CSTU Handbook Rev 402 EN

CAIPO automazione industriale
s.r.l.
CAIPO AUTOMAZIONE INDUSTRIALE S.r.l. CSTU Handbook Rev 402 EN.doc Pag. 1
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INDEX
CHAPTER 1...................................................................................................................... 7
1 SAFETY REGULATIONS ............................................................................................. 7
1.1 Worker information and training...................................................................................... 7
1.2 Personal protection devices (PPD/DPI)............................................................................ 7
1.3 Use of work clothes .......................................................................................................... 7
1.4 Protections and protection devices ................................................................................... 7
1.5 Safety and health indications............................................................................................ 7
1.6 Machine start-up ............................................................................................................... 8
1.7 Isolating energy sources ................................................................................................... 8
CHAPTER 2...................................................................................................................... 9
2 TECHNICAL DATA ...................................................................................................... 9
2.1 Unit identification data ..................................................................................................... 9
2.2 Intended use...................................................................................................................... 9
2.3 Prohibited uses.................................................................................................................. 9
2.4 Types and characteristics of processable materials .......................................................... 9
2.5 Technical specifications ................................................................................................... 9
2.6 Configuration.................................................................................................................. 10
2.7 Operating environment conditions ................................................................................. 10
2.8 Type and characteristics of emissions ............................................................................ 10
3 TRANSPORT AND INSTALLATION ........................................................................ 11
3.1 Conditions of supply....................................................................................................... 11
3.2 Storage environment conditions ..................................................................................... 11
3.3 Parts handling and assembly .......................................................................................... 11
3.4 Electrical Connections.................................................................................................... 12
3.5 Operations and checks to be carried out before start-up ................................................ 13
3.6 Running in ...................................................................................................................... 14
3.7 Lubrication ..................................................................................................................... 14
3.8 Demolition and disposal ................................................................................................. 14
CHAPTER 4.................................................................................................................... 15
4 OPERATOR INSTRUCTIONS .................................................................................... 15
4.1 Zone normally occupied by the operator........................................................................ 15
4.2 Identification residual risks ............................................................................................ 15
4.3 Work clothing ................................................................................................................. 15
4.4 Personnel protection devices .......................................................................................... 16
CHAPTER 5.................................................................................................................... 17
5 DESCRIPTION OF CONTROLS ................................................................................. 17
5.1 Description of LCD Panel & Keyboard ......................................................................... 17
5.2 Machine status indicator LED panel .............................................................................. 18
5.3 Switch Panel ................................................................................................................... 19
5.4 Number Keys and Function Keys................................................................................... 20
5.5 Power up ......................................................................................................................... 21
5.6 Main Menu ..................................................................................................................... 21
5.7 Function of the key <Password> .................................................................................. 22
5.8 Close password ............................................................................................................... 22
CHAPTER 6.................................................................................................................... 23
6 OPERATION AND PROGRAMMING ....................................................................... 23
6.1 Working data setting....................................................................................................... 23
6.1.1 General rules for using the CSTU console .................................................................. 23
6.1.2 Work program setting.................................................................................................. 24
6.1.3 Draft setting ................................................................................................................. 25
6.1.4 Nominal twist setting................................................................................................... 26
6.1.5 Offset type selection .................................................................................................... 26
6.1.6 Slub ramp length selection ......................................................................................... 27
6.1.7 Twist ramp type selection............................................................................................ 31
6.1.8 Working parameters calculation.................................................................................. 31
6.2 Programming .................................................................................................................. 33
6.2.1 Programming step by step ........................................................................................... 33
6.2.2 Automatic program...................................................................................................... 37
6.2.3 List of stored programs................................................................................................ 42
6.2.4 Clear stored programs.................................................................................................. 42
6.2.5 Program names in four digits....................................................................................... 43
6.3 Communication with CARTRIDGE .............................................................................. 44
6.3.1 Cancel a program on an CAIPOMEM5 cartridge ....................................................... 45
6.3.2 List of programs on cartridge CAIPOMEM5.............................................................. 46
6.3.3 Program from cartridge to CSTU ................................................................................ 46
6.3.4 Program from CSTU to cartridge ................................................................................ 46
6.3.5 Wiping the entire cartridge .......................................................................................... 47
6.4 Machine parameters setting ............................................................................................ 48
6.4.1 User Parameters........................................................................................................... 48
6.4.1.1 Execution of the program at machine start............................................................... 50
6.4.2 Display CAIPO parameters ........................................................................................ 51
6.4.3 Edit CAIPO parameters ............................................................................................... 52
6.4.4 MAINTENANCE (servicing) functions...................................................................... 53
6.4.5 CPU data backup on CSTUPAR cartridge .................................................................. 54
6.4.6 CPU data recovery from CSTUPAR cartridge............................................................ 54
6.4.7 Data backup of Machine A(B) drive units on CSTUPAR .......................................... 55
6.4.8 Recovery of drive units Machine A (B) from CSTUPAR cartridge ........................... 55
6.4.9 Motor Testing Machine A (B) .................................................................................... 57
6.4.10 Installation parameters A (B) .................................................................................... 58
6.4.11 Cease sliding control Encoders side A (B)............................................................... 59
6.5 Language selection ......................................................................................................... 60
6.6 Diagnostics ..................................................................................................................... 60
6.6.1 Error Messages Machine A (B) ................................................................................... 61
6.6.2 Machine Monitor A (or B) .......................................................................................... 61
6.6.3 Diagnostics of the Machine A (B)............................................................................... 62
6.6.4 Encoders check-up....................................................................................................... 64
6.6.5 Errorlog A (B) ............................................................................................................. 67
7 MAINTENANCE.......................................................................................................... 70
7.1 Controls and routine maintenance Bearing lubrication .................................................. 70
7.1.1 Bearing lubrication ...................................................................................................... 70
7.1.2 Chains tension ............................................................................................................. 70
7.1.3 Belts tension ................................................................................................................ 70
7.1.4 Cleaning of the control panel ...................................................................................... 71
7.1.5 Cleaning of motor drive units...................................................................................... 71
7.1.5.1 Cleaning of motor drive units CD1K with the fan top mounted .............................. 72
7.1.5.2 Cleaning of motor drive units CD1K with the fan mounted inside......................... 72
7.1.5.3 Cleaning of motor drive units SR614 or SR620....................................................... 73
7.2 TROUBLESHOOTING ................................................................................................. 74
7.2.1 Alarm reset .................................................................................................................. 74
7.2.2 Power supply circuit reset (green indicator light) ....................................................... 74
7.2.3 Programming problems ............................................................................................... 75
7.2.4 Processing problems .................................................................................................... 76
7.2.5 Critical alarms (electrical or mechanical failures)....................................................... 79
7.2.6 CD1K drive alarms...................................................................................................... 82
7.2.7 SR614 or SR620 drive alarms ................................................................................... 84
7.3 Checks on electrical parts ............................................................................................... 86
7.3.1 Checking connections to the electrical panel of the machine...................................... 86
7.3.2 Safety circuit (Emergency stop) .................................................................................. 86
7.3.3 Machine STOP relay ................................................................................................... 87
7.3.4 Machine START signal ............................................................................................... 87
7.4 REPLACING ELECTRICAL PARTS........................................................................... 88
7.4.1 Replacing the CSTU panel (or CPU2000 control board) ............................................ 88
7.4.2 Updating the CPU2000 software................................................................................. 88
7.4.3 LCD adjustment........................................................................................................... 89
7.4.4 Replacing a motor........................................................................................................ 89
7.4.5 Replacing a CD1K type drive...................................................................................... 90
7.4.5.1 LED on drive CD1K................................................................................................. 91
7.4.6 Replacing a SR614 or SR620 type drive .................................................................... 92
7.4.7 Instructions for setting the CANbus address on SR614 drive unit.............................. 93
7.4.8 Alarms on the display of the drives unit SR614 and SR620 ....................................... 94
7.4.9 Motors MA30 MA45 with brake (option)................................................................... 97
7.4.10 Motors DBL5 with brake (option)............................................................................. 98
ANNEXED DOCUMENTS ............................................................................................... 99
A.1 Set-up example in case of CSTU connected to a RING frame..................................... 99
A.2 Set-up example in case of CSTU connected to OPEN END...................................... 100
A.3 Modification of CSTU electrical diagram: cable 205 on KM1 ................................... 101
OVERHAUL DIRECTORY ............................................................................................. 102
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CHAPTER 1
1 SAFETY REGULATIONS
1.1 Worker information and training
− Workers must be provided with proper information and training before operating the spinning
machine after installation of the CSTU unit in compliance with existing legislation.
− Workers must demonstrate good knowledge of the machine and operating modes after installation
of the CSTU unit.
− The safety regulations and operating procedures indicated in this document, as well as in
documents pertaining to units installed on the machine, must always be complied with.
− Workers must scrupulously adhere to legislation concerning safety and hygiene as applicable in
the place of installation.
1.2 Personal protection devices (PPD/DPI)
Always use the Personal Protection Devices prescribed for specific operations.
1.3 Use of work clothes
Always wear suitable clothing before approaching and/or starting work on the machine.
1.4 Protections and protection devices
Do not tamper and/or remove protections and protection devices located on the machine.
1.5 Safety and health indications
Carefully read the indications shown on labels located in various zones of the machine and strictly
follow instructions.
1.6 Machine start-up
Before starting the machine, always make sure that no persons are in hazardous areas.
1.7 Isolating energy sources
Carry out maintenance operations only after isolating energy supply sources.
In certain applications two spinning machines are controlled via a CSTU panel. It is therefore
necessary to isolate the energy supplies to the spinning machine on which maintenance work
is to be performed. For this purpose, use the machine mode selector indicated in Chapter 5.3.
The selector must be turned to the LOCKED position in order to enable

maintenance to be carried out safely and prevent accidental start-up. The
selectors are equipped with keys and can only be operated using such keys.
In all cases use appropriate instruments to check that the electricity supply is off before
operating on the machine.
Make sure that after the machine has been isolated from energy sources and that no residual
energy is stored. Discharge any stored energy before carrying out operations for which
accumulated energy may represent a hazard.
If maintenance must be carried out on the CSTU unit control panel, turn it off via the main
switch. The switch can be locked in the 0 position (OFF) by means of a padlock to avoid the
risk of inadvertent start-up by other personnel. Therefore always use a personal padlock
during maintenance operations.
If maintenance must be carried out on the CSTU unit control panel, turn the off CPS disconnecting the
Battery pack of the device opening the fuses carrier.
Case CSTU connected to a CPS device
The CPS is automatically switched off (through a contactor inside CPS) in case of main line
off or when the selector is turned to LOCKED or OFF.
Moreover, if maintenance must be carried out on the CSTU unit control pan the following
supplementary cautions must be taken:
• Wait 5 minutes time after switch-off to assure that the larger capacitors inside CPS are
discharged
• Check with a voltage meter that no power supply on drive unit DCbus from CSTU
• Remember that the Battery pack inside the CPS is an energy source that can be
dangerous, because its nominal voltage is 120Vdc nominal (a series of 10 battery,
12Vdc each).
CHAPTER 2
2 TECHNICAL DATA
2.1 Unit identification data
The CSTU unit identification data referred to in this manual are indicated on the first page.
2.2 Intended use
- The CSTU unit can be installed on any type of ring or open-end spinning machine in order to vary
the count or twist (optional) for producing slub, multi-count and multi-twist yarns.
2.3 Prohibited uses
The unit must not be used for purposes and processing of materials other than those
described in this manual.
The unit must not be used in environments where flameproof electrical material is required; the CSTU
unit is NOT of flameproof design.
Caution
If any doubts persist as to the suitability of the unit for a particular use, directly contact
CAIPO Automazione Industriale s.r.l. Technical Service
2.4 Types and characteristics of processable materials
The unit is designed for operation with fibres of animal, vegetable and chemical origin, normally used
in textiles processing. The same range of yarns can be processed as prior to installation of the unit on
the spinning machine.
2.5 Technical specifications
The CSTU unit makes it possible to produce slub, multi-count and multi-twist yarns on any type of
spinning machine.
The type of yarn to be produced must be specified when ordering the unit; the unit will then be
provided with the appropriate parts for production of the specified yarn.
2.6 Configuration
The CSTU unit is composed of the following parts:

- Electrical panel including console type control keyboard located on the upper side, drives for the
electric motors used in the specific application. The electrical panel features two independent
channels which can be used to control a single spinning machine or two separate spinning
machines according to the required function: slub, multi-count and multi-twist yarns and the type
of spinning machine.
- Mechanical assembly comprising all mechanical parts, including electric motors, required for
modifying the spinning machine. The composition of this assembly varies according to the
spinning machine on which it is installed: the parts required for each application are indicated in
the kinematics diagram attached with the manual.
- CAIPO-MEM cartridge: solid-state memory module impregnated with epoxy resin. Up to 30
different programs can be stored on each cartridge and subsequently copied into the CSTU
internal memory.
- CSTUPAR cartridge solid-state memory module impregnated with epoxy resin. The CSTUPAR
cartridge is used to have a copy of all parameters of CSTU control card and of drive units, to be
used in case of replacement of one of these parts.
2.7 Operating environment conditions
Minimum temperature: 15 °C
Maximum temperature: 40 °C
Maximum humidity: 80% without condensation
2.8 Type and characteristics of emissions
Dust emission
During processing, certain yarns (e.g. particularly fluffy yarns or yarns with very short fibres) can
cause the release of fibre and dust.
The production of dust is, however, comparable to that normally encountered in the processing cycle
in which the unit is installed.
Noise emission – Sound level emission
The CSTU unit does not affect the sound level on the side of the machine on which it is installed.
Measurements carried out in the vicinity of the CSTU motors gave the following results:
Outlet speed in metres / minute Spindles speed (RPM) Leq in dB(A)

15 8,000 72.0
25 12,000 78.0
(Equivalent continuous sound pressure level measured with an integrated precision phonometer, Type
1, as per norms IEC 804 and IEC 651.)
CHAPTER 3
3 TRANSPORT AND INSTALLATION
3.1 Conditions of supply
The CSTU unit is supplied completely broken down into its component parts and packed in wood
cases. Dimensions vary according to the application and gross weights range between 500 and 800
Kg.
3.2 Storage environment conditions
Minimum temperature: 5° C
Maximum temperature: 45°C
Maximum humidity: 85% (without condensation)
3.3 Parts handling and assembly
The cases in which the components of the CSTU are packed can be handled using appropriate means
such as a fork lift and/or pallet truck.
The lower-weight components of the CSTU can easily be moved manually providing that applicable
load handling safety regulations are observed.
Individual weights of main machine parts:
Part description Weight in Kg.
Gearmotor unit (max) 45

Electrical control panel 100
The CSTU is installed by

CAIPO Automazione Industriale s.r.l. technicians.
CAUTION
- Always use lifting and transport gear of suitable load-handling capacity in relation to the
weight to be lifted.
- Make sure there are no obstacles and/or persons in manoeuvring areas.
- Transport and lifting means should be operated by authorised personnel only.
During lifting and transport adopt all necessary precautions to prevent the part being
handled from falling and/or the vehicle from overturning.
3.4 Electrical Connections
The CSTU control panel must be connected to a mains power supply of 380/400 V
three-phase + earth, 50 - 60 Hz, using cable of appropriate diameter in relation to
the total installed power.
The power supply cable must be attached to the line input terminals located inside
the electrical control panel.
CAUTION
- Use a power cable of suitable diameter in relation to the absorbed power of the machine
and the length of the cable itself.
- Make absolutely certain that the machine is correctly earthed and subsequently test.
- Securely tighten the cable grip through which the power supply cable is inserted.
Connection diagram
At customer charge
Automatic circuit breaker (magneto thermal switch) for connection to the power supply line.
o Circuit breaker nominal current : 50 A
o Residual current (earth leakage) circuit breaker 300 mA type B
There are three types of industry standard residual current protection relay
Type B recommended for three-phase converters, systems TT TN or TN-S
Type A admitted for systems TN or TN-S (not for TT)
Type AC not suitable for three-phase converters
Feeding cable of control unit CSTU (3 + Earth 10 mm2)

Raceway min 10x10cm for CSTU motors cable.
Standard cables length L1+L2+L3 = 25 mt
Longer cables are only available upon request: Specify the length in advance (max 100 mt)
Supplied by CAIPO
CSTU control unit.
Cables of motors and connection of CSTU with the machine’s headstock
Standard length 25 meters.
Longer cables are only available upon request: Specify the length in advance (max 100 mt)
Gear-motor group
Mechanical group and sensors for each machine
Main line specification:

Main line must be 380-480V 50or 60 Hz,
Balanced system (neutral connected to ground): TN-S or TN or TT
(see drawing 1512.SP.001)
The power supply line 380-400 V is direct connected to motor drives units; in case of line 440 or 460
or 480V an autotransformer, mounted inside the CSTU device, lowers the voltage to 400V.
IMPORTANT NOTE: If the power supply line is out of the range, or the source system is unbalanced,
an insulation transformer is necessary.
The transformer is only supplied at customer request (specify the available voltage and system)
Power supply:
6KVA up to 2 motors, slub only;
12KVA up to 4 motors, slub only;
15KVA 3 or 4 motors, slub + twist
ATTENZION !
The correct working of the CSTU is not guaranteed in case of voltage dropping. Owing
to ring frame inertia some or all yarn could be broken. To avoid this problem, we advise
to feed the CSTU device under a privileged line or to equip it with an emergency power
generating set. As, for example, Caipo CPS device.
3.5 Operations and checks to be carried out before start-up
Before starting the CSTU unit you must check that:

- electrical connections have been correctly carried out
- mechanical parts are correctly attached to spinning machine members
- No obstacles hinder moving parts.
On start-up it is also necessary to check that all controls function correctly, particularly the main
switch and the emergency stop controls located on the machine.
3.6 Running in
The CSTU motors and mechanical parts do not require a running in period.
During first few days'operation, however, it is advisable to check that operation is correct so that any
anomalies can be promptly detected: these must be notified without delay to
CAIPO Automazione Industriale s.r.l.
3.7 Lubrication
Certain unit shafts are mounted on bearings which require periodic lubrication using mineral grease
type
KLUEBER TRIBO STAR 2EP

or CENTOPLEX 2 EP
or equivalent
following the directions given in Paragraph 7.1.1 (Chapter 7 Maintenance).
Unless otherwise indicated, lubrication should be carried out with the machine OFF via the special
lubrication points.
Changing and disposal of lubricants
Follow the safety directions for each product.
Spent substances must be disposed of in accordance with environmental protection

regulations in force in the country of use.
3.8 Demolition and disposal
The CSTU can be demolished after its component parts have been removed from the spinning
machine.
Dispose of in accordance with regulations in force in the country of use.
The metal parts of the machine can easily be recycled as they are ferrous materials.
CHAPTER 4
4 OPERATOR INSTRUCTIONS
4.1 Zone normally occupied by the operator
The operator works along the side of the spinning machine on which the CSTU has
been installed. When a yarn is being programmed, or during a change in processing,
the operator will stand in front of the CSTU panel located either in the vicinity of
the machine headstock or in the aisle opposite the machine itself.
4.2 Identification residual risks
Use of the CSTU does not introduce any risks in addition to those already
associated with the design type of the spinning machine on which the CSTU is
installed.
Therefore observe the regulations for conduct indicated in the manual for the
machine on which the CSTU has been installed, typically:
- Do not place hands between moving parts of the spinning machine during automatic
doffing
- In case of danger press the emergency/stop buttons to stop the spinning machine
- Always wear suitable clothes when operating the machine to avoid being caught in
moving parts.
4.3 Work clothing
When working on the machine the following precautions must be taken concerning clothing:
− Wear clothes without flapping parts which may get caught in moving and rotating machine
members.
− Use clothes with fasteners (buttons, zips, velcro, etc.) and make sure they are fastened.
− Do not use clothes with loose-fitting sleeves, unbuckled belts, unfastened braces.
− Do not wear scarves, ties, etc.
− Do not wear pullovers, aprons and similar items draped over the shoulders or wrapped around the
waist.
− Do not wear necklaces, chains, bracelets and rings that may be dragged or caught.
4.4 Personnel protection devices
When operating the spinning machine always wear protective headwear to prevent hair
being caught in machinery.
When dust is produced during cleaning, wear a face mask to protect the respiratory tract.
If the yarn produces fibres or dust during processing wear suitable breathing protection gear.
Caution: Further information regarding protection of the respiratory tract must be provided
by the consulting doctor of the exposed person and in relation to the type of fibres.
CHAPTER 5
5 DESCRIPTION OF CONTROLS
5.1 Description of LCD Panel & Keyboard
Graphic LCD
CAIPOMEM 5 Socket
Number keys and function

Status indicator LED panel
keys
5.2 Machine status indicator LED panel
The LEDs indicate the operating status of the CSTU slub unit, enabling the operator to immediately
verify working conditions without consulting menus (machine ON/OFF, slubbing in progress, twist
change active, alarm condition)
Machine A operating LEDs Machine B operating LEDs
Start LED: lights on input of Machine Start LED: lights on input of Machine
A start signal (#1) B start signal (#1)
Speed LED: lights when Machine A Speed LED: lights when Machine B
moves (#2) moves (#2)
1)
Program LED: lights on launch of Program LED: lights on launch of

Machine A program (#3) Machine B program (#3)
Slub LED: lights on start of Machine A Slub LED: lights on start of Machine B
slubbing (#4) slubbing (#4)
Twist LED: lights on start of Machine A Twist LED: lights on start of Machine B
twist control (#5) twist control (#5)
Alarm LED: lights in case of a Machine Alarm LED: lights in case of a Machine
A alarm (#6) B alarm (#6)
(#1) Machine A: connected to drives on left side of CSTU panel

Machine B: connected to drives on right side of CSTU panel
(#2) Machine movement is detected by ENCODER 1 (speed), installed on the spindles shaft (or on
an integrally connected shaft). Rotor shaft in the case of O.E..
(#3) The Program is launched when the start limit speed is exceeded (Menu 0.4), provided that a
Program has been assigned (Menu 0.1.1)
(#4) Slubbing begins when the start limit speed is exceeded, provided that Slub = ON in the
assigned work set menu (Menu 0.1.1)
(#5) Twist control begins when the start limit speed is exceeded, provided that Twist = ON in the
assigned work set menu (Menu 0.1.1)
(#6) Enter Diagnostics to read the message (see message table further on in the manual)
Press ESC to cancel the alarm (and if necessary press the green button to reset the safety
device).
5.3 Switch Panel
CSTU Main ON/OFF

switch
Machine A Machine B
mode selector mode selector
Machine A RESET Machine B RESET

button button
CSTU Main ON/OFF Switch

In order to safely perform electrical and mechanical maintenance on the CSTU
motors and the parts they drive, always turn the main switch OFF and secure
with a padlock.
Machine mode selector (one per machine)

Position ON CSTU unit in operation
Position OFF CSTU unit shut down (used to operate the machine with its original
draft mechanics and feed )
Position LOCKED Machine locked (used to prevent accidental start-up).
Attention: with the selector in OFF position all the motors have to stay standstill; all the
belts and/or pulleys connecting them to the machine, have to be removed.
If you do not comply with this prescription, in case of motors in motoring over movement,
dangerous voltages in the CSTU control board could be produced, even with the main
switch in OFF position.
RESET button (one per machine)

Press the button and wait until the green indicator light comes on.
The button resets the safety device inside the CSTU panel (one per machine) which ensures that
power is supplied to motor drives only when the spinning machine is not in emergency
condition.
It is necessary to press the button:
- each time the CSTU is turned on
- whenever a spinning machine emergency and/or safety device has activated (mushroom-head
button, safety cables, door-lock micro-switch).
Caution: the safety device is timed so as to delay cutting power to the drives as necessary to
prevent the threads breaking during an emergency stop (except in the case of mains power
failure).
5.4 Number Keys and Function Keys
Symbol Key name (*) Function
MOD Start a session to edit a parameter or set of parameters
OK Confirm an operation
ESC End a session or exit a menu
INS Insert a new line in a program
CLR Cancel the last typed number
ENT Confirm typed number
DEC In program edit mode, decrease selected column value
INC In program edit mode, increase selected column value
PASSWORD Open menu for inserting the unlock code

CLOSE
Prevent access to password-restricted functions
PASSWORD
0
1 in programming mode, hot key to move to last line
2 in programming, mode hot key to move to next page
7 in programming mode, hot key to move to first line
8 in programming mode, hot key to move to previous page
Move cursor to previous line
Move cursor left
Move cursor right
Move cursor to next line
(*) Key name = reference used in this manual
5.5 Power up
When the CSTU is turned on, the control panel displays the logo indicated below.
V A.C. 4.0.0
The logo remains visible for about 20 seconds. The software version is indicated on the top left line
(in the example, V A.C. 1.6). The microprocessor then performs a series of tests which, if passed,
leads to display of the Main Menu.
5.6 Main Menu
V.A.C 4.0.0 - CAIPO Slub & Twist Unit
1 – WORKING data setting

2 - Programming
3 - Communication with CARTRIDGE
4 - MACHINE parameters setting
5 - Language selection
6 - Diagnostics
Select an item
To select a function, type the corresponding number or press the <PASSWORD> key to access sub-
menus (only Sub-menu 6, “Diagnostics”, is not password-restricted).
Note: In each menu the first line in reverse contrast print indicates the function of the menu (the
number identifies the menu). The last line, also in reverse contrast print, always indicates what keys to
use in order to proceed.
5.7 Function of the key <Password>
Pressing the <USER PASSWORD> key opens the password entry window for accessing
password-restricted functions:
then type the password; press <ENT>;
next, press <ESC> to continue.
If “Password error” is displayed, press <ESC> to exit and retry.
The password is obtained by summing the random number to the key number communicated by
CAIPO to its customers on purchase
The sum must be one column at a time and without carry-over to the public key number.
Example
Add password:
key number(hidden)
2345.67
Public key: 0148.28 random number
Add password 2483.85
sum (number that must be
Type a new value CLR to cancel typed to get the password)
Example Private key number 2345.67 not visible

Random number 0148.28
Insert password 2483.85 sum
Attention:
If any operation on the keyboard after some minute the password comes automatically off.
Repeats the procedure to reactivate it.
5.8 Close password

Pressing the <CLOSE PASSWORD> key only when in the entry window blocks access to password-
protected functions. In other words, these functions can only be accessed by repeating the
<PASSWORD> procedure described above.
We suggest to press <CLOSE PASSWORD> key after any access to restricted functions,
to prevent from changing parameters by not qualified people.
CHAPTER 6
6 OPERATION AND PROGRAMMING
6.1 Working data setting

This section is used to set the draft, twist (if the CSTU also controls twist shaft) and all other data
required by the spinning machine (or spinning machines if the same CSTU controls two) to produce
the desired yarn.
0.1 – WORKING data setting

1 – Work program setting
2 – Draft setting
3 – Nominal twist setting
4 – Offset type selection
5 – Slub ramp type selection
6 – Twist ramp type selection
7 – Working parameters calculation
Select an item ESC to exit
NOTE The CSTU unit can control one or more machines in relation to the number of motors required
per machine:
n. 1 or 2 on the feed shafts, a function of the length and type of the machine
n. 1 on the draft shaft for electronic twist change (optional).
In all displayed tables, the parameters in column/line A refer to the machine connected to the devices
mounted on panel A, on the left on the electrical panel; those in column/line B refer to the machine
connected to the devices mounted on panel B, on the right on the electrical panel.
The letter A or B also appears in all alarm signals as well as on the console (indicator LEDs, selector,
reset button) and in the electrics diagrams.
If the CSTU controls one machine only, this is always machine A (all B parameters are not
significant).
6.1.1 General rules for using the CSTU console

- At each step, possible actions are indicated on the bottom line
- The name of the current menu is indicated on the upper line
- Select an item pressing the key number or press <ESC> to return to the previous Menu
- Press <MOD> to enter edit mode: the selected value will appear in reverse contrast print
- Use the arrow keys to move over the table
- Press <MOD> again to modify a number, type the new value, then press <ENTER>
- Press <CLR> to delete the last typed number
- Press <MOD> to modify a function (example: ON to OFF or vice versa)
- Press <ESC> to exit the function or to return to the previous Menu
Numbers are fixed-field (all zeros must be typed; decimal points are automatic) and the symbol ***
indicates the field is empty (program not written).
6.1.2 Work program setting
This section is used to select the previously created program (see Chapter 6.2) to be executed.
The table below is displayed indicating the current settings. To edit the settings:
- press <MOD> to enter edit mode.
- the selected value appears in reverse contrast print. Use the arrow keys to move over the table
- press <MOD> on a selected number and type the new value. Press <ENT> to confirm
- press <MOD> on a selected item to edit it, press <ENT> to confirm
0.1.1 – Work program setting
Machine Prog. n Slub Twist Offset

A 0001 ON ON OFF
B 0201 ON OFF ON
List of stored programs

0001 0002 0201 *** ***
*** *** *** *** ***
Admitted values A B
Acc. length [mm] 2-100 2-012
Dec. length [mm] 2-100 2-050
Actual values
Acc. length [mm] 20 8
Dec. length [mm] 20 15
ESC to exit MOD to edit
For each machine select the program number from those stored in memory and displayed at the
bottom. If you require both machines to produce the same yarn, set the same program in the Prog.n
column. For example, Figure 0.1.1 indicates that Machine A runs program n. 0001 and Machine B
runs program n. 0201.
Caution: programs can be changed on each spinning machine only when the machine is not running
and after setting the Slub e Twist columns to OFF !
Each program indicates the dimensions of the slub and the variation in twist to be applied to the yarn
in production. The Slub and Twist functions must therefore be set to either ON or OFF in the related
columns. Referring to the example in Figure 0.1.1, for Machine A both the Slub and Twist columns
are set to ON. This means that the yarn will be produced as per program n. 001, hence with the slub
effects and the variations in twist that program includes. On Machine B instead, the yarn will be
produced as per program n. 0201, hence with slub effects only and with constant twist: the Twist
column for machine B has in fact been set to OFF, hence the variations in twist contained in program
201 will be ignored. In the same way it is possible run a program turning the Slub column OFF and
the Twist column ON, thereby producing a yarn with a constant count but with the programmed
variations in twist.
The last important parameter to set is Offset. When set to OFF or ON a special function is either
deactivated or activated that introduces random execution of the program in order to prevent
repetitions or moiré type effects on the yarn. See Chapter 6.1.4 for further information on the Offset
function.
When you enable the slub function (Slub ON) the system checks that slub ramps are compatible
with the slub program. If slub ramps are too long the system shows warned with a message and asked
if:
- Automatically fix the values key MOD
- Confirm (don’t change slub ramps) key OK
- Cancel (do not enable slub) key ESC
A detailed description of what are slub ramps and about how to choose the right values is given in
paragraph 6.1.6.
6.1.3 Draft setting
This menu is used to set the nominal draft as well as two other parameters separately for Machine A
and Machine B.
0.1.2 – Draft setting
Machine A B
Draft 020.00 030.00
ZPX 35 *****
ZPY 008 *****
The draft is the ratio between the count of the sliver at the inlet and the count of the yarn at the outlet
during continuous yarn (“pause”) production. As the slub is applied the sliver-yarn ratio is reduced
according to the “thickness” set line by line.
The draft can be set within the range indicated in the machine kinematics diagram (DRAFTS
RANGE), and is fully electronically controlled (no gear wheels need to be changed except on special
machines).
The draft value can be changed while the machine is running.
On certain machines the slub unit motor, instead of driving the feed shaft, drives the pre-draft shaft.
Consequently, the motor-shaft reduction ratios vary in relation to variations in the draft - pre-draft
ratio. In such cases, the correct draft can only be obtained by setting the values ZPX and ZPY (the
draft - pre-draft ratio), as indicated in the table in the machine kinematics diagram.
In all other cases (slub unit motor connected at fixed ratios on the feed shaft,) the parameters ZPX and
ZPY are not required (and do not appear on the display).
6.1.4 Nominal twist setting
If the CSTU is used for twist control (motor on the draft shaft) it is also necessary to set the nominal
twist separately for Machine A and machine B.
0.1.3 – Nominal Twist setting
Machine A B
Twist TPM 0700 0500
The CSTU varies the speed of the draft shaft motor so as to maintain the set twist. Further, during
execution of the program the speed of the motor is varied so as to increase or decrease the twist as
indicated line by line.
Settable nominal twist limits: theoretically, from 0 to 9999 TPM (turns per meter); in practice these
values depend on the limits of the machine and the draft shaft motor (3000 rpm max).
The variation is applied over the whole program line (“pause” execute + “slub” execute).
Variations in motor speed are applied fairly slowly by means of acceleration and deceleration ramps
to prevent unwanted slubs or weak points on the yarn.
The nominal twist value can also be changed while the machine is running.
6.1.5 Offset type selection
0.1.4 – Offset type selection
Machine Offset type

A 1
B 2
1 – Unconditional jump
2 – Jump on pause different from 0
3 – Jump on twist change
Offsetting prevents the program from repeating, i.e. after the entire sequence has been performed,
instead of restarting from the first line, the sequence restarts from a random line. This is what happens
in the case of Offset Type 1 which is the most commonly used. Offsets 2, 3 have been introduced to
avoid undesired effects on structured yarns (slub on slub) and their operating modes are described in
the table below:
1 – Unconditional jump At the end of the program, the sequence jumps to a random line
(instead of restarting from the first line)
2 – Jump on pause other than 0 As 1, but if during the skip it encounters a line with a pause 0, it
passes on to the next line until it finds one with a pause other than 0
3 – Jump on twist change As 1, but in making the skip it must find a line with a twist which
varies that in the previous line, otherwise it passes on to the next line
until this condition is met.
6.1.6 Slub ramp length selection

Starting with the CSTU release VAC 3.0.2 the setting for slub ramps has been changed; no
longer set four types, but you set the length in mm:
0.1.5 – Slub ramp length selection
A B
Acc. length [mm] 20 8
Dec. length [mm] 20 15
Admitted values A B
Acc. length [mm] 2-100 2-012
Dec. length [mm] 2-100 2-050
ESC to exit MOD to modify
d a d
p f
n
a Acceleration. length (profile of the slub rising)

d Deceleration. length (profile of the slub descent)
p Pause length
f Slub length
n Next line pause length
The “admitted values” show the values limit within which choose the acceleration and deceleration
lengths of the program chosen.
The acceleration and deceleration lengths are always given in mm., independently from the unit of
length of the program.
The minimum value is always 2; the maximum value depends on the program that it’s working.
Example
Admitted values A B
Acc. length [mm] 2-100 2-040
Dec. length [mm] 2-100 2-050
It means that for the program that is working on channel A, acceleration ramps from 2 to 100 mm.
can be chosen: while for the program that is working on channel B the acceleration ramp must be
lower than 40 mm, the deceleration ramp lower than 50 mm.
The limit in acceleration is given by the slub shorter in the program (it is not possible to set
acceleration longer, otherwise the slub can’t be made completely); the limit in deceleration is given
instead by the pause shorter.
When you enable the slub function in the menu 0.1.1 (Slub = ON) the system checks that slub ramps
are compatible with the slub program. If slub ramps are too long the system shows warned with a
message and asked if:
- Automatically fix the values key MOD
- Confirm (don’t change slub ramps) key OK
- Cancel (do not enable slub) key ESC
Attention:
To get a good slub shape the slub ramp length must shorter the limit values.
The same the program, performed with different acceleration / deceleration slub ramps, may be very
different, as shown in the two figures below.
Fig 1 Slub produced with long ramps (limit value)

(slub length 42 mm; acceleration / deceleration ramps 40 mm)
Fig. 2 The same slub, produced with shorter acceleration / deceleration slub ramps
(slub length 42 mm; acceleration / deceleration ramps 15 mm)
During processing, the shape of the slub can be seen in 0.6.3 - Monitor machine A (0.6.4 for B).
The display is not as clear as in Figure 1 or 2, because of the production speed, but the difference due
to the acceleration / deceleration ramps is evident.
By the program; it’s always possible to shorten the slubs going on the menu 0.1.5 (it’s not possible to
extend them for the above mentioned reasons).
The advantage of the acceleration and deceleration setting in millimeters is given by the fact that
the length is guaranteed constant when changes the production speed (the acceleration of the slub
motors are automatically adjusted for the purpose).
Besides you can choose more accurately the values (all the ranges from 2 mm. to 100 mm., instead of
4 types of ramps).
Therefore the profiles of the slubs on the yarn can be checked better and are more constants.
Obviously the final result on the yarn still suffers the effects of the ring frame machine, that always
gets to extend the slub.
On the Open End machines the extension of the slub depends essentially on the accumulation of
material in the rotor, that must be unloaded at the end of the slub; for this reason there is an extension
on the slub equal to the circumference of the rotor itself.
Therefore in the Open End machines slubs cannot be shorter than the circumference of the rotor.
On the Ring spinning Frame the extension is lower and depends essentially on the length of the
material in working.
Attention:
We suggest don’t use ramps too short because:
• The choice of the slub ramp has a great influence on the consumptions of the motor.
There can’t be an information beforehand: the consumptions change from machine to
machine, from the speed and from the draft. However: more the ramp is rapid, more the
motor consumes and overheats (till to cause alarms on the drive units, like I2t, IGBT,
Temperature motor)
• More the ramps are short, more goes up the solicitation of the mechanical organs of the ring
frame during the formation of the slub.
• Pay a particular attention to the “deceleration”: more the deceleration is short higher is the
risk of weak points of the slub yarn. These weak points are formed owing to the mechanical
plays of the ring gears that, during the slowing down, that it happens at the end of the slub,
cause the thinning of the yarn and consequently the reduction of the resistance.
COMPATIBILITY setting Ramps previous version
In order to permit an easy reproduction of the yarn made with CSTU versions previous software,
where the ramps possibles were only four (ramp type 1, 2, 3, 4) are enclosed with this handbook
two tables, respectively for ring frame and O.E., where are quoted the lengths in millimeters to set
for the production speed and of the type of ramp previously used.
Table of conversion type ramps/mm on RING

Table of conversion type ramps/mm on OPEN END
NOTE: for the users of the previous model of slub CAIPO CSM90
- Standard working of the CSM90 on the ring spinning frame corresponds
approximately to the ramp type 3 (column 3) on CSTU
- Standard working of the CSM90 on Open End. corresponds approximately to the ramp
type 1 (column 1) on CSTU
Table of conversion Table of conversion
type ramps/mm Type ramps/mm
Ring Open End
1 2 3 4 1 2 3 4
equivalent length in equivalent length in
millimetres millimetres
6 2 2 3 6 80 11 21 43 85
7 2 2 4 7 85 11 23 45 91
8 2 2 4 9 90 12 24 48 96
9 2 2 5 10 95 13 25 51 101
10 2 3 5 11 100 13 27 53 107
11 2 3 6 12 105 14 28 56 112
12 2 3 6 13 110 15 29 59 117
13 2 3 7 14 115 15 31 61 123
Production speed [m/min]
Production speed [m/min]

14 2 4 7 15 120 16 32 64 128
15 2 4 8 16 125 17 33 67 133
16 2 4 9 17 130 17 35 69 139
17 2 5 9 18 135 18 36 72 144
18 2 5 10 19 140 19 37 75 149
19 3 5 10 20 145 19 39 77 155
20 3 5 11 21 150 20 40 80 160
21 3 6 11 22 155 21 41 83 165
22 3 6 12 23 160 21 43 85 171
23 3 6 12 25 165 22 44 88 176
24 3 6 13 26 170 23 45 91 181
25 3 7 13 27 175 23 47 93 187
26 3 7 14 28 180 24 48 96 192
27 4 7 14 29 185 25 49 99 197
28 4 7 15 30 190 25 51 101 203
29 4 8 15 31 195 26 52 104 208
30 4 8 16 32 200 27 53 107 213
Note 1 Slub ramp type 1 isn’t suitable for Ring frame
Note 2 Maximum ramps length is 100
6.1.7 Twist ramp type selection
0.1.6 – Twist ramp type selection
Machine Variation type

A 3
B 3
1 – Very quick
2 – Quick
3 – Slow
4 – Very slow
With “variation type” parameter you select the acceleration and deceleration applied to the motor on
draft shaft (M3 twist change gear) when you introduce a twist variation according to the program.
Acceleration and deceleration of the twist motor have to be selected according to the working speed,
in order to avoid unwanted effects on the material among the rollers when you are doing the twist
variation.
The values 1 and 2 are advised for the machines O.E. type.
The values 3 and 4 are advised for Ring Spinning Frames
6.1.8 Working parameters calculation
This section is used to calculate the parameters for setting up the spinning machine to produce the
desired type of yarn. After specifying the count and inlet sliver, the twist coefficient T-alpha, the final
count of the yarn and the name of the spinning program, the CSTU calculate:
- the mechanical Draft that must be applied to obtain the final count with the desired slub
- the nominal Twist that must be set to obtain the desired twist coefficient
- the slub coefficient which is an indication of how much the slub affects the count and hence
the draft as opposed to the draft that would be applied if the yarn was not slubbed.
NOTE: the value of the resulting mechanical Draft is, in ring spinning machines, less than that which
effectively needs to be applied to obtain the desired yarn count. It must in fact be taken into account
that the shortening of the yarn due to the twist which occurs after the outlet roller, or draft roller, has
an effect of up to 15%. It is therefore normally necessary to increase the calculated mechanical draft
on spinning machines from a minimum of 8% to 15-20%, especially in the case of high twisting. This
phenomenon has less influence on open-end machines where twisting occurs in the turbine, i.e. before
the yarn outlet. In this case the calculated value needs only to be increased by up to 4%.
When in Working data setting press key 7 -Working parameters calculation
The system will first ask you to choose if use Metric or English unit
0.1.7 – Working parameters
System : Metric (0) English (1) __

0001 0002 0201 *** ***
*** *** *** *** ***
Type a new value CLR to cancel
Pressing 0 you will choose Metric unit, i.e. [Nm]

Pressing 1 you will choose English unit, i.e. [Ne]
The choose of Metric or English unit allow you to introduce the input roving count and the final count
in Nm or Ne, which you prefer; but the resulting draft will be the same.
0.1.7 – Working parameters
Program name 0003

Input roving [Ne] 2.00
T-alpha 4.00
Final count [Ne] 30.00
Slub coeff. 1.10
Draft 066.61
Nominal twist 899

0001 0002 0201 *** ***
*** *** *** *** ***
Choose a program from those stored and type it into the “Program name” field; next, type in the
values for: Input roving
T-alpha
Final count
Automatic calculation takes place of:

Nominal Draft
Nominal Twist [TPM] unit
that should be set on the CSTU to get your yarn
(if the CSTU doesn’t control the twist variations, the Nominal twist must be set on the ring frame)
The “slub coefficient” is an indicator of the “heaviness” of the slub (more the slubs per meter, bigger
the slubs, higher the “slub coefficient”).
6.2 Programming
Selecting item 2 on the Main Menu accesses the Programming sub-menu. This sub-menu makes it
possible to perform all operations related to a yarn program such as creating a new program or editing
or deleting an existing one etc. The Programming sub-menu has the following appearance:
0.2 – Programming
1 – Programming
2 – Automatic program
3 – List of stored programs
4 – Clear program
Select an item or press <ESC> to return to the Main Menu.
6.2.1 Programming step by step
This section, which is accessed by selecting item 1 from the menu indicated above, is used to write a
new program or view or edit an existing one. In both cases you should write one line at a time as per
the following instructions. To write new programs automatically, refer to Chapter 6.2.2.
0.2.1–Programming
Program name 0004

Type: cm (0) dm (1) mm (2) 1

0001 0002 0201 *** ***
*** *** *** *** ***
After accessing this section, first type the name of the program to edit or a new program name. The
display Shows the stored programs list, therefore, inserting the number of an existing
program into the "Program name" field (in the example, n. 0001, 0002 or 0201) the related program
parameters will be displayed and can be edited. Type a new number instead if you want to write a new
program (in the example, the number 0004 has been entered, hence a new program). Allowed
program numbers: from 0001 to 9999 (0000 is not allowed).
Note: if the program is being executed or has been assigned to a machine (see Chapter 6.1.1), the
program can only be viewed, not edited. If you want to edit a program during execution, follow this
procedure:
- stop the machine (or machines) to which it is assigned
- disable the program (see Chapter 6.1.1)
- edit
- reassign the program (see Chapter 6.1.1)
- restart the machine
When writing a new program, after typing the new name, press <ENT> to confirm; the second line
will appear prompting you to specify the type, i.e. the unit of measurement of the length, in either
centimetres (0), decimetres (1) or millimetres (2), according to the characteristics of the yarn to be
produced. Bear in mind that when specifying the unit of measurement, the maximum length of each
parameter will be respectively 999 centimetres, decimetres or millimetres (for longer constant
segments use two or more lines).
After selecting the unit of measurement, press <ENT> again; mask 0.2.1 below then appears on the
display:
0.2.1 – Programming
Line Pause Slub Thickness Twist
[cm] [cm] [%]
001 014 012 1.50 100.00

002 022 006 5.00 090.00
003 025 010 2.10 110.00
004 039 010 2.20 100.00
005 017 006 4.80 080.00
006 022 008 2.40 100.00
007 017 008 3.60 095.33
008 031 004 4.20 100.00
009 039 007 1.50 130.00
010 019 005 3.90 086.00
ESC to exit ENT for new line
The display has the above appearance when an existing program is being displayed or edited : all
lines in the program are shown, each defined by :
- “Pause” = length (in cm, dm or mm) of the distance between two slubs
- “Slub” = length (in cm, dm or mm) of the slub
- “Thickness” = ratio between the thickness of the slub and the base count. For example, setting a
thickness of 3.00 means that a slub with count Nm 10 will be produced from a
base count of Nm 30
- “Twist” = twist applied to the line in relation to the nominal value set as indicated in
Chapter 6.1.3. For example, if you set twist = 80%, during this program line the
CSTU will apply a twist equivalent to 80% of the set nominal value.
NOTE: The above indications, as well as those that follow, only apply if the CSTU has been
equipped with the optional "twist control unit" : this means that if different twists are programmed (as
in the example shown above) no variation in twist will be introduced on the yarn unless the optional
torsion "control unit" unit has been purchased and installed.
The same table is displayed for a new program, however all lines must be entered typing in all
required values.
The procedure for editing an existing program or entering a new program is therefore the same. The
procedure is guided by prompts that appear in reverse contrast print on the last line of the display
(ENT for new line, etc. ).
• To start editing an existing program press the key

• To start writing a new program press the key < INS>
During verification and/or editing of the program, the following commands can also be used:
At the beginning: Press the key to move the cursor to the last line.
The other arrow keys can be used to move within a previously written program.
Press MOD to edit the value indicated by the cursor (in reverse contrast print)
Use the key numbers to write the program lines
Press the key ENTER, after any value, to confirm
Press the key INS to add a new line
You can insert a missing line at any point in the program by pressing the INS key
Use the hot keys 8 to move to the next page

2 to move to the previous page
7 to jump to the first line
1 to jump to the last line
Use the special keys <INC> <DEC>
to increase / decrease by one unit an entire column (Pause - Slub – Thickness -Twist values) indicated
by the cursor.
It is recommended that the following indications be observed when writing programs:

- always fully complete a program line
- the maximum number of lines for each program is 500
- values of the length of the pause and the slub can be set in the range 000 to 999
- the length of the pause and the twist can not be set to 000 on the same line at the same time
- lines can be written containing a pause length equal to 000 and a twist length other than 000
- lines can be written containing a twist length equal to 000 and a pause length other than 000
- on ring spinning machines, the physical limit of the minimum slub length obtainable via the
CSTU control is represented by the length of the fibres. This means that it is possible to program
slub lengths lower than the length of the fibre, however the length of the effects produced on the
yarn will not correspond to programmed effects and will essentially depend on the cut length of
the fibres that compose the yarn. Therefore, using the same program, the final appearance of the
yarn may vary from one production batch to another as it is affected (in the case of a slub length
lower than the length of the fibre) by factors that do not depend on the CSTU
- on open-end spinning machines, the physical limit of the minimum slub length obtainable via
the CSTU control is represented by the circumference of the rotor. Assuming that the rotors
have a diameter of 40 mm, the minimum controllable slub will be approx. 130 mm. Programs
can be written specifying lengths lower than the circumference of the rotor used. In this case a
slub will be obtained which is thinner and less evident than the set value, hence the final
appearance of the yarn may vary from one production batch to another as it is affected (in the
case of a slub length lower than the circumference of the rotor) by factors that do not depend on
the CSTU
- the thickness of the slub may assume any value in the range 0.10 to 5.00. This means that it is
possible to program segments of yarn whose thickness is lower than the base count (values
between 0.10 and 0.99), equal to the base count (1.00) and higher than the base count (slubs or
multi-count with values ranging from 1.01 to 5.00). When setting the thickness, take into
account the processing limits of the yarn itself. Excessively thin segments can weaken the yarn,
excessively thick segments can cause a high level of friction on the spinning machine cursor
causing the strands to break. In certain other cases, if the spinning machines outlet speed is
excessive in relation to the accelerations required to produce very thick slubs, the CSTU itself
will stop the machine and display a warning message
- the % variation in twist can be set within a range of 30% to 300% and is applied for the whole
line (pause + slub);
- to avoid unnecessary overheating of the optional "twist control unit" motor, it is advisable to
program segments having variations in twist length equivalent or greater than 2 metres: each
program line containing a different twist will therefore be composed of a pause length + a slub
length of at least 200 cm. While lower lengths can be programmed, the practical effects of the
variation in twist on the yarn are only evident after at least 1.5 - 2 metres for obvious physical
reasons relating to the formation of the twist and which do not depend on the CSTU. This means
that although the speed of the CSTU motor continuously varies so as to produce the
programmed twist variations, the twist can not stabilise if it is continuously varied over
excessively short segments, i.e. less than 2 metres.
- a different value for pause and slub can be set by splitting a line in two and inputting pauses
and/or slubs of length zero (see example in "Automatic program").
After typing a new program or editing an existing program, you must:
press <ESC> once to exit edit mode.

A prompt for confirmation then appears:
OK to save
ESC to exit
If you press <ESC> the new program will not be stored and any modifications made to an existing
program will not be saved.
If you want to save modifications or the new program, press <OK>. The following message then
appears:
Please wait
Saving
Programs are saved in the CSTU computer EEPROM which is battery-free and maintains data
indefinitely.
Note: saving may take approx. 20 seconds in the case of long programs.
Up to 10 programs can be saved in the CSTU computer memory (after which an CAIPO MEM
cartridge can be used).
6.2.2 Automatic program
Choosing option 2 from Programming Menu 0.2 starts the procedure for automatically creating a new
program without having to enter each line as described in Chapter 6.2.1. The CSTU will write a
program composed of a maximum of 500 lines with parameter values (pause length, slub length,
thickness, twist) randomly chosen within the min - max limits set via mask 0.2.2 indicated below.
0.2.2–Automatic program
Program name ___

0001 0002 0201 *** ***
*** *** *** *** ***
After choosing a program name not already contained in memory press <ENT> to confirm. The
display will then be updated as shown below:
0.2.2 – Automatic program
Program name 0204

L.U. : cm(0) dm(1) mm(2)
Number of lines
Multi-count(0) Multi-twist(1) Slub(2) _
Rounded thickness (0-No 1-Yes) _
Pause Slub Thick. Twist

[dm] [dm] [%]}
Min. ___ ___ _.__ ___
Max ___ ___ _.__ ___

0001 0002 0201 *** ***
*** *** *** *** ***
Next, set the following data:

- L.U. , that is the unit of length (i.e. cm, dm or mm)
- Number of lines: indicates the length of the program (max 500 lines)
- Choose the program type, i.e. Multi-count/Multi-twist/Slub. As these yarns have different
characteristics, the CSTU will create a dedicated program for each:
Multi-count = choice 0: The yarn has segments of different counts to which a
proportional twist is associated. The CSTU will set all pause lengths to “0” and
prompt you to set the limits within which the slub lengths vary. In this case, the slub
lengths are represented by the segments of yarn for each count and the thicknesses
associated to them (which are equivalent to the count). The % variation of the twist
associated to each line is directly calculated by the CSTU, in relation to the set
thickness (which corresponds to the count).
Multi-twist = choice 1: The yarn has a constant count without slubs but with
segments having different twists. The CSTU will set all slub lengths to “0”, the
thickness to “1.00” and will prompt you set the limits of the pause and twist
variations represented by the lengths to which the various twist are associated.
Slub = choice 2: This is the classic slub or malfilé yarn with constant count and
twist. The CSTU sets the twist to 100% and prompts you set the limits of the pause
lengths, the slubs and the slub thicknesses.
- Rounded thickness: 0= No => values are random with two decimal figures
1= Yes => values are random up to the first decimal figure, the
second is set to 0
- Set the minimum and maximum values for “Pause”, “Slub”, “Thickness” and “Twist”
according to the pre-selected type of yarn (Multi-count, Multi-twist or Slub).
Automatically created programs can be subsequently edited manually as indicated in Chapter 6.2.1.
Several examples of automatic programming are illustrated below:
Example n.1 Multi-count Program:
Aim: produce a yarn with variations in count ranging, for example, from 20 to 28 Ne over segments of
yarn ranging in length from 2 to 4 m.
Program name 0400

L.U. : cm(0) dm(1) mm(2) 1
Number of lines 200
Multi-count(0) Multi-twist(1) Slub(2) 0
Rounded thickness (0-No 1-Yes) 1
Pause Slub Thickness Twist.

[dm] [dm] [%]}
Min. 0 020 1.00 ___
Max 0 040 1.40 ___

0001 0002 0201 *** ***
*** *** *** *** ***
Set the following characteristics (as shown above):
- Program name = 0400
- L.U. = 1 => lengths will be in dm
- Number of lines 200 : the program will be 200 lines long
- Rounded thickness = 1 => the second decimal figure of the thicknesses is ignored
- Pause and twist are set by the CSTU (multi-count)
- Slub lengths, i.e. the length of the various segments is: min = 20 dm, max = 40 dm
- Thicknesses range from 1.00 to 1.40. (That is, the finest segment of thread, in this case count
28 Ne, is considered as corresponding to a thickness of 1.00. The thickest segment will consist
of count 20 Ne, i.e. the maximum thickness = 1.40 = 28/20)
This newly written program can be displayed and if necessary edited following the procedure
explained in Chapter 6.2.1. The first 10 lines of the program are shown in the table below where it can
be noted that:
- the automatically calculated twist remains constant in relation to the thickness; in the segment
of yarn with thickness = 1.00, i.e. count 28 Ne, it is 100% of the nominal value calculated as
indicated in Chapter 6.1.6;
- thicknesses are limited to values with one decimal figure

[dm] [dm] [%]
001 0 036 1.30 087.70
002 0 028 1.40 084.51
003 0 023 1.00 100.00
004 0 035 1.40 084.51
005 0 025 1.20 091.28
006 0 024 1.00 100.00
007 0 030 1.20 091.28
008 0 032 1.40 084.51
009 0 026 1.30 087.70
010 0 030 1.40 084.51
Example n.2 Multi-twist Program:
Aim: produce a yarn having constant count, without slubs but with random variations in twist over
segments ranging in length from 3 to 8 m. Settings will be as follows:
- Program name = 0500

- L.U. = 1 => lengths will be in dm
- Number of lines 300 : the program will be 300 lines long
- Rounded thickness = 1 => the second decimal figure of the thicknesses is ignored
- The CSTU, given that operation is in multi-twist mode, sets the slub lengths to 0 and the
thicknesses to 1.00 (no slubs or variations in count are applied)
- Pause lengths, i.e. the length of the various segments is: min = 30 dm, max = 80 dm
- % twist to associate to the pause segments: minimum 80%, maximum 150%
Table 0.2.2 below Shows the settings required to automatically create the program.
Program name 0500

L.U. : cm(0) dm(1) mm(2) 1
Number of lines 300
Pause Slub Thickness Twist

[dm] [dm] [%]}
Min. 030 0 1.00 80
Max 080 0 1.00 150

0001 0002 0201 *** ***
*** *** *** *** ***
be noted that:
- twist is produced randomly with values ranging from 80% and 150%
- the slubs always have length 0 and thickness 1.00

[dm] [dm] [%]
001 036 0 1.00 084.70
002 058 0 1.00 100.00
003 043 0 1.00 112.50
004 073 0 1.00 095.15
005 061 0 1.00 136.88
006 049 0 1.00 121.00
007 071 0 1.00 092.78
008 052 0 1.00 100.00
009 034 0 1.00 087.70
010 067 0 1.00 148.15
Example n.3 Slub Program:
Aim: produce a slub yarn the general characteristics of which are:
- 4 slubs per metre

- slub thicknesses variable from double to 3 times base thickness
- slub lengths: all 5 cm long
Table 0.2.2 below Shows the settings required to automatically create the program:
Program name 0600

L.U. : cm(0) dm(1) mm(2) 0
Number of lines 400
Pause Slub Thickness Twist

[cm] [cm] [%]}
Min. 008 5 2.00 ___
Max 032 5 3.00 ___

0001 0002 0201 *** ***
*** *** *** *** ***
be noted that:
- twist is set to 100%
- slub thicknesses vary from 2.00 to 2.95
- these 10 lines include 10 slubs 5 cm long over a total of 250 cm of yarn (= sum of the pause
lengths and slub lengths), equal to 1 slub approx. every 25 cm, i.e. 4 slubs per metre as
required.

[cm] [cm] [%]
001 021 5 2.53 100.00
002 014 5 2.76 100.00
003 026 5 2.00 100.00
004 030 5 2.12 100.00
005 018 5 2.84 100.00
006 011 5 2.27 100.00
007 023 5 2.33 100.00
008 020 5 2.48 100.00
009 029 5 2.95 100.00
010 008 5 2.66 100.00
6.2.3 List of stored programs
Selecting item 3 on the programming menu (see Chapter 6.2), the display Shows the list of programs
stored in the CSTU internal memory. Figure 0.2.3 below shows an example of 3 stored programs
numbered 0001, 0002 and 0c201, hence a further 7 programs can be stored (indicated by *** in the
figure).
0.2.3 –List of stored programs
0001 0002 0201 *** ***

*** *** *** *** ***
6.2.4 Clear stored programs
To cancel a program from the CSTU internal memory, choose item 4 on the programming menu (see
Chapter 6.2). The display will then show window 0.2.4 below:
0.2.4 –Clear memory
Select the program to cancel _____
0001 0002 0201 *** ***

*** *** *** *** ***
Type the number of the program you want to cancel and press <ENT>. A prompt for confirmation is
displayed as shown in Figure 0.2.4. below
0.2.4 – Clear memory
OK to confirm
ESC to exit
If you press <ESC> the new program will not be cancelled. To permanently cancel the selected
program press <OK>.
The following message then appears:
0.2.4 – Clear memory
Please wait
Cancelling
6.2.5 Program names in four digits
Up to the CSTU release VAC 312 the highest program name was 999 (three digits maximum).
Starting from release VAC 400 the program names can have four digits, so the highest name is 9999.
When starting to use a CSTU with VAC 400, all the previous stored programs will be still valid, but a
0 will add to them (example: program 001 changes in 0001).
Attention: to manage programs with four digit names on your Computer also CSTU_Evaluation
needs to be updated to software version 4.0.0.
Attention: program higher that 999 cannot be read by any CSTU device with version VAC 312 or
lower. So, if you need that a program be loaded in CSTU not updated to version VAC 400, you must
use names lower than 999.
Examples (four digit name in old CSTU):

Program 0900 it will be read by a CSTU VAC 312 or lower as……... Program 900
Program 1001 cannot be read by CSTU VAC 312 (impossible to download from Cartridge)
Examples (three digit name in CSTU VAC 400):

Program 200 it will be read by a CSTU VAC 400 as…………..… Program 0200
6.3 Communication with CARTRIDGE
The orange CAIPOMEM5 cartridge can contain up to 30 programs, each comprising 500 lines. It can
be used as an external memory medium to save programs normally resident in the CSTU internal
memory: you are advised to always backup copies of programs in the CAIPOMEM5 .
Once programs have been saved in the CAIPOMEM5 they can be transferred from one CSTU to
another, or transferred to a PC if you have the CSTU-Evaluation software which enables you to
simulate yarns and fabrics on your PC. CSTU-Evaluation software is not supplied as standard with the
CSTU and may be purchased separately.
When you want to copy programs from an CAIPOMEM5 cartridge to the CSTU, or vice versa, select
option 3 on the Main Menu. First, however, insert the cartridge into its socket (see Chapter 5.1) and
leave it inserted for as long as you work in this sub-menu.
After pressing 3 on the Main Menu, the following message is displayed and remains visible for as
long as the CSTU computer requires reading the CAIPOMEM5 cartridge (up to 1 minute if the
cartridge contains many programs).
Please wait!
Loading
If the cartridge is not inserted or is extracted before operations are completed, the following message
is displayed:
ERROR !
ERROR !
If this occurs, press <ESC> to restart the procedure (after inserting the cartridge) or press <ESC>
again to return to the Main Menu and select another option.
If the cartridge is correctly inserted, the following sub-menu is displayed once the CSTU has read the
contents of the CAIPOMEM5:
0.3 – Communication with cartridge
1 – Cancel a program on cartridge

2 – List of programs on cartridge
3 – Program from cartridge to CSTU
4 – Program from CSTU to cartridge
5 – Wipe entire cartridge
6.3.1 Cancel a program on an CAIPOMEM5 cartridge
Selecting item 1 on Sub-menu 0.3 accesses the procedure for cancelling a program from the
CAIPOMEM5 cartridge. Window 0.3.1 below appears on the display.
0.3.1 –Cancel a program on cartridge
Select the program to be erased _____
List of programs on cartridge
0020 0012 0112 *** ***

*** *** *** *** ***
*** *** *** *** ***
*** *** *** *** ***
*** *** *** *** ***
*** *** *** *** ***
Type the number of the program you want to erase and press <ENT>. A prompt for confirmation is
displayed as shown in Figure 0.2.4. below
0.2.4 – Cancel a program on cartridge
OK to confirm
ESC to exit
If you press <ESC> the program will not be cancelled. To permanently erase the selected program
press <OK>. When cancellation has terminated, the CSTU redisplays Cartridge Communication Menu
0.3
6.3.2 List of programs on cartridge CAIPOMEM5
To view the programs contained on an CAIPOMEM5 cartridge choose option 2 on Menu 0.3. A list of
the programs is displayed as indicated in mask 0.3.1, but without a cancellation option.
Press <ESC> to return to cartridge Sub-menu 0.3.
6.3.3 Program from cartridge to CSTU
To copy a program from the CAIPOMEM5 cartridge to the internal CSTU memory, select option 3
from Sub-menu 0.3. The following prompt will then be displayed:
0.3.3 – Program from cartridge to CSTU
Name of program to be copied _____

Name of program in memory _____

0020 *** *** *** ***
*** *** *** *** ***
*** *** *** *** ***
*** *** *** *** ***
*** *** *** *** ***
*** *** *** *** ***
0001 0002 0201 *** ***
*** *** *** ***
Type the name of an existing program on the cartridge (in the example, 0020 is the only program
contained) then the new name that will be assigned to the program in the CSTU memory (this may be
0020 or another number).
After confirming your choice when prompted, the program will be copied (wait a few seconds).
6.3.4 Program from CSTU to cartridge
To copy a program from the internal CSTU memory to an CAIPOMEM5 cartridge, select option 4
from Sub-menu 0.3. The following prompt will then be displayed:
0.3.4 – Program from CSTU to cartridge
Name of program to be copied _____

Name of program on cartridge _____

0001 0002 0201 0020 ***
*** *** *** ***

0020 *** *** *** ***
*** *** *** *** ***
*** *** *** *** ***
*** *** *** *** ***
*** *** *** *** ***
Type the name of a program in memory (for example, 0201) then the new name that will be assigned
to the program on the cartridge (this may be 0201 or another number).
After confirming your choice when prompted, the program will be copied (wait a few seconds).
6.3.5 Wiping the entire cartridge
Select option 5 on Sub-menu 0.3 to cancel all programs contained on the CAIPOMEM5 cartridge.
The following prompt for confirmation will appear on the display:
0.3.5 – Wipe entire cartridge
OK to confirm
ESC to exit
Press <ESC> to exit cancellation. All programs therefore remain on the cartridge.
Press <OK> to PERMANENTLY cancel all programs contained on the cartridge.
6.4 Machine parameters setting
Selecting option 4 on the Main Menu accesses Menu 0.4 indicated below. This menu is used to set the
parameters of the spinning machine on which the CSTU is installed. Since these parameters relate to
the machine and not to the type of yarn to be produced, unless radical modifications are made to the
parameters of the spinning machine itself these parameters are normally not modified. Certain
parameters, those indicated as “ CAIPO Parameters ”, can be displayed but not edited as they are set
by CAIPO specialised personnel only.
0.4 – Machine parameters setting
1 – User Parameters
2 – Display CAIPO Parameters
3 – Edit CAIPO Parameters
4.- Maintenance
5 – Cease A encoders
6 – Cease A encoders
6.4.1 User Parameters

The menu User Parameters contains all the parameters that the user can modify to better adapt the
CSTU to working requirements in relation to the type of spinning machine the CSTU is installed on,
and how the machine is regulated.
From main menu

Press key 4 - Machine parameters setting
Press key 1 - User Parameters
the User Parameters will appear
0.4.1 – User Parameters

A B
Start speed [m/min] 004 004
Stop speed [m/min] 003 003
Maximum doffing time [min] 0010 0010
Twist set/current [%] 100 100
Slub errors [%] 010 010
Twist: TPM(0) TPI (1) 0 -
Slub filter start [m/min] 05.00 05.00
Start slub thickness 01.00 01.00
Start slub duration 00.00 00.00
Sliding cease time [min] 00.00 00.00
Reduction M1 → Feed 0031.62 0041.58
Reduction M3 → Draft 0008.10 0010.32
Reduction on Spindles 0010.53 0009,76
To change the parameters: press the key MOD, move to the parameter to be modified, press again key
MOD, change it, then press key ENT.
At the end, press key ESC to exit the function. and key OK to confirm. (not necessary to turn off the
CSTU electric box).
ATTENTION: changing the User Parameters will affect the behaviour of the CSTU; read carefully
the explanations before any change.
ATTENTION: remember to save them CSTUPAR cartridge after change of the User Parameters
(see CSTU backup paragraph)
ATTENTION: starting from the software version VAC 3.0.0 in the we have in User Parameters
menu three new parameters menu some parameters that, in the previous versions, were placed in the
CAIPO Parameters menu
The parameters are defined below:

Start speed m/min] The speed above which the CSTU unit starts to produce slubs.
Stop speed [m/min] The speed below which the CSTU unit stops producing slubs before the machine
stops. Always set a stop speed value that is lower than the start-up speed value!
Maximum doffing After each stop, the time limit after which the motors are placed in neutral. If the
time [min] stop time exceeds the time limit, the motors will be engaged as soon as the
ENABLE signal is received (machine start-up).
Suggestions:
- Maximum doffing time = 0001 (1 min.)
- In case of many yarn breaks after doffing lift the value, for example to
0030.00 to hold the motors active for 30 minutes after every machine stop.
Twist set/current Indicates an adjustment of the nominal twist to correct deviations induced by the
spinning machine. Standard value 100 (Note 1)
Slub errors Indicates the % limit of allowed errors on slubs or ' short'pauses in excess of
which an alarm is triggered. (Note 2)
Twist: TPM(0) Set to 0 the twist is displayed in turns per minute
TPI (1) Set to 1 the twist is displayed in turns per inch
Attention: the TPM/TPI done for A machine is valid also for B machine
Recommended value 05.00 m/min ( notices 3 )
Slub filter start
The parameter can be useful in some cases to reduce the thin points at machine
[m/min]
start. It must be set to low values, less than the minimum speed of production.
The parameter increases the diameter of the yarn at machine start.
Recommended value 01.00 if no thin points (Note 3)
Start slub thickness In case of thins points at machine start the parameter can be increased (for
example 01.50 increases yarn diameter of 50% at machine start).
The right parameter to reduce thin point can only be found by trials
The parameter determines the time for which is active the diameter extension of
Start slub thickness at machine start.
Recommended value 00.00 if no thin points (Note 3)
Start slub duration
In case of thins points at machine start the parameter can be increased (for
example 02.00 increases yarn diameter for 2 seconds at machine start). The
right value to reduce thin point can only be found by trials
Sliding control timeout in muntes
Sliding cease time
see paragraph 6.6.11
Reduction M1 → Total gear reduction from CSTU Feed Motors to ring frame feeding shaft.
Feed This parameter must be set to the value shown in the CSTU cinematic diagram.
Attention: if the cinematic diagram shows many values, need choose the right
reduction value used at the moment on the ring frame machine.
Reduction M3 → Total gear reduction from CSTU Twist Motor to ring frame delivery shaft.
Draft This parameter must be set to the value shown in the CSTU cinematic diagram.
Attention: if the cinematic diagram shows many values, need choose the right
reduction value used at the moment on the ring frame machine..
Reduction on Reduction from spindle to speed reference shaft.
Spindles This parameter must be set to the value shown in the CSTU cinematic diagram..
Note n. 1 : Set/current twist

If the twist is not correct when set to a value of 100, the cause may be that the speed of the spindles in
turns/min is incorrect, for example due to slippage between the spindles and the speed reference shaft,
or because the declared reduction is not exact.
If twist is too low set values >100 (e.g. 102)
If twist is too high set values <100 (e.g. 98
Note n. 2: slub errors

If excessively short slub lengths are set in relation to the outlet speed of the yarn, and, with the set
speed ramps, the slub unit motor is not able to reach steady state speed before the programmed end of
the slub, the CSTU can not guarantee that slubs will be accurately performed. The same may occur
with pauses. In this case, the CSTU records an error in that each slub is controlled both as regards the
acceleration ramp and deceleration ramp.
After 100 speed variations (50 slubs), if the number of errors is equal to the set slub error value, the
CSTU stops the machine and indicates the presence of slubbing errors.
Error values can be set in the range 1 (= stop on 1st error) e 100 (= non-stop, i.e. the control function
is disabled).
When a slub error alarm is signalled, verify that the program is compatible with processing conditions
(production speed, length of fibres, draft etc.). If you do not want to modify the program, you can
raise the “slub error” limit. Bear in mind, however, that the higher the limit, the less accurately
execution of the program will be controlled and the resulting slubs may appear shorter and thinner
than set in the program.
Caution: operating when slubs errors are present can lead to high motor power consumption.
Note 3 The values recommended for this parameters are valid only for CSTU software versions
VAC 2.2. and following (in case of VAC 2.1.1 please consult CAIPO).
6.4.1.1 Execution of the program at machine start.
The setting of the Start speeds and Stop speed defines limit speed under which the CSTU doesn'
t
produce slubs ( neither effect of torsion ).
Not producing slubs at low speed may be useful to avoid yarns breakage at machine stop (blazes
under the cylinders).
Two cases are possible:

Normal behaviour to produce slub yarn.
In this case we recommend to set Start speed about 2/3 of the minimum production speed; and Stop
speed about 1/3 of the production speed
For example with speed of production among 10 and 15 m/min good values may be Start speed = 6
and Stop speed = 3 m/min..
Attention: at any machine stop the CSTU recovers to perform the first line of the program
Setting to hold the right program line at machine stop.

To hold the right line of the program, that’s useful in case of multicount yarn, where no risk of yarns
breakage at machine stop, the Start speed and Stop speed must be both set to zero.
Moreover the Maximum doffing time must be set to an high value (for example 30 min).
With such a setting the CSTU will continues to perform the right program line even in case of
normal machine stop. (if the machine stops last less then doffing time value).
Other events
CTUS alarms: In case of some alarm the CSTU normally continues to perform the slubs till the
production speed goes down the Stop speed.. But in some particular cases, when that is not possible;
for example in case " Feed motor over speed " the CSTU is stops immediately to produce slubs..
Moreover, in case of drive’s alarm, the CSTU immediately stops all the motors.
In all this cases to the CSTU will restart performing the first line of the program.
Main line power failure

In the case main line power failure when the spinning machine is running all motors stop immediately,
so all yarn will break.
The only solution to avoid the break of the yarn is the use of a UPS device to feed the CSTU.
6.4.2 Display CAIPO parameters

The menu CAIPO Parameters contains the parameters that must never been changed. They defines the
basic setting of a CSTU in a ring frame or O.E. machine
ATTENTION: starting from the software version VAC 3.0.0 many parameters have been moved
from CAIPO Parameter to other menus:
- the encoder parameter s have been moved in " diagnoses Encoder " (0.6.7 )
- the parameter related to the motors have been moved in " maintenance” menu
- -other parameters have been moved in the menu " User Parameters " ( 0.4.1 )
From main menu

Press key 4 - Machine parameters setting
Press key 2 – Display CAIPO Parameters
0.4.2 – Display CAIPO parameters

A B
Feed Encoder 1300.00 1230.77
Draft Encoder 0428.00 0406.25
Speed Encoder 0200.00 0236.36
Feed Roller 0027.00 0025.00
Draft Roller 0030.00 0025.00
Start time 0030.00 0030.00
Stop time 0030.00 0030.00
Slub filter 0000.06 0000.06
Twist filter 0001.00 0001.00
Delay on start [s] 0000.00 0000.00
Motors (0=CD1K 1=SR614) 0 0
Alim. on pre-draft 0 0
LCD OFF: Si (1) No (0) 0 0
Slub missing hard stop 0 0
Feed Encoder Number of encoder pulses per turn of feed shaft (the same for all encoders
installed on the various feed shafts)
Draft Encoder Number of encoder pulses per turn of draft shaft
Speed Encoder Number of encoder pulses per turn of machine speed reference shaft (fixed
ratio with spindles speed)
Feed Roll Diameter of feed shafts in mm
Draft Roll Diameter of draft shafts in mm
Start-up time Maximum time between enable signal – start of movement - overcoming
of the start-up speed (see Note).
Stop time Maximum time between decrease below speed limit and actual stop, i.e.
zero encoder pulses (see Note)
Slub filter Functional parameter, recommended value 0000.06
Twist filter Functional parameter, recommended value 0001.00
Start delay [s] Twist motor start delay.
Value 000.00 except cars that require the lead time of start.
If you set a value different from zero the twist motor will leave delayed
(measurement unit: seconds). For instance: by setting 0010 00 the twist
motor leaves 10 seconds after the spindles.
The parameter does not affect the other motors.
Motors The CSTU can mount two types of motors :
0=CD1K - series MA30/MA45 with CD1K drives
1=SR614 - series DBL5 with SR614 or SR620 drives.
Both assure the same performance but have different dimensions (diameter,
length). CAIPO chooses one or the other according to the type of machine.
Alim. on pre-draft This parameter must be set as shown in the CSTU cinematic diagram.:
0 = if the motors directly drive the feed shaft
1 = if the motors directly drive the pre-feed shaft and only intermediately
the feed shaft; in this case the parameters must be used ZPX and ZPY
(draft – pre-draft ratio) (see 0.1.2)
LCD OFF: Si (1) No (0)
If set to 1 the LCD display will automatically switch off if unused
0 = normal operation
Slub missing hard stop 1 = in case of “slub missing alarm” the CSTU stops the machine, and,
further, it stops also CSTU motors (may causes the breakages of all yarns)
Note on start/stop times

If the start or stop limit times are exceeded, the machine is stopped and an error message is
displayed. This feature is designed to prevent the machine from operating in abnormal
conditions (for example, slubbing is not applied if the start speed is not exceeded). See also
“error messages” and "signal sequence diagrams”
6.4.3 Edit CAIPO parameters

This operation is restricted to CAIPO technicians and requires a CAIPO password.
From main menu
Press key 4 – Machine parameters setting
Press key 3 – Edit CAIPO Parameters
To enters to the CAIPO parameters (same as the previous menu Display CAIPO parameters); but with
the possibility to modify them (function reserved to CAIPO technicians; CAIPO password is
requested).
Caution: after any modification to CAIPO parameters, it is compulsory to reboot the

machine (on power-up the CSTU checks what motors are installed/not installed and
recalculates the coefficients).
Caution: unauthorised modification of CAIPO parameters can lead to serious
malfunction and/or serious processing defects.
6.4.4 MAINTENANCE (servicing) functions
The servicing functions allowed are the following:
- Backup and recovery of CSPU parameters on CSTUPAR.
- Backup and recovery of DRIVE UNITS parameters on CSTUPAR
- Motors testing
- Motors parameters setting
From main menu
Press key 4 – Maintenance
By entering the function it appears the advice

0.4.4 Maintenance
Attention, after this

you will be obliged to switch off
OK to confirm
ESC to cancel
Insert the CAIPOPAR cartridge (only for backup or recovery function); then press key OK to start the
enter in the maintenance menu.
The functions selection appears
0.4.4 Maintenance
1- CPU
2- A Machine
3- B Machine
4- A Motor Test
5- B Motor Test
6- Installation parameters
Select and entry ESC to exit
The CSTUPAR cartridge is used to have a copy of all parameters of CSTU control card and of drive
units, to be used in case of replacement of one of these parts. The CSTUPAR cartridges are equal to
CAIPOMEM5 cartridges, but with a different label to distinguish the functions.
CAIPO inserts in every CSTU control board a special CSTUPAR cartridge with the parameters
foreseen for that board during the planning, its serial nr. is indicated in the label.
We advise to save copy of CAIPO parameters or of drive units’ data on CSTUPAR after each
modification of the same..
After the operations of data backup or recovery, or motors testing, always appears the following
writing.
04.3 Edit CAIPO parameters
Switch off the panel and wait a minute
ATTENTION: the switching off in advance of the control board (before the advice on
the display) could cause the parameters loss (and it becomes compulsory to write them
again or to load them again from CSTUPAR memory).
6.4.5 CPU data backup on CSTUPAR cartridge
The data backup is used to do a copy of all CSTU parameters on the special CSTUPAR cartridge, in
order to have them available for the replacement of CSPU control cards.
From main menu, insert the CAIPOPAR cartridge, then

Press key 1 – CPU
0.4.4.1 CPU
1- CPU → CSTUPAR (Data Backup )

2- CSTUPAR → CPU (Data Recovery )

Press key 1 – CPU → CSTUPAR (Data Backup )
Press key OK to confirm
Type the CSTU serial number, then ENT to confirm.
Attention: after the updating of the software you need always do again the data recovery from CSTU
to CSTUPAR.
6.4.6 CPU data recovery from CSTUPAR cartridge

The data recovery, enables to load on a CPU card all CSTU parameters previously saved on the
special CSTUPAR cartridge, in order to have them available when replacing the CPU control cards
The recovery of CPU data can be done with user’s password (Caipo password is not required).

Press key 1 – CPU
0.4.4.1 CPU
1- CPU → CSTUPAR (Data Backup )

2 - CSTUPAR → CPU (Data Recovery)
Press key 2 – CSTUPAR → CPU (Data Recovery)

Attention
During the recovery of CPU data from cartridge are reloaded
- CAIPO parameters
- USER parameters
- Working settings (program, draft, twist, ramps)
Therefore after the recovery of CPU data you have always
- to check the user’s parameters
- to reload the working settings (program, draft, twist, ramps)
-
6.4.7 Data backup of Machine A(B) drive units on CSTUPAR
The backup of the drive units data is used to do a copy of all drive unit parameters controlling M1A
motor on the special CSTUPAR cartridge, in order to have them available when replacing the CPU
control cards (see 7.4.1).

Press key 2– A Machine

0.4.4.2 A Machine
1. AZ1 → CSTUPAR (Data Backup)
6. CSTUPAR → AZ1 (Data Recovery)

Press key 1 – AZ1 → CSTUPAR (Backup data)

The same is for the their drive units AZ2 and AZ3;
Same procedure for the drive units of machine B
Attention: after every modification of drive units parameters (i.e.: motors direction) you
have always to save on CSTUPAR in order to have all data available, necessary when
replacing the drive units.
6.4.8 Recovery of drive units Machine A (B) from CSTUPAR cartridge

The drive units’ data recovery enables to reload on the drive units all the required parameters for
motor control.
Attention: The recovery operation has to be done every time you use a new drive unit
(see 7.4.4 or 7.4.5); or when you exchange the drive units, either from another CSTU or
from a position to another one in the same CSTU control board.

Press key 2– A Machine
0.4.4.2 A Machine
1. AZ1 → CSTUPAR (Data Backup )
6. CSTUPAR → AZ1 (Data Recovery )


To reload the setup data for drive unit Az.1
Press key 6 – AZ1 (Recovery data)

Press key 3– B Machine

0.4.4.3 B Machine
6. CSTUPAR → AZ1 (Data Recovery )


6.4.9 Motor Testing Machine A (B)
The motor testing function is used to check the CSTU motors.
Attention:
The motor testing operation has to be done only from the servicing personnel,
following the safety instructions.
The motors have to be let turning when the machine is stopped (all the yarn will
break down)
During the motor testing the connection to the machine emergency is active : the motor can’t
start or is stopped if the machine emergency contacts open (always if such connections have
been done properly as indicated (see 7.3.1. of this manual)
From main menu

Press key 4– A Motor test
0.4.4.4 A Motor test
1 - Motor 1
2 - Motor 2
3 - Motor 3
To test the first motor, machine A

Press key 1 – Motor 1
The functions menu appears

0.4.4.4.1 Motor 1
RPM START
Motor 1 0500 OFF
Select and entry MOD to modify
Press key MOD twice

Set the motor speed (ex. 100 rpm), than ENT to confirm
Press key to move the cursor under START
The drive is now ready to start
to START the motor: key MOD
to STOP the motor: key MOD again or key ESC
Same procedure for the other drive units of machine A

Attention: After the substitution of a drive unit remember to reload the parameters of the drive from
CSTUPAR cartridge, and to verify that the sense of march is correct. A wrong setting, or a bad motor
direction, can damage the mechanical parts.
6.4.10 Installation parameters A (B)
The Installation parameters contain the following information:
- how many motors are installed on the CSTU
- motor type
- the sense of rotation of the motors
From main menu

Press key 6 – Installation parameters
The motor list selection appears
0.4.4.6. – Installation parameters

A B
Az.1 Enable 1 0
Az.2 Enable 1 0
Az.3 Enable 1 0
Az.4 Enable 0 0
Az.5 Enable 0 0
Motor 1 direction 1 1
CPS Enable 0 0
LCI 0 0

Az.1 Enable Headstock feeding motor 1= installed 0 = not inst.
Az.2 Enable Counter-headstock feeding motor 1= installed 0 = not inst.
Az.3 Enable Delivery motor (draft shaft) 1= installed 0 = not inst.
Az.4 Enable Reserved function To be set = 0
Az.5 Enable Reserved function To be set = 0
Motor 1 direction Headstock feeding motor 0= CW 1 = ACW
Motor 2 direction Counter-headstock feeding motor 0= CW 1 = ACW
Motor 3 direction Delivery motor (draft shaft) 0= CW 1 = ACW
Motor 4 direction Reserved function To be set = 0
Motor 5 direction Reserved function To be set = 0
CPS Enable To be set to 1 if the CSTU is connected to the CPS device (the CPS device
supply the CSTU for short time in case of main line power failure)
LCI Reserved for CAIPO; set to 0
To exit the function

Press key ESC
To modify some parameter

Press key MOD
Press arrow key to move to the parameter to be modified
Press key MOD again
Type the new value, the ENT to confirm
Press key ESC
Press key OK
After the operations wait for the following writing.
Switch off the panel and wait a minute
ATTENTION: the switching off in advance of the control board (before the advice
on the display) could cause the parameters loss (and it becomes compulsory to write
them again or to load them again from CSTUPAR memory).
ATTENTION: changing the User Parameters will affect the behaviour of the CSTU; read carefully
the explanations before any change.
ATTENTION: remember to save them CSTUPAR cartridge after change of the User Parameters (see
CSTU backup paragraph).
6.4.11 Cease sliding control Encoders side A (B)

The function “interruption controls A” permits to exclude temporarily the control on the
Encoders EST and EAL (errors of slipping, see Diagnostic Encoder – paragraph 6.6.4)
Entering the request of interruption appears

0.4.5. – Cease A encoders
Cease the encoder controls?

OK to confirm
ESC to cancel
ENT to confirm ESC to exit
Choosing OK, it appears the report of interruption.

The controls on the encoders (alarms, slipping) will remain suspended until the end of the
timer
0.4.5. – Cease A encoders
Remaing time : 35
Press ESC immediately enable.
ESC to exit
The starting value of the timer can be setted between the user’s parameters (see paragraph 6.3.7)
The function for the side B is the same
6.5 Language selection
Type 5 on the Main Menu to change the interface language. Menu 0.5 below is then displayed.
0.5 – Language selection
1 – Italian
2 – English
3.– Spanish
ESC to exit
Type the number corresponding to the language you require, or press <ESC> to exit the menu.
6.6 Diagnostics
The diagnostic menu is used to:
- see current alarm messages and reset them
- see info data about the current CSTU status
- see the alarm message history
- manage the Encoder diagnostic
0.6 Diagnostics
1 - Error messages A
2 - Error messages B
3 - Machine A Monitor
4 - Machine B Monitor
5 - Machine A check-up
6 - Machine B check-up
7 - Encoder check-up
8 - Errorlog A
9 Errorlog B
Select an item
Press 1 to display Machine A error messages, if any.

Press 2 to display Machine A operating conditions.
6.6.1 Error Messages Machine A (B)
Whenever a serious error is detected, the CSTU stops the spinning machine it is connected to and
turns on an alarm LED on the lower left (see Chapter 5.2).
To discover the cause of the error, press 1 for Machine A or 2 for Machine B, as indicated in the
diagnostic menu. The error will be displayed as shown in example 0.6.1 below:
0.6.1 Error Messages A

ERROR !
Three phase down
Pending spinning frame emergency
ESC to exit
See the Troubleshooting paragraph (7.2) for the meanings of error messages.
Pressing the key ESC the error message will be cancelled. Further, if the error is caused by a drive,
the drive will be reset.
Repeat the operation until all the errors are cancelled.
If some error continues to appear, seek the causes reading alarms and remedies described in the
following paragraphs.
6.6.2 Machine Monitor A (or B)

From diagnostic menu select item 3 to display the operating status of the CSTU and of the spinning
machine A.
Select item 4 to displays same data for machine B.
0.6.3 – Machine A Monitor

Program name 0002 Draft 020.00
Temperature 028 Twist TPM 0500.00
Slub Error 0 Speed m/min 022.00
Line number 1 Offset 0
Slubs
900% …………………………………………………………………………………………………..
800% …………………………………………………………………………………………………..
700% …………………………………………………………………………………………………..
600% …………………………………………………………………………………………………..
500% …………………………………………………………………………………………………..
400% …………………………………………………………………………………………………..
300% …………………………………………………………………………………………………..
200% …………………………………………………………………………………………………..
100% …………………………………………………………………………………………………..
…0% …………………………………………………………………………………………………..
Twist
300% …………………………………………………………………………………………………..
250% …………………………………………………………………………………………………..
200% …………………………………………………………………………………………………..
150% …………………………………………………………………………………………………..
100% …………………………………………………………………………………………………..
.50% …………………………………………………………………………………………………..
…0% …………………………………………………………………………………………………..
ESC to exit
Program name Indicates the name (number) of the program being executed
Temperature Indicates the internal temperature of the CSTU control panel (Note)
Slub Error Indicates the instantaneous % value of incorrect slubs (see 0.4.-1)
Draft Indicates the working draft (see 0.1.2)
Twist TPM Indicates the working twist (see 0.1.3)
Speed m/min Indicates the instantaneous value of production speed (metres of
yarn per minute)
Line number Indicates which line of the program is currently executed.
Offset Indicates the last offset value used (jump over a casual line in the
execution of the program; see paragraph 6.1.4)
Slub trend
The “slub” graph shows the trend of the count of the yarn being produced.
Values > 100% indicate slubs (the speed of the feed shaft is increased)
Values < 100% indicate negative variations (the speed of the feed shaft is decreased)
Twist trend
The “twist ” graph shows the trend of the twist of the yarn being produced.
Values > 100% indicate increases in twist (draft shaft speed is reduced and less yarn is produced)
Values < 100% indicate decreases in twist (draft shaft speed is increased and more yarn is
produced)
Variations in twist are deliberately slower to prevent lumps or dots forming on the yarn.
Note on internal panel temperature

The temperature should always be lower than 40°C; if the temperature exceeds 40°C, then:
– Clean panel filters on the inlet (on the detachable panel) and the outlet (on the rear at the top)
– Check fans
– Check drive temperatures
Caution: overheated drives are an indication of excessive motor power consumption. This may be
caused by excessively heavy operating conditions (suggestion: reduce the number of slubs per metre
or decrease the production speed).
6.6.3 Diagnostics of the Machine A (B)

From diagnostic menu select items 5 to display the motors speed and Encoders shaft speed for
machine A
Select item 6 to displays same data for machine B
0.6.5 –Machine A check-up
rpm Act
M. Feed 426
M. Draft 2108
E. Feed. 35.05
E. Draft 231
E. Vel. 3600
Spindle 16000
m/min Act
Feed. 01.14
Draft 22.85
ESC to exit CLR to reset
The display shows the speeds in some meaningful points of the spinning machine
M. Feed [rpm] Indicates the speed of the slub motor ( motor on the feed shaft)
M. Draft [rpm] Indicates the speed of the motor for twist control (motor on draft shaft).
E. Feed. [rpm] Indicates the speed of the encoder on feed shaft
E. Draft [rpm] Indicates the speed of the encoder on draft shaft
Indicates the speed of the encoder on speed shaft, measuring the speed of
E.Vel. [rpm]
the spinning machine.
Indicates the spindles speed ( presumed speed, drawn by the encoder
Spindle [rpm]
speed .multiplied by the reduction parameter Vel- spindle).
Feed. [m/min] Indicates the speed of feed of the car, in meters per minute
Draft [m/min] Indicates the production speed , in meters per minute
Attention: some data are shown only if the CSTU is equipped with the motor that drives then draft
shaft; they are not visible if the CSTU controls only the slub function.
6.6.4 Encoders check-up
From diagnostic menu select item 7 to display detailed data about encoders on machines A and B
(useful in case of encoder sliding error)
From the software version VAC 2.2.5 the menu 0.6.7 appear as in the icon below
Example: r CSTU model FFT (1 machine, 3 motors)

0.6.7 – Encoder check-up
Conn ON/OFF Motor Encoder Rounds
EAL1 C3a 1 4210688 4202496 0
EAL2 C4a 1 4210688 4197758 0
EAL3 C5a 1 4210688 4213487 0
EAL4 C1a 1 4210688 4422597 0
EAL3 C2b 0
EAL4 C3b 0
EST1 C2a 1 4220858 4200858 0
EST2 C5a 1 4220858 4207411 0
Toll. a 0
The first column identifies the encoder: function:

EAL means Encode on Feeding Shaft
EST means Encode on Delivery Shaft
and connection
C3a means Connector position 3 (from top bottom) on SCN2000 board on panel a (left side)
example
EAL1 C3a Encoder on feeding shaft 1^ machine A - connector 3 on SCN2000 board side A
EST1 C2a Encoder on delivery shaft 1^ machine A - connector l on SCN2000 board side A
EST2 C5a Encoder on delivery shaft 2^ machine A - connector 5 on SCN2000 board side A
Note: the number of Encoder connected in a CSTU depends on CSTU type and machine type; look
the wiring diagram of your CSTU to see how many encoders are connected and their function.
Note: as a rule a CSTU can have a maximum of five Encoders (because only five connectors in each
SCN2000 board). Only the CSTU version FFT can have more then five Encoders, using an auxiliary
board SCN2000 boards, mounted side b (right); so we have
EAL3 C2b Encoder on feeding shaft 3^ machine A - connector 2 on SCN2000 board side B
EAL4 C3b Encoder on feeding shaft 4^ machine A - connector 3 on SCN2000 board side B
Note: the Encoder EVEL1 (spindle or rotor speed measurement) doesn’t appears on the Encoder
check-up menu, because is behaviour is checked in a different way.
The two central columns are for Caipo technicians and show the values of internal contactors to CSTU
dedicated to slipping control.
The last column shows the slipping revolutions, that is the rotation error taken on the shaft of the
encoder (the control is repeated every 128 rounds (revolutions) of the motor moving the shafts where
are installed the encoder).
0 indicate no error
1 indicates error of 1% (precisely 1/128)
2 indicate error of 2% about (precisely 2/128)
64 it indicates that the encoder turns at a speed equal to 50% (error in the ratios)
128 indicates that the encoder is disconnected, or turn bad direction, or it is faulty
ATTENTION If you enter the menu Encoders Diagnostics after the machine stop with “encoder
slipping” error, you can see the values that have caused the alarm (which encoder and how many
slipping revolutions).
The ON/OFF column shows which encoder are under control (value 1) and which ones are out of the
control (value 0): by pushing on MOD key (and by typing in the password) you can change the
setting, by including or excluding from the control the encoder on the same line.
By setting 1 you activate the control: if the shaft does not turn at the expected speed is generated a
“slipping” error. By setting 0 is deactivated the control even if the shaft turns at a different speed than
what expected, the CSTU will not give any alarm.
The “slipping” can be caused by:

- Working with different reduction ratios than those expected in the kinematics diagram
- Wrong setting of mechanical ratios in “CAIPO parameters”
- Slipping of mechanical parts in motor-shaft transmission
- Motor feedback time a acceleration or deceleration control
Practically, if everything is OK, in the column on the right is shown 0 slipping revolutions, hardly
ever 1 slipping revolution. To enable the control on different machines it has been added the
possibility to define the control tolerance.
By pressing the key MOD and moving on the last line you set the tolerance, that is how many slipping
rounds are accepted (on 128 motor revolutions, which is the control term) Press ESC to exit.
The tolerance is applied to all encoders controlled:

Tol. at = 0 0 slipping rounds(on 128) admitted Stop if slipping rounds . 1 (*)
Tol. at = 1 1 slipping rounds(on 128) admitted Stop if slipping rounds 2 (*)
Toll at = 2 2 slipping rounds (on 128)admitted Stop if slipping rounds. 3
Tol. at = 3 4 slipping rounds (on 128)admitted Stop if slipping rounds 5
Tol. at = 4 8 slipping rounds(on 128) admitted Stop if slipping rounds l. 9
Tol. at = 5 16 slipping rounds(on 128) admitted Stop if slipping rounds. 17
(*) Suggested values

N.B If the machine works only with higher tolerance values we advise to check encoder and ratios.
ATTENTION: to ease the operations of control activation and tolerance setting, the machine stopping
is excluded while you operate on the menu “Diagnostic Encoder” (the slipping rounds are shown, but
the machine is not stopped).
The function of machine control and stopping (for slipping rounds higher than the set limit) is taken
again when you exit from the menu, or you let the CSTU active in the menu for various minutes.
Example: of Encoder check-up menu in case of CSTU for 2 machines
If the CSTU controls two ring frame or O.E. machines the of Encoder check-up shows also the
Encoders of machine connected to CSTU side B (right panel).
0.6.7 –Encoders check-up

Conn ON/OFF Motor Encoder Rounds.
EAL1 C3a 1 4210688 4202496 0
EAL2 C4a 1 4210688 4197758 0
EAL3 C5a 1 4210688 4213487 0
EAL4 C1a 1 4210688 4422597 0
EAL3 C2b 0
EAL4 C3b 0
EST1 C2a 1 4220858 4200858 0
EST2 C5a 1 4220858 4207411 0
Toll. a 0
Conn ON/OFF Motor Encoder Rounds
EAL1 C3b 0
EAL2 C4b 0
EAL3 C5b 0
EAL4 C1b 0
EST1 C2b 0
EST2 C5b 0
Toll. b 0
In this case all the Encoders for machine A are connected side a (SCN2000 left side); all the Encoders
for machine B are connected side b (SCN2000 right side
EAL1 C3b Encoder on feeding shaft 1^ machine B - connector 3 SCN2000 board side B
Note: the tolerance for side B is selected at the bottom line
Note about the Encoders (which compulsory, which optional)
EVEL1 Spindle or rotor speed measurement Compulsory for CSTU with twist control
EST1 Delivery speed measurement Compulsory for all machines
EST2 On the second delivery shaft Optional
EAL1 - 4 Feeding shaft speed measurement Optional (but as a rule at least one is mounted)
6.6.5 Errorlog A (B)
From diagnostic menu select item 8 to display the record of the errors on machine A
Select item 9 to displays same data for machine B
0.6.8 –Errorlog A
H.M
00186.33
00000.05 12 00151.13 11
00000.05 14 00171.11 12
00000.05 11 00171.11 14
00002.22 12 00171.11 11
00002.22 14
00002.22 11
00033.12 12
00033.12 14
00033.12 11
00084.00 12
00084.00 14
00084.00 11
00101.23 12
00101.23 14
00110.23 11
00144.03 12
00144.03 14
00144.03 11
00151.13 12
00151.13 14
In this page you can see a record of the last 60 alarm messages registered by the CSTU device.
Top left, you can see the total running time in H.M (hours and minutes), that is all time the CSTU
has been switched on).
In the three columns appears: the code of the alarm and the running time when the alarm happened
(20 alarms per column, 60 in total ).
The record of more alarm messages at the same time is normal.
In the example shown:

- the time of job is 00186.33 (86 hours and 33 minutes).
- the last 3 alarm happened at running time 171 hours and 11 minutes:
code 12
code 14
code 11
The alarm code 12 is due to the emergency on the spinning machine (mushroom-head push button,
stop cables, door locking micro opened); they alarm code 14 (three-phase down) and 11 (AP |Power
undervoltage) are a consequence of the alarm code 12 (because the emergency opens the three-phase
power supply to the drives).
All the code alarms of the CSTU are shown in the following pages (the remedies later).
The alarm record can be cleared using key <CLR> and Caipo password ( the running time never
doesn't clear ).
Code List of the alarms
In the list are shown: the code, the message and the device that has produced it (that may be the CSTU
itself (CPU control board ) or one of the drives.
For the causes and the remedies go to the special paragraph.
The record of more alarm messages at the same time is normal
List of the alarms coming from CSTU control board

code Alarm Message device
1 Enable without consent, CSTU
2 Movement without consent, CSTU
3 Start time not observed, CSTU
4 Stop speed not reached, CSTU
5 Stop time not observed, CSTU
6 Doffing time not observed, CSTU
7 Movement without enable, CSTU
8 Draft roller Overspeed, CSTU
9 Feed roller Overspeed, CSTU
10 Misstart, CSTU
11 CAN Bus Timeout, CSTU
12 Pending spinning frame emergency, CSTU
13 Faulty slubs error, CSTU
14 Three-phase down, CSTU
15 CAN Bus SDO error, CSTU
16 End of parameter saving, CSTU
17 End of drive parameter saving, CSTU
18 End of drive parameter restore, CSTU
19 Machine in work, CSTU
20 Reset error, CSTU
21 Possible slub missing CSTU
22 CPS operation, CSTU
23 I2C Bus Timeout, CSTU
24 I2C Bus Error, CSTU
25 CPS Error : 24V CSTU
26 CPS Error : Temp/generic CSTU
27 CPS Error : Batt/overload CSTU
50 Feed roller sliding (E3), CSTU
54 Feed roller sliding (E3-B), CSTU
55 Feed roller sliding (E4-B), CSTU
56 Draft roller sliding (E2), CSTU
57 Draft roller sliding (E5), CSTU
List of the alarms coming from drives type CD1K (motors MA30/MA45/MA55)
code From code From code From Alarm Message

100 Az.1 200 Az.2 300 Az.3 Position Limits
101 Az.1 201 Az.2 301 Az.3 I2t
102 Az.1 202 Az.2 302 Az.3 RDC
103 Az.1 203 Az.2 303 Az.3 Following Error
104 Az.1 204 Az.2 304 Az.3 EEPROM
105 Az.1 205 Az.2 305 Az.3 Syncro CAN
106 Az.1 206 Az.2 306 Az.3 Low Speed
107 Az.1 207 Az.2 307 Az.3 Procedure
108 Az.1 208 Az.2 308 Az.3 Current_Offset
109 Az.1 209 Az.2 309 Az.3 Temp. Motor
110 Az.1 210 Az.2 310 Az.3 Init 400V
111 Az.1 211 Az.2 311 Az.3 Over Current
112 Az.1 212 Az.2 312 Az.3 Overvoltage error
113 Az.1 213 Az.2 313 Az.3 24 V error
114 Az.1 214 Az.2 314 Az.3 Short-circuit motor phases/ground
115 Az.1 215 Az.2 315 Az.3 System braking resistor error
116 Az.1 216 Az.2 316 Az.3 Fan system error
117 Az.1 217 Az.2 317 Az.3 Motor brake error
118 218 318 Invalid code
119 Az.1 219 Az.2 319 Az.3 IGBT
120 Az.1 220 Az.2 320 Az.3 AP Power undervoltage
121 Az.1 221 Az.2 321 Az.3 Resolver
(the code is the same from all unit, only first letter changes)
List of the alarms coming from drives type SR614 SR620 (motors DBL……)
code From code From code From Alarm Message
100 Az.1 200 Az.2 300 Az.3 Generic Error
101 Az.1 201 Az.2 301 Az.3 No BTB/RTO
102 Az.1 202 Az.2 302 Az.3 Earth short (F22)
103 Az.1 203 Az.2 303 Az.3 No mains/line-BTB (F16)
104 Az.1 204 Az.2 304 Az.3 Overvoltage in DC-bus (F02)
105 Az.1 205 Az.2 305 Az.3 Undervoltage in DC-bus (F05)
106 Az.1 206 Az.2 306 Az.3 Supply line missing (F19)
107 Az.1 207 Az.2 307 Az.3 Ambient temp. too high (F13)
108 Az.1 208 Az.2 308 Az.3 Heat sink temp. too high (F01)
109 Az.1 209 Az.2 309 Az.3 Motor temp. too high (F06)
110 Az.1 210 Az.2 310 Az.3 Fault in 15V aux. (F07)
111 Az.1 211 Az.2 311 Az.3 Fault in A/D converter (F17)
112 Az.1 212 Az.2 312 Az.3 Fault in output stage (F14)
113 Az.1 213 Az.2 313 Az.3 Ballast (F18)
114 Az.1 214 Az.2 314 Az.3 Could not enable Drive
115 Az.1 215 Az.2 315 Az.3 CAN Bus Off (F23)
116 Az.1 216 Az.2 316 Az.3 I2t (F15)
117 Az.1 217 Az.2 317 Az.3 Overspeed (F08)
118 Az.1 218 Az.2 318 Az.3 Lag/following error
119 Az.1 219 Az.2 319 Az.3 Braking error/fault (F11)
120 Az.1 220 Az.2 320 Az.3 Feedback device error (F04)
CHAPTER 7
7 MAINTENANCE
7.1 Controls and routine maintenance Bearing lubrication

You are advised to carry out the following routine maintenance operations:
7.1.1 Bearing lubrication
Bearing lubrication: unsealed bearings with a lubrication socket must be lubricated at least once a
month, or once every two weeks in particularly heavy operating conditions. Lubricate with the
machine at a standstill by inserting the grease gun into the lube socket on the bearing case. Use
mineral grease with lithium thickener, consistency type 2, such as KLUEBER TRIBO STAR 2EP
or CENTOPLEX 2 EP or equivalent.
7.1.2 Chains tension

Check that tension is correct on chains and drive belts that transmit motion from the gearmotor
controlled by the CSTU to the spinning machine gears. Yarn quality is affected by excessive
clearance. Damage can also be caused by excessive tension leading to premature wear of chain or of
the gearmotor.
7.1.3 Belts tension

Check that tension is correct on the belts fitted to the encoders on draft rollers, feed rollers, spindle
speed reference shafts (refer to installation kinematics diagram).
The toothed belts require less servicing than what required by any other type of belt, but for a correct
working the pulleys have to be aligned and the axis perfectly parallel.
You haven’t absolutely to force the belt on the pulleys by means of various tools in order to avoid to
cause breaking, apparently invisible, to the resisting inserts and to endanger irreparably the
performance and the life of the belt.
Check if the pulley supports are fixed stiffly and perfectly locked in order to avoid wheel base
variations, pulleys misalignment, axis vibrations and parallelism error.
The toothed belts, transmitting the mesh motion and being inextensible, do not require the assembling
stretching of the other types of belts and consequently:
- a too high assembling stretching causes noise and early wear
- a too low assembling stretching causes vibrations, early wear and the belt teeth overcoming the
pulleys teeth.
The belt has to be stretched in order to have on each branch a stretching of 10N (1 kg.).
7.1.4 Cleaning of the control panel
Caipo strongly recommends holding always clean the inside of the control panel
- keep the electric panel always closed
- periodically clean the front filters
- if the control panel inside temperature rise above 40°C (menu 0.6.3 )clean the box
- if case of alarm from the drive units about the temperature, such as “Ambient temp. too high
(F13)” or “Heat sink temp. too high (F01)” clean the fans inside the drive (see instructions later).
- checks that the air enters exclusively from the front filters (if any anomalous entrance seal it)
♦ Caipo strongly recommends to periodically clean the front filters of the control
panel
♦ The cleaning of the front filters is mandatory when the control panel inside
temperature rise above 40°C
The inside temperature is shown on the diagnostic menu 0.6.3 – Machine Monitor
Cleaning of front filters of the control board
The two front filters can be cleaned without opening the door of the control panel
- remove the external cover
- take out the filter
- clean it accurately
- put back the filter
Front filters
External cover
Keeping the filters clean the drive units and their fans are cooler, they need less power and they last
of more
7.1.5 Cleaning of motor drive units
For good operation of the drive units, Caipo recommends to keep them clean; and, if necessary, to
remove the dust inside the fans.
To get a good behaviour of the motor drive you are advised to carry out a dust cleaning of drive itself,
paying special attention to the fan placed inside them:
7.1.5.1 Cleaning of motor drive units CD1K with the fan top mounted
CD1k drives, produced from 2005, have the fan placed on the top of the unit; that allow an easily
cleaning
INSTRUCTIONS FOR CLEANING

- When the ring frames are standing still, turn off the main switch of the CSTU
- Wait 5 minutes before opening
- Open the CSTU control box
- Clean the fan over the drive units
- Clean all the dust inside the CSTU control box
- Check that all the connectors are well fixed
- Close the control box
- Switch on the main line then Restart the CSTU and the machines
7.1.5.2 Cleaning of motor drive units CD1K with the fan mounted inside
CD1k drives, produced before 2005, have the fan placed inside the unit (left side, see
figure).

- Stop the ring frames connected to the CSTU device
- Wait 5 minutes
- Loosen the screws of the drive (two screws upside, two screws bottom side)
- Move up the drive, pulling it out of the seat
- Look for the fan, that’s placed left side of the drive (see the figure)
- Loosen the two screws that fix the fan
- Pull out the fan without disconnecting the cables
- Clean the fan inside the drive unit, removing all the dust piled up
- Put again the fan inside the drive, t, paying attention to the cables
- Tighten the screws
- Place again the drive in it’s seat
- Clean all the other drives units
- Switch on the main line
- Restart the CSTU and the machines
7.1.5.3 Cleaning of motor drive units SR614 or SR620
In the drive SR614 or SR620 the fan is placed at the back of the unit, bottom side. The first cleaning
can be done with a vacuum cleaner (rarely, when very much dust inside, the drive unit must be
removed and cleaned).
The cleaning is mandatory if case of any alarm from the drive units about the temperature, such as
“Ambient temp. too high (F13)” or “Heat sink temp. too high (F01)” clean the fans inside the drive

- Wait 5 minutes
- Clean the fan over the drive units
- Switch on the main line then Restart the CSTU and the machines
7.2 TROUBLESHOOTING
7.2.1 Alarm reset
The malfunctions are signalled by the CSTU unit via a red LED on the console and output of an error
message.
In such cases the message must be displayed and reset before the unit can be restarted.
The message display and reset procedure is as follows:

- press key < 6 > to enter “Diagnostics “
- press key < 1> to display Machine A errors, or
- press key < 2> to display Machine B errors
- press < ESC > to cancel
If more than one error is indicated, repeat the procedure for each error until all errors have been
cancelled and the red LED turns off.
7.2.2 Power supply circuit reset (green indicator light)
The drives power supply circuit (DS1 and KM1 in the electrics diagrams) remains disabled while the
spinning machine is in emergency mode (mushroom-head emergency buttons pressed, safety cables
triggered, door-lock switches open). In this case the green indicator light does not come on.
Also, if the three-phase power supply fails, the drives remain in alarm condition, the red LED on the
CSTU remains ON and the following message is displayed in Diagnostics: “Three-phase power OFF”.
The power reset procedure is as follows:

- reset the emergency devices on the machine (mushroom-head emergency buttons, safety cables,
door-lock switches)
- press the green button on the CSTU and check that the green indicator light turns on
- cancel all error messages
Caution: the power circuit can not be reset while a drive or drives are in alarm mode due to an
electrical fault or start-up error (all drive alarms except “Three-phase power OFF”) The drive fault
must be corrected before the power circuit can be reset.
7.2.3 Programming problems
Message Suggested solution

Program on
processing, READ The program you want to edit is running: it can be viewed but not edited.
ONLY!
Program already The program name you want to use has already been assigned to another
existing program.
ERROR! Program
The program is running and can not be cancelled.
on processing,
The program name is already used: use a different name or cancel the previous
Name already used
program.
Maximum number
The program has reached the 500-line maximum limit for the CSTU.
of lines
ERROR! Not
The typed program name is not stored in the CSTU memory.
existing program
Full memory ! There are already 10 programs stored in the CSTU memory. Cancel an existing
Cancel a program program before writing a new one.
There are already 30 programs stored on the CAIPOMEM cartridge. Cancel an
Cartridge full!
existing program or use a new CAIPOMEM cartridge.
Faulty write-in to Transfer of the program to the CSTU memory was not successful.
internal EEPROM Try again: if the fault persists, replace the CPU2000 card.
Program on Before changing a program, always turn Slub = OFF and Twist = OFF.
processing The program you want to edit is running: it can be viewed but not edited
The program being executed can not be changed while the machine is running,
Machine running
nor is it possible to modify slub and twist settings.
Other programming problems without error message output.

Transfer of the program from the CAIPOMEM was not successful. Possible
causes:
Programs on
- the CAIPOMEM was extracted before transfer was completed
CAIPOMEM lost
- the CAIPOMEM cartridge is defective
- the CPU2000 card, or cable, are defective
7.2.4 Processing problems

- one of the emergency and/or safety devices on the machine has intervened
(mushroom-head push button, stop cables, door locking micro), causing the
Pending spinning
opening of CS1 emergency circuit of CSTU.
frame emergency
- the start the green push button on CSTU has not yet been pressed .
- dust on the auxiliary N.C. contacts of the KM1 contactor. Clean them.
Power failure to drives. possible causes:
- the green button on the CSTU was not pressed on start-up
- an emergency and/or safety device has triggered on the machine (mushroom-
head emergency buttons, safety cables, door-lock switches), causing CSTU
emergency circuit DS1 to open.
- mains power momentarily failed to the CSTU
- an alarm was output for one of the drives (when a drive is in alarm mode
mains power is automatically cut off to all drives operating on the same
Three-phase down machine). In this case a specific alarm indicating the origin of the problem
will be output as well as the message “Three-phase down
- dust on the auxiliary N.O. contacts of the KM1 contactor. Clean them.
It is possible to modify the connection on the KM1 contactor to avoid the
problem of the dust on N.O. contact. See annexed document “How to change
the connection of the cable 205 on N.O. contact”
Besides this message appears always together with the previous “Pending
spinning frame emergency”, as in this case too the voltage to the drive units is
cut out.
- When a drive-related error message is cancelled, a reset signal is also sent to
the drives in alarm mode. Occasionally the drive is not fully reset, for
example when a “Three-phase power OFF” alarm is cancelled immediately
after pressing the green button without waiting for the voltage to stabilise.
RESET ERROR The message Shows that one of the drives requires a further reset signal:
simply repeat the cancellation procedure, view the error and press <ESC>.
- If the message doesn' t disappear after having turned off /on the CSTU, verify
the resolver cables of the motors: an interruption of one of the inside cables
may cause the “Reset Error” message.
The CSTU receives the machine START signal from the spinning machine but
does not detect any movement. Possible causes:
- Start-up of the machine was suspended after the START signal had already
been received by the CSTU
- Encoder EVEL1 has failed, is disconnected or does not rotate
Miss start - Encoder EST1 has failed, is disconnected or does not rotate
The Speed LED - The START signal is connected to a relay of control board that closes too
does not come on early as to the real movement; the delay must not exceed “Start Time” set in
6.4.2.
- In some kind of spinning machines, after a change of yarn twits from S to Z
or vice versa, the EVEL1 encoder turns to the contrary; in this case the signal
cables of the Encoder EVEL1 go exchanged (exchange among them yellow
and white cables on the J101 connector of SCN2000.- see diagrams).
Possible causes:
- The set start-speed (see 6.4.1 - User parameters) is higher than the real speed
of the machine; change the start-speed value with a lower one.
Start time not - The machine starts very slowly and doesn’t reach the start speed in time; go
observed. to CAIPO parameter (see 6.4.2) and increase the “Start time” parameter).
-.The ring frame started and then stopped immediately, when the speed was
very low. You have only to cancel l the alarm and to restart.
-. The Encoder
- In some kind of spinning machines, after a change of yarn twits from S to Z
or vice versa, the EVEL1 encoder turns to the contrary; in this case the signal
cables of the Encoder EVEL1 go exchanged (exchange among them yellow
and white cables on the J101 connector of SCN2000.- see diagrams).
- The set stop time (see 6.4.1 - User Parameters) is higher than the operating
Stop speed not
speed.
reached
- Adjust the setting.
- After decelerating below the stop speed, the spinning machine does not stop
within the set time limit.
Stop time not - Check the parameters “Stop Speed” and “Stop Time” (see 6.4.1 - User
observed
Parameters)
If it checks on machine start-up, increase the start-up speed value.
- The enable signal remains active during doffing and the machine stop time
Doffing time not exceeded the maximum doffing time. Increase the maximum doffing time (see
observed 6.4.1 - User Parameters).
The CSTU detects machine motion without having received the machine start-
Movement without up signal.
enable - Check connections on the machine start-up signal path. .
The Start LED does - The message may be output due to movement (with the machine not running)
not come on of the shaft on which encoder EVEL1 is installed, or of the shaft on which
encoder EST1 is installed.
The CSTU has received the machine START signal before enabling start-up.
Enable without This type of fault should never occur if the MACHINE STOP relay on the
consent CSTU is correctly connected. Check that with the selector turned to LOCKED
the spinning machine is not able to start.
The CSTU detects machine motion without having enabled motion.

- Check that with the selector turned to LOCKED the spinning machine is not
Movement without able to start (MACHINE STOP relay connection)
consent - The message may be output due to movement (with the machine not running)
of the shaft on which encoder EVEL1 is installed, or of the shaft on which
encoder EST1 is installed.
The work settings (machine speed - draft - twist) require excessive feed motor
speed (3000 rpm). Possible solutions:
- Reduce production speed.
Feed roller over
speed
- Reduce the thickness of the thicker slubs
Other possible cause: encoder EVEL1 or encoder EST1 do not rotate
smoothly. Check the encoder attachment, belt tension, and attachment of the
cog wheel.
The work settings (machine speed - draft - twist) require excessive feed motor
speed (3000 rpm). Possible solutions:
Draft roller over
- Reduce production speed.
speed
Possible cause: encoder EVEL1 does not rotate smoothly.
Check the encoder attachment, belt tension, and attachment of the cog wheel.
The motor does not reach the slub or Stop speed within the set time (see also
"slub errors in 6.4.1 - User Parameters). Possible causes and solutions
- Slubs too short: increase length
- Pauses too short: increase length
Faulty slub error
- Ramp too slow: change value
- Reduce production speed
- Alternatively, change the "slub error %" limit, as described in 6.4.1. This will
however reduce accuracy of slub application.
If the CSTU shows this message when the machine is running, it means that an
functional abnormal condition happened , with risk of production of yarn
Possible slub
without slubs. We recommend to switch off and on the CSTU, and to verify
missing
the yarn produced before and after the alarm. If repeated : please contact
Caipo .
The batteries that supply the +24Vdc converter PS1, UPS2410 type, in case
CPS Error: 24V of power failure are discharged or damaged.
The LEDs in the DC-DC converter PS1 gives further detail about batteries:
(24V low battery) - Yellow LED blinking fast: the batteries are OK, in charge
- Yellow LED blinking fast: the batteries are OK, full charged
- Yellow LED blinking 1 time : bad polarity
- Yellow LED blinking 2 time : battery non connected
- Yellow LED blinking 3 time : battery damaged
- Yellow LED blinking 4 time : wrong battery ( Voltage > 33V)
- Red LED on Low battery: alight means low battery
- Red LED on Mains relay: alight means main line off
Warning to the risk of electric shock on CPS unit.
The batteries (12 in series) that supply the motors from CPS unit in case of
CPS Error: power failure are discharged or damaged:
Batt/overload - check the batteries
(CPS device Remark: in case CSTU device not work for long time the batteries are self
low battery or discharged: it take many hours to charge them again. (Attention: the Battery
overload) charger (CPS board) is connected to the DClink of the drive units; so it
charges them only when the drive unit voltage is on).
The alarm can arise also in case of overload: if the power failure happens
when the motors needs a very high pick of power the CPS can be overloaded
(CPS nominal power limit is 6KW)
This alarm means that the CPS is in trouble
CPS Error:
- the CPS board inside the CPS is damaged
Temp/generic
- the CPS board temperature is too high, due to board failure or because too
long time loaded (CSTU control failure)
(CPS device
Remark: the CPS system has been designed for short time load (20 seconds
temperature or
max). The CSTU should never hold the CPS system turn on for more 20
failure)
seconds
Other processing problems without error message output.

The motor does not reach the slub speed within the set time (see also "slub
errors in 6.4.1 - User Parameters). Possible causes and solutions
Insufficient slub
- Slubs too short: increase length
thickness
- Ramp too slow: change value
- Reduce production speed
Slub and pause lengths are assured by the CSTU: any error can only be due to a
Incorrect slub or
programming error or an error in the set reduction ratios (which would in any
pause length
case be signalled automatically if the control encoders are set to 1)
Slub application on start-up is controlled via the parameter "Start-up speed"

Failed application of (see 6.4.1 - User Parameters).
slubs at low speed Further, slub application is suspended when the speed decelerates below the
"Stop speed" (see 6.4.1 - User Parameters).
- Check if “Slub = ON” in “Setting work programs”
No slubs are applied - Check the parameter "Start-up speed" (see “User Parameters").
- Check that the selector on the control panel is turned to ON.
No twist change is - Check if “Twist = ON” in “Setting work programs
applied - Check the program being executed
Program offset is - Check if “Offset = ON” in “Setting work programs”

not applied - Check which type of Offset is selected offset (1,2,3)
- Check the set twist value
- Check the parameter "Twist set/current [%]" (See 6.4.1 "User Parameters")
- Check that the mechanical ratio between the spindles and encoder speed
Twist error reference shaft have not been changed, and that the spindle ratio set in 6.4.2
(different from is correct
required value) - Check that the Speed Encoder parameter set in 6.4.2 is correct (pulses/rev.
multiplied by mechanical reduction)
- Check that the mechanical ratio between M3 and the extractor shaft have not
been changed, and that the ratio set in 6.4.2 “CAIPO parameters” is correct
- Check the set draft value
- Caution: the set draft value must take into account the slub effect (see 6.1.6).
- Caution: the set draft value must take into account the shortening of the yarn
Yarn count error
due to twisting (see 6.1.6).
(different from
- If lines ZPX and ZPY appear in 6.1.2 "Draft Setting", check that the set
required value)
values are correct
- Check that the mechanical ratio between M1 and the feed shaft have not been
changed and that the ratio set in 6.4.2 “CAIPO parameters” is correct
This may depend on an error in the drive control parameters (refer to Paragraph
Fine points
“Maintenance - Machine A or B” for drive setting instructions) or from the
in the yarn
mechanical adjustments of the ring frame.
Check that motors rotate smoothly during production of continuous yarn.
Uneven yarn
(Check that encoders EST1 and EVEL1 rotate smoothly).
diameter
Check that the count of the material at the inlet is constant.
7.2.5 Critical alarms (electrical or mechanical failures)

Feed roller sliding The feed shaft on which there is an encoder error (EAL1, EAL2, EAL3,
E3 = Encoder 3 (Al ) EAL4) is not rotating at the required speed.
E4 = Encoder 4 (Al.2) - Check if the Encoder and the belt are OK;
E5.b = Encoder 5 (Al.3) - Check if the shaft of encoder is well fixed
E1.b = Encoder 1 (Al.4) - Check the connection on SCN2000 board
- Mounting a new encoder take care of the code and pulse/rev. number
- Check that the mechanical ratio between M1 and the feed shaft is correct
E3.b = Encoder 3 (Al.3) (see 6.4.2 “CAIPO parameters”).
E4.b = Encoder 4 (Al.4) See also paragraph 0.6.7 Encoder check-up
The draft shaft on which there is an encoder error (EAL1, EAL2, EAL3,
EAL4) is not rotating at the required speed.
Draft roller sliding - Check if the Encoder is OK or out of order
EStl.1 ESt.2 - Check if the shaft of encoder is well fixed
E2 = Encoder 2 (St ) - Check the connection on SCN2000 board
E5 = Encoder 5 (St.2) - Check that the mechanical ratio between M3 and the feed shaft is correct
(see 6.4.2 “CAIPO parameters”).
See also paragraph 0.6.7 Encoder check-up
One or more drives do not communicate with the CPU2000 card. Possible
causes:
- Check CANbus cable connections and 120 ohm resistor.
CANbus Timeout - Check that the drives are fed at 24 V dc.
- Check drive settings (see “Installing a new drive”).
- Replace the broken drive (disable the motors one at a time to locate the
failed drive).
CANbus SDO error Verify drive type setting in the paragraph 6.4.3 (CD1k o SR614)
The CPU2000 has lost the work data.

CAIPO parameters
missing Reload CAIPO parameters (See 6.4.3): if the problem reoccurs, replace
the CPU2000 card.
USER
parameters missing Reload user parameters (See 6.4.3): if the problem reoccurs, replace the
CPU2000 card.
WORK parameters
missing Reload work parameters (See 6.4.3): if the problem reoccurs, replace the
CPU2000 card.
Other critical problems without error message output.

- Check machine emergency devices (mushroom-head emergency buttons,
safety cables, door-lock switches).
- Check no drive is in alarm mode due to an electrical fault.
The green indicator light - Check the CSTU emergency circuit cable and relays .
does not come on - Check device DS1 (see electrics diagram).
- Check the N.C. contact on contactor KM1.
- If the device is connected to the CPS device, check the N.C. contact on
contactors inside the CPS.
If the LEDs on the panel do not light up:
- check fuses F1, F2 on three-phase supply to PS1
The CSTU keyboard - check 24V power supply to the CPU2000 card; check fuse F1 on the
panel or display do not card
come on or do not work. If the display works but the LEDs do not come on:
- check cable connections to the LCD
- check whether the green LED on the card blinks
- Check that encoders EVEL1 and EST1 rotate smoothly
A motor does not run - Check the resolver cable; check resolver mechanical fitting is correct.
smoothly - Check motor power cable.
- If a new drive has been installed, check parameter settings.
- Check the trip current of the differential circuit breaker: it must be ≥ 300
Protection trips on three- mA, delayed
phase line to CSTU panel - Check the fuse ratings or the current limiter setting
- Check the input current and fuse ratings
- Check mains power is within limits (360V - 460V)

Drives do not work
- Check that mains power is three-phase balanced type (see examples on
and/or fail
CSTU electrics diagrams)
A power failure when the machine is running may cause all the yarns on
Mains power fails and
the spinning machine to break as there is no power reserve to enable the
yarns break on spinning
CSTU motors to stop gradually.
machine
The only solution is to install a UPS (Please contact Caipo company).
- Check whether there is a message signalling failure of one of the drives.
- Check connections.
- Check the machine (reduction unit - chain – belt – gears)
- Check encoder EVEL1 (see suggestions, note 1)
Motor M3 remains
- Check that the motor is activated (see “ CAIPO parameters ” in 6.4.2).
stationary when the
machine starts up
- -After a change of yarn twits from S to Z (or Z to S), verify if the EVEL1
encoder turns same direction; if the direction changes the yellow and
white cables on the J101 connector of SCN2000 go exchanged.- see
diagrams)
- Check whether there is a message signalling failure of one of the drives.
- Check connections.
Motor M1 and M2
- Check the machine (reduction unit - chain – belt – gears)
remain stationary when
- Check encoder EST1 (see suggestions, note 1)
the machine starts up
- Check that the motor is activated (see “ CAIPO parameters ” in 6.4.2).
- Check that the parameter "Motor Rotation" is correctly set (6.4.2
Motor rotates in opposite
“Displaying CAIPO parameters ”).
direction
- Check CSTU earth connections
Motors emit loud hum - Check drive chain between motor and load is taut (clearance and slack in
when not running mechanisms and couplings).
The problem can occur only at the installation or after a replacement of one
of the drive units.
One of the motors turns
- Reload the data from CSTUPAR
in the opposite direction
- Do the motors testing, by setting again the turning direction set in CAIPO
parameters until it turns in the right direction (see 6.4.3).
7.2.6 CD1K drive alarms
The following alarms relate specifically to CD1K type drives or MA type motors (see “CAIPO
parameters ” in 6.4.2).
Note: drive alarm messages are preceded by the related drive/motor identification number. Examples:
“az 1:…………..” Motor M1 (feed shaft) drive alarm.
“az 3:…………..” Motor M3 (draft/extractor shaft) drive alarm.
CAUTION: After turning off a CSTU panel with CD1K drives, wait at least 30 seconds before turning
it back on otherwise the drives will output an error signal.
Caution : Inspection of electrical parts indicated below must only be carried out by qualified
personnel following the safety directions indicated in Chapter 1 of this manual.
Power undervoltage
AP Power Check that three-phase power is on (see “Three-phase power OFF”).
undervoltage Check fuses.
Check cables.
A problem occurred at start-up: one drive is not enabled.
Init 400V Turn off the panel, wait 30 seconds then turn it back on.
Check that power supplies are correct.
Three-phase power supply voltage is too high or has temporarily spiked.

Overvoltage error Check that mains voltage is of the three-phase balanced type (see examples in
the CSTU electrics diagrams).
An interruption in CANbus communications has occurred between the drive and

Syncro CAN
CPU2000 card. Check CANbus cables.
Motor over-temperature.
Check that operating conditions are not too heavy (machine speed, slubs per
Motor Temp.
metre, load on motor).
Check mechanical parts downstream of the motor.
Maximum I2T value exceeded.
metre, load on motor; slub ramps):
- reduce the speed of the ring frame or O.E. machine
- change the “Slub ramp type selection” (menu 0.1.5 ), setting a slower
I2t
acceleration ramp (alarms on Az1 or Az2).
If a new drive has been installed, check parameter settings.
Check if the motor is running well (you can check with motor test function)
If motor with brake: check if the brake ifs working (see paragraph “Motors
MA30 MA45 with brake”
Break on resolver cable.
RDC
Check the cable and connectors on both the motor and drive sides.
Break on resolver cable.

Resolver
Check the cable and connectors on both the motor and drive sides.
Motor overcurrent
Check motor cables.
Over Current Check that operating conditions are not too heavy (machine speed, slubs per
The motor can not perform the required movements.
Check motor cables.
Following Error Check that operating conditions are not too heavy (machine speed, slubs per
Excessive temperature of the drive due to the high current to the motor: see the
suggestions for the I2T alarm
Excessive temperature of the drive due to defect in the ventilations: verify the
operation of the fans on the drive.
Final power stage failure: replace the drive with a new one.
IGBT
Check that there are no short circuits in the electrical power connection to the
motor.
Check the brake resistor and its connections.
If the alarm occurs on installation of a new drive, check the voltage at the power
terminals (connector X9 of the CD1K).
System braking Check the brake resistor and its connections.
resistor error Change the drive unit that gives the error (AZ1)
24 V error Check 24V supply at connector X8 of the CD1K drive.
Fan system error Check that the internal drive fan rotates.
Ground short-circuit.
Short-circuit motor
Check that there are no short circuits between motor phases and ground phases.
phases/ground
Check the motor and its power cable.
The drive has lost control parameters.

EEPROM
This type of error should never occur on a CSTU unit: if a new drive has been
Low Speed
installed, check parameter settings.
Procedure
Corrent_Offset
Position Limits This type of error should never occur on a CSTU unit: if a new drive has been
Motor brake error
NOTE The drive type CD1K has three LEDs on the front panel; they show the drive status.
More information about them in paragraph: LED of the CD1K drive
7.2.7 SR614 or SR620 drive alarms
The following alarms relate specifically to SR614 OR SR620 type drives or DBL type motors (see
“CAIPO parameters ” in 6.4.2).
Note: drive alarm messages are preceded by the related drive/motor identification number. Examples:
“az 3:…………..” Motor M3 (draft/extractor shaft) drive alarm.
Caution : Inspection of electrical parts indicated below must only be carried out by qualified
personnel following the safety directions indicated in Chapter 1 of this manual.
Internal drive heat-sink temperature too high.

Check that operating conditions are not excessive (machine speed, slubs per
Heat sink temp. too
high (F01)
Check that the internal drive fan rotates.
Three-phase power supply voltage is too high or has temporarily spiked.
Overvoltage in DC-
Check that mains voltage is of the three-phase balanced type (see examples in
bus (F02)
the CSTU electrics diagrams).
Undervoltage in
Power supply voltage is too low or has temporarily dropped.
DC-bus (F05)
Motor over temperature.

Motor temp. too
high (F06)"
If a new drive has been installed, check parameter settings
Fault in 15V aux. Internal auxiliary voltage unstable. Check 24V supply at connector X4 of drive
(F07) SR614.
Motor Overspeed.
Overspeed (F08) See also “Feed roll Overspeed” “Draft roll Overspeed”
Clean the FAN inside the drive unit
Clean the dust inside the CSTU control box and the air filter
Ambient temp. too Check that operating conditions are not excessive (machine speed, slubs per
high (F13) metre, load on motor).
Check that the internal drive fan rotates.
Final power stage failure.
Fault in output Try turning off then on; if the fault persists, the drive has failed.
stage (F14) Cable short-circuit.
Check if the motor is running well (you can check with motor test function)
Maximum I2T value exceeded.
I2t (F15) Check mechanical parts downstream of the motor.
Il the motor is with brake: check if the brake ifs working (see paragraph
“Motors DBL5 with brake”
2 or 3 power supply phases are missing.
No mains/line-BTB Check that three-phase power is on (see “Three-phase power OFF”).
(F16) Check fuses.
Check cables (after turning off power to the control panel).
Fault in A/D A/D conversion error, normally caused by particularly high electromagnetic
converter (F17) disturbance.
Load circuit fault.

Ballast (F18) Try turning off then on.
A phase on the power supply is missing.

Supply line missing
Check fuses.
(F19)
Check cables (after turning off power to the control panel).
Ground short-circuit.
Earth short (F22) Check that there are no short circuits between motor phases and ground phases.
Check the motor and its power cable.
An interruption in CANbus communications has occurred between the drive and

CANbus Off (F23) CPU2000 card. Check CANbus cables.
The drive is not enabled. Check connections at connector X3 of drive SR614.

Could not enable Try turning off then on.
Drive
The motor can not perform the required movements.
Lag/following If a new drive has been installed, check parameter settings.
error
Il the motor is with brake: check if the brake ifs working (see paragraph
“Motors DBL5 with brake”
The drive is not enabled. Check connections at connector X3 of drive SR614.

No BTB/RTO
Try turning off then on.
Generic error: the drive can not identify the error.

Generic Error Try turning off then on.
NOTE: The drive type SR614 and SR620 have a little display on the front panel, on which are
visualized both alarms messages and warning messages
More information about this part on paragraph:
Alarms on the display of the drives SR614 and SR620
7.3 Checks on electrical parts
7.3.1 Checking connections to the electrical panel of the machine
The CSTU unit requires several connections to the machine:

Emergency stop
ENABLE contact with spinning machine
Machine START signal
You are advised to check connections in the order they are presented (first Emergency stop, then
ENABLE, finally START).
7.3.2 Safety circuit (Emergency stop)
The purpose of the CSTU safety circuit is to prevent the CSTU motors from starting when the
machine is in emergency mode (mushroom-head emergency buttons pressed, safety cables triggered,
door-lock micro switches open).
It is compulsory for the safety circuit to be connected as indicated in the CSTU diagrams.
(Refer to “Safety device” and “Emergency stop connection” in the electrics diagrams).
Safety device DS1 cuts the three-phase power supply to the drives by means of contactor KM1.
The device is timed so as to introduce a delay and prevent breakage of the threads during an
emergency stop of the spinning machine (15 seconds, as set by CAIPO).
To test that the device is connected correctly, press the emergency stop button on the machine: after
15 seconds the green indicator light will turn off and the CSTU will output the alarm message “Three-
phase power OFF”.
If you press the green button on the CSTU, the indicator light should not come back on while the
emergency button on the machine is engaged.
Repeat the test to verify that the green light does not come on in any of the following conditions:
- any of the emergency buttons on the machine is engaged
- any of the door-lock micro-switches on the machine is open
- any safety cables on the machine have been triggered
- machine control panel off
The DS1 safety circuit has a double connection to the machine: relays REM1 and REM2 in the
diagram. If either of the relays fails and remains closed, the DS1 opens (power OFF) and does not re-
close. Operation of the 3 green LEDs on the DS1 is as follows:
- LED PRW : if off, indicates 24V supply failure or short circuit
- LED CH ½ : turns on when the DS1 activates and turns off automatically on a machine
emergency
- LED CH ½ t turns on when the DS1 activates and turns off when the timer zeroes out
when the machine enters emergency mode
7.3.3 Machine STOP relay
This is an internal CSTU relay contact that must be connected in order to stop the machine or prevent
the machine from starting when the CSTU is not ready (i.e. OFF, or ON but in alarm mode).
Caution: the STOP relay contact must be connected to the normal stop circuit of the machine, not to
the emergency stop circuit.
To check that the relay is correctly connected on the machine side, perform the following tests:
Caution: all tests must be performed before loading the machine. If the
machine is not correctly connected, all threads will be broken if it is started.
1. CSTU off, selector turned to ON - the machine must not be able to start
2. CSTU off, selector turned to OFF - the machine must be able to start
3. Turn the selector to ON and turn on the CSTU unit without pressing the green button: the CSTU
will enter alarm mode and the machine must not be able to start
4. Press the green button, cancel the alarm message and start the machine
5. Turn the selector to LOCKED: when the new alarm message appears the machine must stop.
7.3.4 Machine START signal

This is the signal that the machine must output to the CSTU immediately prior to start-up.
The signal is transmitted by means of a N.O. contact which closes before the machine starts (it does
not need to remain closed after start-up).
This is normally performed using a relay connected to one of the contactors which close in order to
supply power to the spinning machine motor.
It may also be performed by means of an auxiliary contact on the spinning machine motor drive, or a
contact on the start button (which does not need to remain closed after start-up).
Note: If the START signal activates but the machine does not start or does not reach the start-up limit
speed, a “Start-up fail” alarm message is output.
7.3.1 Encoder troubleshooting

Encoders EST1 and EVEL1 (on CSTU featuring twist change control) are essential to operation of the
CSTU. If they malfunction or rotate in the wrong direction, the motors will not start.
Also, uneven encoder rotation will produces uneven rotation of the motors and the yarn produced will
be below the required standard.
The other encoders (EAL1,2,3,4 and EST2) are used for axes motion control. This control can be
deactivated (see “CAIPO parameters” in 6.4.2).
Suggested encoder test procedure:

- during rotation of the shaft, the two LEDs near the encoder connector must both be lit
- when the shaft is stationary, the two LEDs near the encoder connector may remain lit or be off
- when the shaft is slowly rotated in the correct direction, the LEDs must light up in sequence: first
the lower one then the upper one (if the opposite occurs this indicates that connection of the
yellow and white wires has been inverted - see wiring diagrams)
- the belt must have the correct tension; slackness will cause oscillations while the bearings may be
damaged if it is too tight
- if the cog wheel is off-axis, oscillations occur during rotation of encoders EVEL1 and EST1 that
cause continuous acceleration and deceleration of the motors
- After a change of yarn twits from S to Z or vice versa, the EVEL1 encoder turns to the contrary,
so the signal cables go exchanged ( yellow and white cables on the J101 connector of SCN2000.-
see diagrams).
7.4 REPLACING ELECTRICAL PARTS
7.4.1 Replacing the CSTU panel (or CPU2000 control board)
When replacing the CSTU panel (or the CPU2000 card) all parameters and data must be reloaded into
the new panel (into the CPU2000 card behind the panel).
The better way to reload parameters and data is to use the CAIPO cartridge (CAIPOMEM for
programs; CAIPOPAR for parameters)
Procedure :
Before removing the old panel (or card)
1. Copy all programs from CSTU to a CAIPOMEM cartridge

See CSTU instruction manual 6.3.4 Program from CSTU to cartridge
2. Save parameters from CSTU to CAIPOPAR cartridge

A cartridge CAIPOPAR is stored in each CSTU electrical panel: insert it in the connector
upon the panel and follow the CSTU instruction manual 6.4.4 Maintenance functions; execute
6.4.5 CPU data backup on CSTUPAR cartridge.
After having installed the new panel (or card)
3. Reload parameters from CAIPOPAR cartridge to CSTU

Follow the CSTU instruction manual 6.4.4 Maintenance functions: execute 6.4.6 CPU data
recovery from CSTUPAR cartridge.
4. Copy all programs from CAIPOMEM cartridge to a CSTU

See CSTU instruction manual 6.3.3 Program from cartridge to CSTU
5. Check that all parameters have been correctly copied to the new card
- check user parameters (menu 0.4.2)
- check Caipo parameters (menu 0.4.1)
- check working settings (program, draft, twist, ramps)
- if any parameter not correct, it must be set following the instruction manual.
7.4.2 Updating the CPU2000 software

The updating of the software can be done only by CAIOPO technicians.
Caution: after updating the CPU2000 card software, certain parameters may indicate spurious values.
This indicates that the parameter settings have been lost. If such a case occurs, it is important to
reload all parameters. Values which appear correct must also all be rewritten. (example: the setting
Slub = OFF may appear, but to change program it is necessary to edit the value (MOD key).
Caution
- After software updating all parameter and data must be checked
- After software updating reloads data from CSTU to CSTUPAR (CPU2000 parameters and
motors parameters); so the cartridge will be ready with updated data.
7.4.3 LCD adjustment
The trimmer show in the figure, on the LCD2000 printed circuit board, mounted under the LCD itself,
can be used to adjust the LCD when necessary.
LCD adjustment
7.4.4 Replacing a motor
Important Note
Only professional personnel with extensive knowledge in the fields of electrical
engineering and drive technology are allowed to commission the servo amplifier.
Caution !
Never disconnect any of the electrical connections to the servo amplifier while it is live.
Capacitors can still have residual charges with dangerous levels up to 300 seconds after
switching off the supply power.
Replace the motor with one of identical type only (the drives are specifically calibrated for
only one type of motor).
Always check the full identification code of the installed motors. Apparently similar
replacement motors may have different power ratings or operating voltages.
To test the operation of the motors you may use the "motor test" function in the MAINTENANCE
menu.
You are advised to proceed as follows:
- at once start the free motor (only reduction unit) and check the direction of rotation.
- start the machine set for smooth yarn (Slub = OFF, Twist = OFF) and check that the motors
run correctly (regular speed, no abnormal noise)
- check there are no slippage errors
- launch the program (Slub = ON, Twist = ON).
The direction of rotation is set in 6.4.1 “CAIPO parameters”
Clockwise motor rotation
Anticlockwise motor rotation
Attention: Never look for open a motor . The brushless motor contains permanent magnets very
powerful: after opened is not possible to put again it in order. Only the motor maker company is able
to repair a broken motor. So, in the case, any broken must be send back motor to Caipo company.
7.4.5 Replacing a CD1K type drive
Important Note
Caution !
Heat sinks and front panels of the amplifier can reach a temperature of up to 80°C in
operation.
Check (measure) the heat sink temperature. Wait until the heat sink has cooled down
below 40°C before touching it.
Use only CD1-k drives supplied by CAIPO Automazione Industriale, with specifically pre-set slub
unit operating parameters.
Procedure to be followed, in case of:

- The installation of a new drive unit,
- Or exchange of drive units, either from other CSTU or from other position in the same
control board,
Switch off the CSTU control board ((lock the switch on OFF)
Wait for 5 minutes at least for the residual current discharge on the condensers
Make sure the motors are stopped (if they are dragged they generate dangerous voltages)
When replacing the drive units, check all the connections
Set the DIP SWITCHES of new drive unit as indicated in the following table
Switch off, then switch on again
Insert CSTUPAR memory and reload the data of drive units installed (see 6.4.4.2)
Switch off, wait a minute and switch on again
After replacing a drive you are advised to proceed as follows:

The DIP SWITCHES are located near the

DIP SWITCH settings X9 power connector on the upper part of
the CD1K
Motor M1 Drive - main feed shaft (headstock)

setting for Az.1
Motor M2 Drive - auxiliary feed shaft (counter-
headstock)
setting for Az.2
Motor M3 Drive - draft shaft (“twist change"

function)
setting for Az.3
Caution :
The Drive mounted second place from left side in CSTU panel must have the DIP SWITCHES setting
as for the motor to which it is connected:
Az.2 for M2 (feed motor 2)
or Az.3 for M3 (twist change motor)
Drive and motor layouts are indicated in the electrics diagrams (CSTU layout)
CAUTION
- An error in DIP SWITCH settings can cause serious damage (e.g. incorrect direction of
rotation, breakage of free wheels).
- Not reloading the drive units’ data from CSTUPAR (Point 7 of the procedure) can cause
serious damages (e.g..: to burn a motor by using a drive unit with parameters for a bigger
motor).
- Inverting two drives without correctly setting DIP SWITCHES can cause serious damage
(e.g. incorrect direction of rotation, breakage of free wheels).
- Using a drive which is calibrated for a different motor to the one on which it is mounted can
cause serious malfunction of the machine.
7.4.5.1 LED on drive CD1K
On the drive CD1K there are three LEDs with the following meaning
Indicates he connection to the CSTU control board (CANbus).

Led ON = OK ; the CANbus connection works.
Led blinking = Error; the CANbus connection doesn’t work
Suggestions:
- check if in the CAIPO parameters there is CD1K type motor = 0
- check if in the CAIPO parameters there is motor presence =1
- check if in the settings of the DIP SWITCHES on each drive are right
- check the CANbus cables and connectors
Indicates the three phase main line status

Led ON = OK , three phase main line is OK
Led blinking = error three phase main line
Suggestions:
- check if green lamp on the CSTU panel is ON; check if the machine is in emergency
- check the contactor KM1; check the KM1 auxiliary contacts
- check the fuses
Indicates the status of the drive

Led OFF = OK , the drive is OK
Led ON = the drive is faulty
Suggestions, only for qualified electricians, following the safety prescriptions:
- open the main CSTU switch close the padlock
- wait 5 minutes to allow the discharge of the capacitors
- check that the drive is in order and no dust in it
7.4.6 Replacing a SR614 or SR620 type drive
Important Note
Caution !
Heat sinks and front panels of the amplifier can reach a temperature of up to 80°C in
operation. Check (measure) the heat sink temperature. Wait until the heat sink has
cooled down below 40°C before touching it.
Use only SR614 (nominal current 14 A) or SR620 (nominal current 20A; for bigger motors) drives
supplied by CAIPO Automazione Industriale, with specifically pre-set slub unit operating parameters.
Procedure to be followed, in case of:

- the installation of a new drive unit,
- or exchange of drive units, either from other CSTU or from other position in the same box
PROCEDURE
• Switch off the CSTU control board ((lock the switch on OFF)
• Wait for 5 minutes at least for the residual current discharge on the condensers
• Make sure the motors are stopped (if they are dragged they generate dangerous voltages)
• When replacing the drive units, check all the connection
Switch on and Set CANbus address of new drive unit as shown in the underlying table
• Switch off, than on again
Insert CSTUPAR memory and reload the data of drive units installed (see 6.4.2.4)
• Switch off, than on again
After replacing a drive you are advised to proceed as follows:

CAUTION
- An error in CANbus address settings can cause serious damage (e.g. incorrect direction of
rotation, breakage of free wheels).
- Not reloading the drive units data from CSTUPAR (Point 7 of the procedure) can cause
serious damages (e.g..: to burn a motor by using a drive unit with parameters for a bigger
motor)
- Inverting two drives without correctly setting CANbus address can cause serious damage
(e.g. incorrect direction of rotation, breakage of free wheels).
- Using a drive which is calibrated for a different motor to the one on which it is mounted can
cause serious malfunction of the machine.
The address is shown on the 3-digit display on drive SR614 or
CANbus address setting
SR620 (press the 'down arrow'key )
Motor M1 Drive - main feed shaft
(headstock) setting for Az.1
Motor M2 Drive - auxiliary feed shaft

(counter- headstock) setting for Az.2
Motor M3 Drive - draft shaft (“twist

change" function) setting for Az.3
Caution :
The Drive mounted second place from left side in CSTU panel must have the CAN bus address as for
the motor to which it is connected:
Az.2 for M2 (feed motor 2)
or Az.3 for M3 (twist change motor)
Drive and motor layouts are indicated in the electrics diagrams (CSTU layout)
Press the key near the display on drive SR614 or SR614to read the CANbus address.
7.4.7 Instructions for setting the CANbus address on SR614 drive unit
11. Install the new drive

12. Turn on the CSTU panel without pressing the green button (no power)
13. If the CSTU panel indicates CANbus Timeout, this means that at least one of the drives
does not have the correct CANbus address.
However, even if this error message is not displayed, some CANbus codes may still be
incorrect (inverted drives!)
14. Wait until the display indicates a reading such as

15. Press . The 3-digit number that appears is the CANbus address of the drive.
Three correct addresses are:
Motor M1 Drive - main feed shaft (headstock)
Motor M2 Drive - auxiliary feed shaft (counter- headstock)
Motor M3 Drive - draft or extractor shaft
16. If the number displayed on the newly installed drive does not correspond to the motor to
which it is connected, press the or key until the correct number is indicated.
17. Next, hold down the key and press . Then release the key followed by the
key. In this way the drive stores the last displayed address.
18. Proceed with the other drives.
19. Reboot.
20. Re-check all CANbus codes.
7.4.8 Alarms on the display of the drives unit SR614 and SR620
The display mounted on the drive SR614 or SR620 shows the following data.
or at power on (after the auto test; the number is the current rating of the drive)
or when there is the three-phase on (green led on the CSTU panel)
or when the motors are powered
Instead any messages that begin with n (warning) or F (Fault) announce abnormal condition.
o
The following charts bring the meaning of the abnormal conditions and possible remedies..
Warning messages (on the display of the drive unit)

Number Designation Explanation
n01 I²t I²t threshold exceeded
n02 regen power reached preset regen power limit
n03* S_fault exceeded preset contouring error limit
n04* response monitoring response monitoring (field bus) has been activated
n05 supply phase supply phase missing
n06* Sw limit- switch 1 Setting parameters lost – not suitable for CSTU
n07* Sw limit- switch 2 Setting parameters lost – not suitable for CSTU
n08 motion task error Setting parameters lost – not suitable for CSTU
n09 no reference point Setting parameters lost – not suitable for CSTU
n10* PSTOP Setting parameters lost – not suitable for CSTU
n11* NSTOP Setting parameters lost – not suitable for CSTU
n12 default values only for HIPERFACE® : motor default values loaded
n13* expansion card expansion card not operating correctly
n14 SinCos feedback SinCos commutation failure
n15 table fault fault as per speed/current table INXMODE 35
n16-n31 reserve reserve
n32 firmware beta version firmware version has not been released
* = these warning messages result in a controller shut-down of the drive (braking by emergency
stop ramp). In case of warning without * the motor is able continue to work; but
she/he/it/you would be able with the time give of the problems
Fault messages (on the display of the drive unit)

Number Designation Explanation
F01* heat sink temperature heat sink temperature too high
limit is set by manufacturer to 80°C
F02* Overvoltage Overvoltage in DC-link
limit depends on the mains supply voltage
F03* contouring error message from the position controller
F04 feedback cable break, short circuit, short to ground
F05* undervoltage undervoltage in DC-link
limit is set by manufacturer to 100V
F06 motor temperature motor temperature too high (or temp. sensor defect)
limit is set by manufacturer to145°C
F07 aux. voltage internal aux. voltage not OK
F08* Overspeed motor runs away, speed is too high
F09 EEPROM checksum error
F10 Flash-EPROM checksum error
F11 brake cable break, short circuit, short to ground
F12 motor phase motor phase missing (cable break or similar)
F13* internal temperature internal temperature too high
F14 output stage fault in the output stage
F15 I²t max I²t max value exceeded
F16* supply BTB/RTO 2 or 3 phases missing in the supply feed
F17 A/D converter error in the analog-digital conversion
F18 regen regen circuit faulty or incorrect setting
F19* supply phase a phase is missing in the supply power feed
F20 slot error slot error
F21 handling error software error on the expansion card
F22 earth/ground fault only for 40/70 A instruments: earth fault
F23 CAN bus off severe CAN bus communication error
F24 warning warning display is evaluated as fault
F25 commutation error commutation error
F26 limit-switch homing (drove onto hardware limit-switch)
error
F27 AS-option operational error with -AS- option (control signal for –AS-option
appears simultaneously with the ENABLE signal)
F28 reserve reserve
F29 Sercos error only in SERCOS systems
F30 SERCOS timeout Sercos timeout, leads to emergency stop
F31 reserve reserve
F32 system error system software nor responding correctly
Removing fault/warning (suggestions from drive unit manual)

Fault Possible causes Measures to remove the cause of
fault
F01: heat sink
-permissible heat sink temperature exceeded -improve ventilation
temperature
F02 message: -to much power on regen (braking) resistor -shorten the RAMPS
Overvoltage - Excessive voltage in the DC-link circuit. -use mains transformer
-supply voltage too high
F04: -feedback connector not properly inserted -check connector
feedback unit -feedback cable is broken, crushed or -check cable
otherwise damaged
F05: -supply voltage not present or too low when --The drive has been enabled when
undervoltage drive is enabled the mains supply voltage was too
low.
- Check main supply voltage
F06: -motor thermostat has been activated -wait until motor has cooled down,
motor temperature -feedback connector is loose or break in then check why it became so hot
feedback cable -tighten connector or change
feedback cable
F07: -the aux. voltage produced by the drive is -return the drive to the manufacturer
aux. voltage incorrect for repair
F08: motor runs away -motor phases swapped -correct motor phase sequence
(over speed) -feedback set up incorrectly -set up correct offset angle
F11: Braking -short-circuit in the supply cable for the -remove short-circuit
Remark : the CSTU do motor-holding braking -check shielding of braking cable
not uses the braking -fault in braking cable -braking parameter set to
- unsuitable drive parameters "WITHOUT"
- reload the parameters of the drive
F13: -improve ventilation
-permissible internal temperature exceeded
internal temperature
F14: -motor cable has short-circuit/ground short -replace cable
output stage fault -motor has short-circuit / ground short -replace motor
-output module is overheated -improve ventilation
-output stage is faulty -return the drive to the
-short-circuit / short to ground in the manufacturer for repair
external regen (braking) resistor -remove short-circuit / ground short
F16: -enable was applied, although the supply --The drive has been enabled when
mains BTB/RTO voltage was not present. the mains supply voltage was too
-at least 2 supply phases are missing low.
-check electrical supply
F17 A/D converter -error in the analog-digital conversion, -reduce EMI, check screening and
Not used in CSTU usually caused by excessive EMI grounding
F25: Commutation -wrong cable -check wiring
error -wrong phasing - reload the parameters of the drive
F27: error AS-option --AS-24V relay hardware or software -check PLC programming and
Not used in CSTU enable wiring
- unsuitable drive parameters - reload the parameters of the drive
motor does not rotate - not enabled -apply enable signal
-break in set point cable -check set point cable
-motor phases swapped -correct motor phase sequence
-braking not released -check braking control
-drive is mechanically blocked -check mechanism
-- unsuitable drive parameters - reload the parameters of the drive
motor oscillates - unsuitable drive parameters - reload the parameters of the drive
-shielding in feedback cable has a break -replace feedback cable
-AGND not wired up -join AGND to CNC-GND
drive reports following
error
motor overheating - unsuitable drive parameters - reload the parameters of the drive
n12: Motor default
values loaded
n14:
Wake & shake active
7.4.9 Motors MA30 MA45 with brake (option)
The motors of the CSTU can be equipped with motor brake: this special version is used on some type
of ring frame machines, on motors M1 and M2 (feeding shafts).
The complete set of an installation for motor with brake is listed below.
To easy identify the parts the label BRAKE is placed in each part (the brake is inside the motor: you
cannot see it from the outside).
Main part necessary for MA30 or MA45 motors with brake
ATTENTION: the use of a motor with brake in a CSTU not properly equipped for the function
will damage to the brake inside the motor.
1) Motors MA30 o MA45

To recognize if a motor is with or without brake you must see the motor type number
Motors without brake Motors with brake
MA30C.000 010B.00 MA30C .000 210B.00
MA45C.000 010B.00 MA45C .000 210B.00
The motor brake hold the motor shaft when no power to the motor (or no power to the CSTU)
The drive unit supplies the brake immediately before giving power to the motor.
supply specification: 24Vdc +6/-10%; 1,2 A for both MA30 and MA45
2) Power cable to the motor in case of brake

The power cable to the motor needs extra wires for the brake
power cable without brake power cable with brake
(4 x 2,5)shielded ((4 x 2,5) +(2 x 2,5) shielded) shielded
3) Drive unit setting

The drive unit manage the brake only if the BR jumper in ON: to check it you must see at the
bottom of the drive unit, as shown in figure. Moreover the setup parameters must be “with
brake”.
4) 24VDC PS1 supply adjustment

To be sure that the supply to the brake is above the upper limit, even if the motor cables are
very long (100mt is the maximum) the Vout of PS1must be adjusted so that Vout = 26Vdc
How to check the MA30 or MA45 motors with brake
Check the CSTU is equipped as described above (motors, cables, drive units, 26Vsupply);
then:
- Go the CSTU function “Motor test”
- Set motor test speed to 0000 rpm
- Press the key MOD (power to the motor, but with zero speed): you can hear the typical “clang”
of a clutch when activated.
- Press again the key MOD: you can hear the typical “clang” of a clutch when de-activated.
7.4.10 Motors DBL5 with brake (option)
The motors of the CSTU can be equipped with motor brake; this special version is used on some type
of ring frame machines, on motors M1 and M2 (feeding shafts).
The complete set of an installation for motor with brake is listed below.
To easy identify the parts the label BRAKE is placed in each part (the brake is inside the motor: you
cannot see it from the outside).
Main part necessary for DBL5 motors with brake
ATTENTION: the use of a motor with brake in a CSTU not properly equipped for the
function will damage to the brake inside the motor.
1) Motors DBL5 with brake

To recognize if with or without brake you must with brake
Motors without brake Motors with brake
DBL5-1700-30-Y-560 S-B P DBL5-1700-30- Y-560 S-B B P
DBL5-2200-30-3-560 S-B P DBL5-2200-30- Y-560 S-B B P
The motor brake hold the motor shaft when no power to the motor (or no power to the CSTU)
The drive unit supplies the brake immediately before giving power to the motor.
supply specification: 24Vdc +/-10%; 0,75 A
2) Power cable to the motor in case of brake

The power cable to the motor needs extra wires for the brake
power cable without brake power cable with brake
(4 x 2,5)shielded ((4 x 2,5) +(2 x 2,5) shielded) shielded
3) Drive unit setting

To manage the brake, the drive unit SR614, need a special setting. Caipo mark the SR614 units
with the label “BRAKE” it has the right parameters for the brake. When replacing a drive unit,
the setup parameters can be updated through the CAIPOPAR cartridge.
How to check if the drive unit manages correctly the motor brake is described below.
4) 24VDC PS1 supply adjustment

To be sure that the supply to the brake is above the upper limit, even if the motor cables are
very long (100mt is the maximum) the Vout of PS1must be adjusted so that Vout = 26Vdc
How to check the DBL5 motors with brake
Check the CSTU is equipped as described above (motors, cables, drive units, 26Vsupply);
then:
- Go the CSTU function “Motor test”
- Set motor test speed to 0000 rpm
- Press the key MOD (power to the motor, but with zero speed): you can hear the typical “clang”
of a clutch when activated.
- Press again the key MOD: you can hear the typical “clang” of a clutch when de-activated.
ANNEXED DOCUMENTS
A.1 Set-up example in case of CSTU connected to a RING frame

0.4.1 – User Parameters SLUB MULTICOUNT
A B A B
Start speed [m/min] 005 005 000 000
Stop speed [m/min] 003 003 000 000
Maximum doffing time [min] 015 015 060 060
Slub filter start [m/min] 05.00 05.00 Attention : read carefully

Start slub thickness 01.00 01.00 instruction before modify
Start slub duration 00.00 00.00 to the “Slub filter start”
and “start slub..”
Note 1 : Stop and Start speed: in case of slub yarn must be as shown above, tom avoid yarn breakage at stops
Note 2: The Parameter Slub filter start must be lower than the ring frame minimum production speed in mt/min
Note 3: The Value of parameters Slub filter start Start slub thickness and Start slub duration shown are valid
only for software versions VAC2.2.2 and following (software version: VAC 211 contact CAIPO).
0.4.2 – CAIPO parameters display pag. 3

A B
typical value in case of Ring

Start time 0020.00 0020.00
frame
Stop time 0010.00 0010.00
Slub filter 0000.06 0000.06 Slub filter 0000.30 max

Twist filter 0001.00 0001.00
Delay on start [s] 0000.00 0000.00

Note 4: The Parameter Slub filter can be increased to 0000.30 max (to lower the ripple on the feeding motor
speed); never use any value higher than 000.30 (can be cause of yarn breakage at machine start)
Note 5: If the Parameter Delay on start, is set to any value higher that zero, the twist motor M3 will start
delayed (in a ring frame this will cause much more twist at any machine restart.
0.1.5 – Slub ramp selection Selecting 3 or 4 will slightly

change the yarn
If set to 1 or 2 : risk of thin
A B
points in the yarn! .
Acceleration type 3o4 3o4
Deceleration type 3o4 3o4
1 – Very quick
2 – Quick
3 – Slow
4 – Very slow
A.2 Set-up example in case of CSTU connected to OPEN END
0.4.1 – User Parameters Attention : don’t’ change

A B this parameters (useless for
Start speed [m/min] 005 005 O.E. machines).
Stop speed [m/min] 003 003
Maximum doffing time [min] 001 001
Slub filter start [m/min] 05.00 05.00

Start slub thickness 01.00 01.00
Start slub duration 00.00 00.00
Note 1 : Stop and Start speed: in case of slub yarn must be as shown above, tom avoid yarn breakage at stops
Note 2: The Parameter Slub filter start must be lower than the ring frame minimum production speed in mt/min
Note 3: The Value of parameters Slub filter start Start slub thickness and Start slub duration shown are valid
only for software versions VAC2.2.2 and following (software version: VAC 211 contact CAIPO).
0.4.2 – CAIPO parameters display pag. 3 SE 8-SE 9-SE 10-SE 11 R 20 - R40

A B A B
Start time 0060.00 0060.00 0200.00 0200.00

Stop time 0020.00 0020.00 0020.00 0020.00
Slub filter 0000.06 0000.06 0000.06 0000.06

Twist filter 0001.00 0001.00 0001.00 0001.00
Delay on start [s] 0000.00 0000.00 0080.00 0080.00
Note 4: The Parameter Slub filter can be increased to 0000.30 max (to lower the ripple on the feeding motor
speed); never use any value higher than 000.30 (can be cause of yarn breakage at machine start)
Note 5: If the Parameter Delay on start, depends on the O.E. machine type: zero in case of SE8/9/10/10/11;
standard value 0080.00 in case of R20 machine.
Acc/Dec type:
0.1.5 – Slub ramp selection
Selecting 3 or 4 will slightly
change the yarn
A B If set to 1 or 2 : risk of thin
Acceleration type 2 2 points in the yarn! .
Deceleration type 2o3 2o3
1 – Very quick
2 – Quick
3 – Slow
4 – Very slow
A.3 Modification of CSTU electrical diagram: cable 205 on KM1
To avoid the problem of alarms “three-phase down” due to fault on N.O. contact of KM1 a
modification as been made CSTU electrical diagram, starting from 2006.
- the cable 205 moved to KM1-A1, wired together to the cable217
The same modification can easily be done on the CSTU produced before 2006, as shown in the figures
below.
The modification must be done both side of the CSTU: panel A and panel B
Diagram before the modification Diagram after the modification
KM1 before the modification KM1 after the modification
OVERHAUL DIRECTORY
Data
Overhaul Description of the main modifications
/software
Rev. 2.0 Chapters 6 and 7 updated to V AC 2.0 software version 05.10.04
Paragraph. 6.4.2 Introduced some new Caipo parameters
Paragraph. 6.4.3 New procedure to modify Caipo parameters
Paragraph. 6.4.4 “SERVICING” functions (Motors testing and data and parameters
backup on CSTUPAR memory)
Paragraph. 7.3.2 Alarm messages, various modifications
Paragraph 7.4 Replacement of drive units, or CPU card, by using CSTUPAR
Rev. 2.1 Paragraph 6.4.1.1 Execution of the program at machine start 10.12.04
Paragraph 6.4.2 : Encoder setting - revision
Rev 2.2 Paragraph 6.1.6 Twist ramp type selection 21.0705
Paragraph 6.4.1 User parameters: new parameters (thin points at machine start)
Paragraph 6.4.3 Diagnostic of the machine – revision
Paragraph 6.4.4 Diagnostic of the encoders – new
Paragraph 6.4.5 Errorlog, record of the alarms – new
Paragraph 7.1.3 Cleaning the driver
Paragraph 7.2.3 Troubleshooting and Error r messages – modifications
Paragraph 7.4.5 Replacing a drive CD1K - revision
Paragraph 7.4.6 LED on drive CD1K
Paragraph 7.4.7 Replacing a drive SR614 or SR620 - revision
Paragraph 7.4.8 Alarms on the display of the drives SR614 or SR620
Rev 3.0 Paragraph 6.4.4 Encoder diagnostic 29.03.06
Paragraph 7.1.4 Cleaning electrical panel
Paragraph 7.1.5 Cleaning motor drive units
Paragraph 7.4.9 Motors MA30/45 with brake
Paragraph 7.4.10 Motors DBL5 with brake
Annexed A1 Setup example: CSTU on ring frame
Annexed A2 Setup example: CSTU on O.E. machine
Annexed A3 Modification cable 205 on CSTU control box
Rev 3.1 Paragraph 1.7 Isolamento delle fonti di alimentazioni – dispositivo CPS 20.03.06
Par. 3.4 Residual circuit breaker specifications
Par. 3.7 Lubrication
Rev 3.2 Paragraph 6.1.2 Work program setting VAC 3.0.2 22.04.08
Paragraph 6.1.6 Slub ramp length selection (instead of ramps type) ) VAC 3.0.2
Paragraph 6.3.7 User paramter – new parameter: Sliding cease time
Paragraph 6.4.11 Cease sliding control Encoders side A (B)
Rev 3.21 Paragraph 6.1.6 Slub ramp length selection (modifications) VAC 3.0.2 21.10.08
Rev. 400 Paragraph 6.2.5 Program names extended to four letters VAC 4.0.0 25.01.10
Rev. 4.0.1 Small corrections of the firmware, no changes to the instruction manual VAC 4.0.1 15.02.10
Rev. 4.0.2 Paragraph 6.4.2 new parameter “Slub missing hard stop” VAC 4.0.2 15.04.11

CSTU Handbook Rev 402 EN

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CSTU Handbook Rev 402 EN

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CAIPO automazione industriale

1.1 Worker information and training

1.2 Personal protection devices (PPD/DPI)

1.3 Use of work clothes

1.4 Protections and protection devices

1.5 Safety and health indications

1.7 Isolating energy sources

The selector must be turned to the LOCKED position in order to enable

Case CSTU connected to a CPS device

2.1 Unit identification data

2.2 Intended use

2.3 Prohibited uses

2.4 Types and characteristics of processable materials

2.5 Technical specifications

The CSTU unit is composed of the following parts:

2.7 Operating environment conditions

2.8 Type and characteristics of emissions

Noise emission – Sound level emission

Outlet speed in metres / minute Spindles speed (RPM) Leq in dB(A)

3 TRANSPORT AND INSTALLATION

3.1 Conditions of supply

3.2 Storage environment conditions

3.3 Parts handling and assembly

Individual weights of main machine parts:

Part description Weight in Kg.

Gearmotor unit (max) 45

The CSTU is installed by

Feeding cable of control unit CSTU (3 + Earth 10 mm2)

Main line specification:

3.5 Operations and checks to be carried out before start-up

Before starting the CSTU unit you must check that:

CAIPO Automazione Industriale s.r.l.

KLUEBER TRIBO STAR 2EP

following the directions given in Paragraph 7.1.1 (Chapter 7 Maintenance).

Changing and disposal of lubricants

Follow the safety directions for each product.

Spent substances must be disposed of in accordance with environmental protection

3.8 Demolition and disposal

Dispose of in accordance with regulations in force in the country of use.

4.1 Zone normally occupied by the operator

4.2 Identification residual risks

4.3 Work clothing

− Do not wear scarves, ties, etc.

5.1 Description of LCD Panel & Keyboard

Number keys and function

Machine A operating LEDs Machine B operating LEDs

Program LED: lights on launch of Program LED: lights on launch of

(#1) Machine A: connected to drives on left side of CSTU panel

CSTU Main ON/OFF

Machine A RESET Machine B RESET

CSTU Main ON/OFF Switch

Machine mode selector (one per machine)

RESET button (one per machine)

Symbol Key name (*) Function

MOD Start a session to edit a parameter or set of parameters

ESC End a session or exit a menu

INS Insert a new line in a program

CLR Cancel the last typed number

ENT Confirm typed number

DEC In program edit mode, decrease selected column value

INC In program edit mode, increase selected column value

PASSWORD Open menu for inserting the unlock code

1 in programming mode, hot key to move to last line