Sets the main reel forward output if the pump is running.
4 Main Drive (Reel) Stop manual switch (SMDST)
Resets the reel outputs (forward or backward) for both manual and auto mode, as
long as the input is on.
5 Main Drive (Reel) Reverse (backward) manual button (BMDRSR)
Sets the main reel backward output.
6 Seam Detector Enable button (BSDS/R)
Once the button is pressed the SEAM DETECTION modules are enabled. Then, if one
seam magnet is found, the main pump and the main reel stop. Reset is achieved by
a second press of the same button, or by pressing the main pump start button.
The SEAM DETECTION FOUND input turns the beacon lamp on until it is reset as
described above. The alarm, also, sounds for 1 second.
7 Unload Start-Stop switches
By moving the switch left wise the unloading reel moves forwards, while moving it
right wise it moves backwards. There are also the “+” and “-“ buttons for controlling
the unloading reel speed manually. As shown in the photo of the Control Panel
above, there are two switches. For machines with three or less ports there exists only
one switch that controls all three (or less) unloading reels at the same time. For
machines with four or more ports there are two switches. The switches control the
Page 63|64
unloading reels accordingly. (i.e. for four port machines, switch 1 controls the two
unloading reels and the 2 the other two. For five port machines, switch 1 controls the
first three unloading reels and switch 2 the next two unloading reels and for 6 port
machines switch 1 controls the three first unloading reels and switch 2 the next three
unloading reels.)
8 Cancel Alarm button (BCAL)
Shuts the Beacon alarm off when it is pressed.
9 Emergency STOP Switch (BES)
As long as the input is on, the alarm “EMERGENCY STOP PRESSED” is displayed on the
controller.
10 Reel Speed Control Potentiometer (POT)
Uses for manual adjusting of the main reel speed, when the main reel is already
activated manually, or during load/unload.
11 Add Tanks Switch
It’s the manual way for the operator to confirm the preparation of the chemicals in
the tanks. If it is turned left wise T1 preparation is confirmed, while if it is turned
right wise, Τ2 preparation is confirmed.
12 Next Step Button
It’s the manual way to confirm the Next Step function while loading/unloading.
13 Door Lamp Button
The button to turn on/off the door(s) lamp(s).
14 Temperature High / Pressure High Light
If the machine temperature exceeds 85oC this yellow light indicator is ON and the
machine is locked and under pressure. The discharge valve is held off.
15 Operator Call Light
This indicator red light is ON when an operator message/call function is activated on
the controller.
16 Digital Speedometer
It’s the digital speedometer showing the reel speed.
17 Digital Thermometer
It’s the digital thermometer showing the machine’s temperature.
18 Seam Monitor
It’s the digital seam monitor showing the chamber’s number where the seam
magnet is found.
Page 64|64

MACHINES FEATURES CONTROLLER SM5500+ - Rev.0

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ATHENA4 - MACHINE’S FEATURES & CONTROLLER SM5500+ Rev.

MACHINE’S FEATURES & CONTROLLER

2.1. MACHINE CONTROL SYSTEM .................................................................................. 18

3.4.2. PROGRAM END ................................................................................................ 35

1. MACHINE TECHNICAL SPECIFICATIONS

1.1. MACHINE VESSEL

1.1.1. DOUBLE SOFT FLOATINGTM (DSF) DYEING SYSTEM

1.1.2. VARIABLE SPEED OPEN PLAITING SYSTEM WITH

1.1.3. STORAGE CHAMBERS

1.1.4. PTFE SHEET

1.1.6. STANDARD MAIN VESSEL COMPONENTS

1.2. LIQUOR CIRCULATION MAIN PUMP

1.3. FLOW BALANCING DEVICE (FBD)

FBD is a unique development of Sclavos which eliminates any interference on machine’s

1.4. HEAT EXCHANGER

1.4.1. HEAT EXCHANGER INLET-OUTLET VALVES

1.5. ADDITION TANK

1.5.1. STANDARD ADDITION TANK COMPONENTS

1.6. SECOND ADDITION TANK

1.6.1. SECOND ADDITION TANK COMPONENTS

1.7. CONTINUOUS FLOW DOSING SYSTEM (CFD)

1.8. UNLOADING SYSTEM FOR SINGLE AND DOUBLE ROPE

UNLOADING SYSTEM consists of the following equipment:

1.8.1. EXTENDED LENGTH UNLOADING ROLLER WITH

1.8.2. SEPARATING GUIDE

1.8.3. SPLASH GUARD

1.9. FRONT PLATFORM

1.10. SEAM DETECTION MANAGEMENT

1.11. TO KNOW LIQUOR RATIO SYSTEM (TKLR)

1.12. SCLAVOS DRY SALT TRANSFER & FINE DOSING SYSTEM

➢ No operator presence is required during operation of the system (except refill is

➢ Salt hopper with salt capacity up to 250Kg.

1.13. AQUACHRON CONTINUOUS WASHING SYSTEM

1.13.1. AQUACHRON 4G (patented)

It is a further development of the established Sclavos continuous washing system, which

1.13.2. AQUACHRON FLX (patented)

1.13.3. AQUACHRON CALCULATOR

- Dyeing Temperature, and

1.14. AUTOMATIC SETTINGS ADJUSTMENT (ASA)

▪ Avoid running the pump at maximum speed manually.

1.15. MONITORING THE CONSUMPTIONS OF UTILITIES

1.16. GENERAL SPECIFICATIONS OF THE REQUIRED UTILITIES

2. CONTROLLER SCLAVOS SEDOMAT 5500+ TECHNICAL

The Sclavos automation philosophy is based on:

The fully automated system includes:

2.1. MACHINE CONTROL SYSTEM

2.2. CONTROLLER/ADDITION TANKS CONTROL PANEL

2.3. AUXILIARY CONTROL PANEL

2.4. FULLY AUTOMATION BY SCLAVOS SEDOMAT 5500+

➢ SCLAVOS Sedomat 5500+ Microprocessor based at Windows CE® operating system,

Main vessel full automation functions:

Addition tank full automation functions:

3. CONTROLLER SCLAVOS SEDOMAT 5500+ FUNCTIONS

MAIN PARALLEL DATA SPECIAL

Draining Control Off Reel Speed Prog. End

Heat / Cool Dosing Tank Label Function

Hold Time Transfer Tank Jump

Save L.R. AQUACHRON CTRL Next Batch

Recall L.R. Cycloclean Prepare Prod.

Recirculation Tank Wait Prod.

Heat Tank Check Prod.

Salt Prepare (Optional)

Salt Transfer (Optional)