MODELS:SJD,2SR2/V,1SR2/SI,4SJ4/SI

VPL TOTAL FACTORY MANAGEMENT SYSTEM

Sept. 2013
ISO 3593_00_Display Operator Manual
 TABLE of CONTENTS

ISO……………………………………………………………………………………………………...3

OP SUPPLEMENT…………………………………………………………………………………....4

WARRANTY TIME…………………………………………………………………………………….5

SAFETY LABLES……………………………………………………………………………………..6

ORDERING INSTRUCTIONS………………………………………………………………………..11

VANGUARD PAI LUNG-TOTAL FACTORY MANAGEMENT SYSTEM…………………….....12

ISO 3593_00_Display Operator Manual 2

 ISO 3593_00_ DISPLAY Operators Manual
This edition applies to the Vanguard Pai Lung LLC SJD, 2SR2/V,1SR2/SI and 4SJ4/SI circular knitting
machines.

The construction of the Vanguard Pai Lung LLC knitting machines and accessories embody the most ad-
vanced features and engineering techniques obtainable in modern knitting equipment. These are the result of
over 75+ years of manufacturing experience. Today, VPL knitting machines and accessories are in use the
world over. Innumerable types of circular knit fabrics have been produced profitably using VPL products. We
are proud of the performance record our products have compiled in knitting mills throughout the world and we
are pledged to maintain this high standard.

Changes are periodically made to the information herein; any such changes will be reported in subsequent
editions or technical bulletins.

This Operators Manual for SJD,2SR2/V,1SR2/SI/and 4SJ4/SI has been prepared as an aid and guide to
efficient knitting.

It’s immediate purpose is to illustrate the proper assembly, operation, adjustment and maintenance of VPL
Delta machines. Read and follow this manual carefully and you will be repaid with longer machine life,
more efficient operation, higher production, better quality fabric and lower knitting costs.

Before leaving our plant, each machine is inspected, test-run and set to operate at peak efficiency for
normal yarn and normal mill conditions. No further mechanical adjustments should be necessary.

The information contained herein does not imply to cover all details or variations of machinery in connec-
tion with maintenance. Should further information be required, contact the Vanguard Pai Lung Customer
Service Department for assistance. This publication could contain technical inaccuracies or may con-
tain typographical errors.

Vanguard Pai Lung LLC, claims proprietary rights to the material disclosed herein. This publication may not
be reproduced in whole or in part without written permission from VPL or a subsidiary or affiliated company
authorized by VPL to give such permission.

Requests for VPL publications should be made to your local VPL representative or to VPL at the address
below:

Vanguard Pai Lung

601 Mac Arthur Circle
P.O. Box 9

Monroe, NC 28111-5009 U.S.A.

Phone: 704/283-8171 Toll Free: 800/222-1971 Fax: 704/283-

www.vanguardpailung.com

ISO 3593_00_Display Operator Manual 3

 MANUAL SUPPLEMENT January 31, 2012

After extensive testing of the Delta SJ4AC/D machine throughout the last 10 years some of the
primary factors that prohibit Higher Speeds were Yarn Quality, Creel and Tubing Design, Knitting
Mill Air Quality , Lint Control, Proper Maintenance and Machine Overhaul Procedures. These
factors are critical for all knitting machines, but with the increased Delta speeds they proved to be
detrimental towards the machines overall performance and reaching higher speed factors.

Suggested Speed Factors for the SJ4AC/D, DI, DI2, DI3 Knitting Machines

Plain Jersey Fabrics UP To 1750 Speed Factor, 16 to 28 cut.

Polyester and Lycra UP To 1150 Speed Factor, 16 to 28 cut.

Cotton Yarns and Lycra Up To 1150 Speed Factor, 16 to 28 cut.

Pattern Work and No Lycra Up To 1500 Speed Factor,16 to 28 cut.

Suggested Speed Factors for the SJ3AC/D, DL, DI, DI2, DI3 Knitting Ma-
chines

After testing at the factory on the 3 feeds per inch machines, it has been deter-
mined this machine’s top speed should be for the following Fabrics, 28 cut and
down.

Plain Jersey Fabrics UP To 1850 Speed Factor, 16 to 28 cut.

Polyester and Lycra UP To 1350 Speed Factor, 16 to 28 cut.

Cotton Yarns and Lycra Up To 1200 + Speed Factor, 16 to 28 cut.

Pattern Work and No Lycra Up To 1500 Speed Factor, 16 to 28 cut.

MACHINE BREAK IN PERIODS:

We encourage all customers to allow 4 weeks of run time at the Factory set
Speed of 1000 before increasing the speed factor of Delta Knitting Machines. We
suggest increasing the speed approximately 187.50 Hz. each week until the top
speed is accomplished for your particular type of machine.

NOTE: If the above is not observed, it will result in Voiding the Warranty
of the machine

ISO 3593_00_Display Operator Manual 4

 Section 3. Warranty Coverage Time

All Warranty's are Covered From Day of Startup.

1. Electrical 90 Days
2. Mechanical 1 Year
3. Cylinder 2 Years
4. Cams (Cylinder and Sinker) 2 Years
5. Yarn Carriers 1 Year

ISO 3593_00_Display Operator Manual 5

 Section 4. Safety Labels

SAFETY NOTICE - EMBLEMS PAST AND PRESENT

Pages 12 thru 15

In Spanish and English Language

ISO 3593_00_Display Operator Manual 6

 SAFETY NOTICE - NEW STYLE LABELING (continued)

HAZARDOUS VOLTAGE EXISTS INSIDE ENCLOSURE WITH MAIN POWER SW ITCH OFF.

EXISTE TENSIÓN PELIGROSA DENTRO DE LA CAJA CON EL INTERRUPTOR DE ENERGÍA

PRINCIPAL APAGADO.

HAZARD FROM FLYING DEBRIS. SERIOUS EYE INJURY CAN OCCUR.

 SAFETY GLASSES MUST BE WORN WHEN NEAR AN OPERATING MACHINE.
PELIGRO DE MATERIAL VOLANTE. PUEDE PRODUCIR GRAVES HERIDAS EN LOS OJOS.
 HAY QUE USAR LENTES DE SEGURIDAD EN LAS CERCANIAS DE UNA MAQUINA
EN MARCHA.

HAZARD FROM AIRBORNE NOISE. SERIOUS EAR INJURY CAN OCCUR.

 HEARING PROTECTION MUST BE WORN WHEN NEAR AN OPERATING MACHINE.
PELIGRO DE RUIDO EXCESIVO. PUEDE PRODUCIRSE GRAVES HERIDAS EN LOS OIDOS.
 HAY QUE USAR PROTECCION ACUSTICA (OREJERAS) EN LAS CERCANIAS DE UNA
MAQUINA EN MARCHA.

READ AND UNDERSTAND THE OPERATOR'S MANUAL BEFORE USING THIS MACHINE.
 FAILURE TO FOLLOW THE OPERATING INSTRUCTIONS COULD RESULT IN DEATH OR
SERIOUS INJURY.
ASEGÚRENSE DE LEER Y ENTENDER EL MANUAL DEL OPERADOR ANTES DE USAR ESTA
MÁQUINA.
 LA FALTA DE SEGUIR LAS INSTRUCCIONES OPERACIONALES PUEDE RESULTAR EN LA
MUERTE O HERIDAS SERIAS.

HOT SURFACE. DO NOT TOUCH.

TO AVOID POSSIBLE SKIN BURNS, ALLOW SURFACE TO COOL BEFORE SERVICING.

SUPERFICIE CALIENTE. ¡NO TOCAR!

Paraevitar quemaduras en lapiel, permita que la superficiese enfríe antes del
servicio.

NOTE: Machine safetysigns and labels shall periodicallybe inspected and cleaned bythe operator to maintain good
NOTE: Machine safety signs and labels shall periodically be inspected and cleaned by the operator to
legibility. Replace machine safetysigns and labels when theyare no longer legible. Replacement safety
maintain good legibility. Replace machine safety signs and labels when they are no longer legible. Replace-
signs and labels are available through Vanguard Supreme or through the local machine agent.
ment safety signs and labels are available through Vanguard Pai Lung or through the local machine agent.

ISO 3593_00_Display Operator Manual 7

 SAFETY NOTICE - NEW STYLE LABELING (continued)

The following pictograms represent safety procedures for various countries and economic communi-
ties around the world. Read and understand the various warnings and procedures in this manual be-
fore operating or repairing the machine.

MAIN POWER. MACHINE LOCKOUT POINT.

CORRIENTEPRINCIPAL. Lugar de bloqueo yvetiquetado de la máquina.

Contact with oil can result in defattening of the skin and in certain cases
irritation can develop from sensitivity. Consult the MSDS and/or Technical Data
Sheet supplied with the lubricating oil for first aid procedures and
recommended personal protective equipment.

El contacto con resultado de la lata de aceite en defattening de la piel y en

cierta irritación de los casos puede convertirse de sensibilidad. Consulte el
MSDS y/o la hoja de datos técnica provistos del aceite lubricante para los
procedimientos de los primeros auxilios y el equipo protector personal
recomendado.

NOTE
NOTE : Machine
: Machinesafety signs
safetysigns andand
labelslabels shall periodically
shall periodically be cleaned
be inspected and inspected
bytheand cleaned
operator bygood
to maintain the operator to
maintain good legibility. Replace machine safety signs and labels when they
legibility. Replace machine safetysigns and labels when theyare no longer legible. Replacement safetyare no longer legible. Replace-
ment safety signs and labels are available through Vanguard Pai Lung
signs and labels are available through Vanguard Supreme or through the local machine agent. or through the local machine agent.

ISO 3593_00_Display Operator Manual 8

 SAFETY NOTICE - NEW STYLE LABELING

The following pictograms represent safety procedures for various countries and economic communi-
ties around the world. Read and understand the various warnings and procedures in this manual be-
fore operating or repairing the machine.

HAZARD FROM ROTATING PARTS. SERIOUS INJURY OR DEATH CAN OCCUR.

 TURN OFF MAIN POWER BEFORE OPENING SAFETY GATES.
 OPERATE MACHINE ONLY WITH SAFETY GATES SECURELY CLOSED AND LATCHED.
 DO NOT ATTEMPT TO COMPROMISE OPERATION OR INSTALLATION OF SAFETY DEVICES.
 LOCKOUT/TAGOUT MAIN POWER PRIOR TO SERVICING THIS EQUIPMENT.

PELIGRO DE PARTES GIRATORIAS. PUEDE OCASIONAR GRAVES LESIONES O LA MUERTE.

 APAGAR LA CORRIENTE PRINCIPALANTES DE ABRIR LAS PUERTAS DE SEGURIDAD.
 HACER FUNCIONAR LA MÁQUINA SÓLO CON LAS PUERTAS DE SEGURIDAD CERRADAS.
 NO INTENTAR CAMBIAR OANULAR LOS MECANISMOS DE SEGURIDAD.
 Bloquear y etiquetar la corriente principal antes dereparar este equipo.

HAZARD FROM ROTATING PARTS. SERIOUS INJURY OR DEATH CAN OCCUR.

 TURN OFF MAIN POWER BEFORE OPENING SAFETY GATES.
 OPERATE MACHINE ONLY WITH SAFETY GATES SECURELY CLOSED AND LATCHED.
 DO NOT ATTEMPT TO COMPROMISE OPERATION OR INSTALLATION OF SAFETY DEVICES.
 LOCKOUT/TAGOUT MAIN POWER PRIOR TO SERVICING THIS EQUIPMENT.

PELIGRO DE PARTES GIRATORIAS. PUEDE OCASIONAR GRAVES LESIONES O LA MUERTE.

 APAGAR LA CORRIENTE PRINCIPALANTES DE ABRIR LAS PUERTAS DE SEGURIDAD.
 HACER FUNCIONAR LA MÁQUINA SÓLO CON LAS PUERTAS DE SEGURIDAD CERRADAS.
 NO INTENTAR CAMBIAR OANULAR LOS MECANISMOS DE SEGURIDAD.
 Bloquear y etiquetar la corriente principal antes dereparar este equipo.

HAZARD FROM ELECTRIC SHOCK. SERIOUS INJURY OR DEATH CAN OCCUR.

ENCLOSURE CONTAINS: 460 VAC, 3 PHASE, 50/60 HZ CIRCUITS
 ONLY QUALIFIED SERVICE PERSONNEL TO ACCESS THIS ELECTRICAL ENCLOSURE.
 LOCKOUT/TAGOUT SUPPLY DISCONNECTING DEVICE PRIOR TO SERVICING
ELECTRICAL ENCLOSURE.

PELIGRO DE DESCARGA ELÉCTRICA. PUEDE OCASIONAR GRAVES LESIONES O LA MUERTE.

Esta área eléctrica contiene: 230 VAC, 3 FASES, 50/60 HZ CIRCUITOS
 Sólo el personal de servicio debidamente capacitado debe tener acceso a
estas áreas eléctricas.
 Bloquear y etiquetar el dispositivo desconectador de suministración de
energía antes de efectuar servicio en estas áreas eléctricas.

NOTE
NOTE : Machine
: Machinesafety signs
safetysigns andand
labelslabels shall periodically
shall periodically be cleaned
be inspected and inspected
bytheand cleaned
operator bygood
to maintain the operator to
maintain good legibility. Replace machine safety signs and labels when they
legibility. Replace machine safetysigns and labels when theyare no longer legible. Replacement safety are no longer legible. Replace-
ment safety signs and labels are available
signs and labels are available through Vanguard through
Suprem
Vanguard Pai
Vanguard Pai Lung or
Lung e or through the local machine agent.
through the local machine agent.

ISO 3593_00_Display Operator Manual 9

 SAFETY NOTICE - OLD STYLE LABELING

The following pictograms represent safety procedures for various countries and economic communities around the world.
Read and understand the various warnings and procedures in the operator’s manual before operating the machine .

WARNING:
HAZARD FROM AIRBORNE NOISE
SERIOUS EAR INJURY CAN OCCUR
HEARING PROTECTION MUST BE WORN WHEN
NEAR AN OPERATING MACHINE

WARNING:
HAZARD FROM FLYING DEBRIS
SERIOUS EYE INJURY CAN OCCUR
SAFETY GLASSES MUST BE WORN WHEN
NEAR AN OPERATING MACHINE

WARNING:
HAZARD FROM ROTATING PARTS
SERIOUS INJURY OR DEATH CAN OCCUR
* TURN OFF MAIN POWER BEFORE OPENING
SAFETY GATES OR REMOVING COVERS.
* OPERATE MACHINE ONLY WITH SAFETY GATES
SECURELY CLOSED AND LATCHED.
* DO NOT ATTEMPT TO COMPROMISE OPERATION
OR INSTALLATION OF SAFETY DEVICES.
* KEEP HANDS, JEWELRY, CLOTHING, AND
HAIR AWAY FROM ROTATING PARTS.

WARNING:
HAZARD FROM ELECTRIC SHOCK
SERIOUS INJURY OR DEATH CAN OCCUR
* ONLY QUALIFIED SERVICE PERSONNEL TO
ACCESS THIS ELECTRICAL ENCLOSURE
* LOCK OUT SUPPLY DISCONNECTING DEVICE
BEFORE SERVICING ELECTRICAL ENCLOSURE.

WARNING:
GENERAL HAZARD, SERIOUS INJURY OR
SEVERE DAMAGE TO THE MACHINE CAN OCCUR
READ AND UNDERSTAND THE PROCEDURES
IN THE OPERATOR’S MANUAL BEFORE
OPERATING THE MACHINE.

NOTE: Machine safety signs and labels shall periodically be inspected and cleaned by the operator to
maintain good legibility. Replace machine safety signs and labels when they are no longer legible. Replace-
ment safety signs and labels are available through Vanguard Pai Lung or through the local machine agent.

ISO 3593_00_Display Operator Manual 10

 Ordering Instructions

When ordering parts for your Vanguard Supreme Circular Knitting Machine, please include the following information:

*Machine Model *Needle Gauge

*Machine Serial Number *Part Number of Item Needing Replacement

*Cylinder Diameter and Cut *Description of Item Needing Replacement

Do not use the item or page numbers from this manual except as additional information.

Each page of this parts manual identi-

A Item Number for an Assembly D Part Name

B Item Number for a Part E Assembly Number

C Assembly Name F Part Number

* If a part number is not available for an assembly or an individual part, ”No P/N” will appear
in the part no. column. Order the individual part if the assembly does not have a part number.
Order the assembly if the individual part does not have a part number.

1A 2

AA 3
2A B B

E
ITEM PART NUMBER DESCRIPTION

1A Specify Dia & Cut Inserted Cylinder Assembly

A 2A 117344-DIA Section Block Assembly C

(See Figure 8 for Illustrated Parts Breakdown.)

1 7769 Shoulder Screw

F
2 805354 Dowel Pin

D
3 6426 Socket Head Cap Screw 1/4-20 x 1 1/4
B
4 No P/N Cam Retaining Ring

ISO 3593_00_Display Operator Manual 11

 Return To Table of Contents

VPL Total Factory Management System

Total Factory Management

Areas of Savings and Profitability:

Fabric defect scanner:

Using infrared fabric defect scanning reduces yarn and knitted fabric waste considerably by detecting defects immediately. The
defects are tagged by location and type for inspection. This increases overall plant efficiency and fabric quality.

Yarn Rate Monitor:

Yarn rate monitoring will detect overfeeds and underfeeds of yarn usage. This will correct density, porosity, sizing and shrinkage
issues and can save a considerable amount in yarn usage.

Fabric Quality Improvements:

Fabric quality improvements are seen in the combined technologies of detecting and eliminating fabric imperfections. The tech-
nologies used to improve fabric quality are defect scanning, yarn rate monitoring and preventative maintenance procedures and are
organized through the Knit monitoring system. Combining these technologies can help to increase your customer satisfaction and
leads to increased orders and heightened branding of your company’s reputation.

Machine Speed Increase Allowance:

Increasing speeds with maintained quality and efficiency leads to increased production and efficiency. This is done through main-
tained awareness of the machine healthiness using real-time data from the Knit monitoring system.

Labor Cost Reductions:

Coordinated communications from Knitter to Mechanic and to the healthiness of all the machines are used to organize the knitting
room floor. This increases productiveness of employees and reduces labor costs.

Downtime Reductions:
All machine and employee functions are logged and classified for review. Inefficiencies are easily identifiable and addressable.
Production becomes smoother and more efficient.

Yarn Quality Improvement:

By using the tools provided by the Knit monitoring system, mill owners have the ability to demand higher quality yarn from their sup-
pliers. This can be done using the historical data generated and with the defective fabric on hand.

ISO 3593_00_Display Operator Manual 12

 Knitting Room Data Acquisition Software | VPLH

ISO 3593_00_Display Operator Manual 13

 Knitting Room Data Acquisition Software

VPL TOTAL FACTORY MANAGEMENT SYSTEM

The complete data acquisition software package for knitting rooms

This document will give an overview of the knit monitoring software. For information regarding the
hardware operation, please refer to the VPL 5000 Installation & Operation Guide.

ISO 3593_00_Display Operator Manual 14

 1. INTRODUCTION
Vanguard Pai Lung Total Factory Management System is a complete package to schedule, monitor
and manage a knitting room. The system uses many advantages to give you the information you
want when you want it. The Ethernet network that connects the machines to PC is fast and reliable
and is easily supportable by any IT department. This eliminates special networking bridges and cost
to bring data from the machines to the database software. Reports can be generated and exported
to practically any platform. Real-time devices keep track of when things happen to give the most ac-
curate information.

1. Vanguard Pai Lung Total Factory Management System

Real-time monitoring of knitting equipment

Virtual knitting floor
Knitting floor status indicators
Preventive maintenance counters with visual warning indicators and op-
tions for machine run prevention
Machine information database
Fabric Style database with machine download
Equipment and personnel tracker
Downtime
Shift and Knitter Efficiency
Machine problem declarations
Fabric defect types
Piece data
Shift, Fabric Style and Knitter scheduling
Comprehensive Reporting
Graphical and Text Messaging
Machine “Help and Documentation screen” programming
MySQL database
TCP communications
2. MAIN SCREEN
The main screen of the Knit Monitoring software contains the Virtual Floor layout where the Ma-
chine icons are placed. The main screen also has a status bar at the bottom of the screen for sys-
tem information to be displayed. This section will describe the main screen window and its con-

ISO 3593_00_Display Operator Manual 15

 2.1 Virtual Knitting Floor
The virtual knitting floor is a graphical representation of the actual Knitting Room floor (see Figure 1).

Figure 1: Main Screen

2.2 Status Bar
The status bar is located at the bottom of the main screen window. It displays the current user logged in, com override status, and
system data and time. The knit monitoring software broadcasts the system date and time to all machines connected. This will syn-
chronize the machine date and time to the system date and time.

ISO 3593_00_Display Operator Manual 16

 2.3 Machine Icon
The machine icon is a representation of an individual machine on the knitting room floor. (See Figure 2) Each icon in the main win-
dow of the knit monitoring software is a visual representation of a machine on the knitting room floor. Each icon can be positioned
so that it will correspond with the actual location of the machines that they represent. At a glance, the information on each icon
quickly conveys the complete status of the machine.

Figure 2: Default Machine Icon

2.3.1 Main Display

The main display can be set up to show the knitter efficiency, shift efficiency, current fabric style loaded on to the machine or the
knitter currently logged on to the machine. When the pointer arrow is over the status indicator, a pop-up caption will be displayed.
This pop-up caption is used to show the other information not currently being displayed without constantly changing the indicator
setup. When the indicator is set to display the shift efficiency, then the caption will display what knitter is currently logged on to the
machine. When the indicator is set to display the knitter currently logged on to the machine, then the caption will display the shift
efficiency. When the indicator is set to display the current fabric style loaded on to the machine, then the caption will display what
knitter is currently logged on to the machine and the shift efficiency. The background color of the status indicator can be set to
change depending on the efficiency of the machine. (See Figure 20, Figure 21, Figure 22, Figure 23)

2.3.2 Declaration / PM Panel

When a knitter encounters a problem with his machine, it must be entered, or declared, depending on the type of problem that has
occurred. The declaration indicator is color-coded to a list of available problem options that a Knitter enters right at the machine.
The color of the declaration indicator will, therefore, change depending on the code entered. In addition, the knit monitoring soft-
ware can also initiate a declaration from a separate list of possible problems.

ISO 3593_00_Display Operator Manual 17

 Routine preventive maintenance (PM) is performed on a machine that has reached a predetermined revolution count. When this
preventive maintenance level has been reached, the declaration indicator will flash the letter “D.” This gives a clear indication that
the PM level has been reached even if other declarations are being shown at the same time.

The list of declarations available from the knitter is:

1. # NOT ASSIGNED 20. Looping 40. Take-Up Chain-Gears

2. Air-gauge leak 21. Main Drive 41. Take-Up Rollers

3. Airline/Air Hose 22. Needle Detector 42. Take-Up Turn Table

4. Broken Needle 23. Needle/Sinker 43. Tape/Quality Wheel

5. Broken Sinker 24. No Tickets 44. Thick/Thin Yarn

6. Creel/Tubes 25. No Yarn 45. Thrown Roll

7. Electrical/Machine 26. Oiler/Leaks/Line 46. Too Many Defects

will not start 27. Overhaul-PM 47. Blow/std/Machine
8. Electrical run away 28. Overhaul-PM Audit 48. Fabric Scanner
9. Electrical/bad motor 29. PM Audit 49. Scanner-Cal-Err
10. Electrical/Light 30. Porc Evlts Sprg 50. Cylinder change
11. Check Machine 31. Press Off 51. Gram-Machine
12. Call Mechanic 32. Quality/Draw 52. Change Doff Revs
13. Task Completed 33. Rag-n-Needles 53. Start/Up Gram
14. Task Canceled 34. Regulator-Air-Leak 54. Start/Up Knit/Down
15. Flutter Blower 35. Reneedle 55. Start/Up Tie/Yarn
16. Gate Switch 36. Resinker 56. False-Fabric-Defects
17. Gates 37. Sinker Streak 57. Fan
18. Holes/Drops 38. Take-up Spreader
19. IPF (Memminger) 39. Take-up Belt

The list of declarations available from the Knit Monitoring software is:

1. Machine Memory Full

2. Incorrect Protocol from Machine

3. Machine Shift Change Needed

4. PM Level # Warning

5. PM Level # Reached

6. Run Disabled for PM

7. Knitter Message Waiting

2.3.3 Ravel Panel

The ravel panel, as depicted by the letter “Y”, shows the status of the rate of yarn coming into the machine. It also displays the
status of the tolerance for the ravel, which is the minimum and maximum rate acceptable to maintain proper machine function.
When the ravel is correct, the indicator turns green. When the ravel falls outside the accepted tolerance, the indicator turns red.
The machine can also be stopped, if desired, when the ravel has been out of tolerance for a given amount of revolutions. To ac-
cess a machine’s real-time ravel reading from the knit monitoring software, move the pointer arrow over the ravel indicator until the
pop-up caption appears. Each ravel is displayed in inches and centimeters.

ISO 3593_00_Display Operator Manual 18

 2.3.4 RPM / Fault Panel
The RPM / fault panel shows the status of the machine speed. The machine is sent the correct RPM and a tolerance for the RPM
by the knit monitoring software. This is done using the fabric style data for the machine. The RPM is then monitored by the ma-
chine. When the RPM is correct the indicator turns green. When the RPM is out of tolerance the indicator turns yellow. The ma-
chine can also be stopped, if desired, when the RPM has been out of tolerance for a given amount of revolutions. When the pointer
arrow is over the RPM indicator, a pop-up caption will be displayed. This pop-up caption is used to show the real-time RPM read-
ing from the machine. Anytime the machine stops, the RPM indicator will display a color code that represents the stop and the pop
-up caption will show the description and downtime of the stop.

2.4 Machine Information Screen

The machine information screen can be displayed by left-clicking on one of the Virtual icons or by left-clicking on “More Info” in the
machine database screen. (See Figure 3) All of the real-time data collected from the machine can be viewed from this screen. This
includes all totalized counters, machine fault counters, fabric defect counters, style information, shift information, piece information,
knitter information, efficiencies, machine status, declaration status, down-time status and the date and time of the last download.
All of this information is organized on one screen so that it can be quickly reviewed.

ISO 3593_00_Display Operator Manual 19

 Figure 3: Machine Information Screen

3. MENU FUNCTIONS

Figure 4: Main menu

3.1 File Menu

The file menu contains the com override toggle, align floor layout, save floor layout, refresh floor layout, and exit options as seen in
Figure 5.

ISO 3593_00_Display Operator Manual 20

 Figure 5: File Menu

3.1.1 Com Override

Under normal operation, machine icons display a “No Com” message when they are not connected. By activating “Com Override”,
disconnected machines will instead show their last known status. Prolonged use of com override may cause machine connectivity
issues to go unnoticed.

3.1.2 Floor Layout

The floor layout menu items are used in creating the virtual knitting floor. The icons that represent each machine in the main win-
dow of the knit monitoring software are a visual representation of the machines on the knitting room floor. These icons can be posi-
tioned so that they will correspond with the actual location of the machines that they represent. When lining up the icons across the
floor, use the menu item ‘Align Floor Layout’ to snap the icons into place. This will force the icons on an imaginary grid so that they
are lined up evenly across the window (see Figure 6). Once the virtual knitting room floor is laid out, use the ‘Save Floor Layout’
menu item to save the locations of the icons in the window. The icons can be moved without saving for other uses as in temporarily
grouping problem machines that need attention. Once this arrangement is not needed, use the ‘Refresh Floor Layout’ menu item to
move all the icons back to their previously saved positions.

ISO 3593_00_Display Operator Manual 21

 Figure 6: Grid Snapping

3.2 Setup Menu

The setup menu contains the Add/Edit submenu and the extended shift option. The Add/Edit submenu contains links to machines,
styles, yarns, yarn vendors, PMs, cycles, knitters, fixers, and groups. (See Figure 7)

Figure 7: Setup Menu

3.2.1 Add/Edit Machines

All machines that will be monitored must first be entered into the database using this window. (See Figure 8) To add new machines,
click ‘New’. You will be prompted to enter the machine number and serial number. After this is entered, you will be shown the newly
created machine’s blank entry that must be populated. After entering in the machine’s data, click ‘Save’.

ISO 3593_00_Display Operator Manual 22

 The machine data window contains several fields that must be populated for full functionality of the knit monitoring software. The
left side of the window contains several general pieces of data about the machine: Manufacturer (Vanguard, etc.), Model (SJ4AC/
DI2, etc.), Type (Jersey, Rib), Cylinder Size (Inches), Cut, Number of Needles, Number of Feeds, RPM Tolerance (How much the
machine can deviate from the prescribed RPM before it shuts down.), Roll Weight (Pounds), Speed Factor, Machine Value (for knit-
ter assignments).

The machine window also contains four individual PM counters. These counters decrease with each revolution of the machine it is
associated with. Each PM counter has a warning count level, a negative count level, a run prevention selection and a description
associated with it.

When any of the PM counters drop below its respective warning level count, a declaration is triggered. The declaration indicator on
the associated icon turns blue. (See Figure 2) If the pointer arrow is over the indicator, a pop-up caption will be displayed. The
caption will display “PM Needed” with the counter number and description of the PM level as entered in the machine database.
When any of the PM cycle counters drop to zero, the “D” in the declaration indicator flashes.

When any of the PM cycle counters drop below their respective negative level count with the run prevention selection checked, that
particular machine is stopped until the PM is taken care of and correctly logged into the PM Logging window. The machine data-
base also has a selection for showing or hiding the machine icon on the screen. When adding machines to the knit monitoring floor
layout, the “Show Icon” must be check marked. The check mark can be removed to remove the icon from the floor layout.

The PM descriptions are custom preset PMs that are created by you. If you have no selectable PM descriptions or the one you
want is not an option, you must add that PM with the Add/Edit PMs window. (See Figure 10)

The machine window also displays cycle presets. These cycle presets are settings that you create with the Add/Edit Cycles win-
dow. (See Figure 11) If no cycles are selectable or the desired cycle is not an option, you must create it.
Finally, the machine must be setup for yarn/belt matching. There can be up to 4 belts and 4 yarns. Multiple belts can use the same
yarn type, but only one yarn type can be put on a belt. For example if you want YARN1 to be used on belts 1 and 2 and YARN2 to
be used on belt 3 and belt 4 is out of use, check belts 1, 2, and 3, and select YARN1 for belts 1 and 2, and select YARN2 for belt 3.

ISO 3593_00_Display Operator Manual 23

 Figure 8: Machine Database Window

3.2.2 Add/Edit Styles

All the fabric styles used on the Knitting Floor can be entered into the Fabric Styles Database using this window (See Figure 9). To
create a new style, click ‘New’ and input the style name. Then fill in the form for the new style and click ‘Save’.

Figure 9: Style Window

ISO 3593_00_Display Operator Manual 24

 3.2.3 Add/Edit PMs
Enter PM descriptions into this form to populate selectable PMs in the Add/Edit Machine Window. You must click ‘Save’ to save
typed data. (See Figure 10)

Figure 10: Add/Edit PMs

3.2.4 Add/Edit Cycle

Use this window to pre-program cycles according to Table 1 below. (See Figure 1)

Table 1 – Cycle details

Parameter Name Range Description

Inspection Cycle 0 – 99999 Cycle counter that indicates to the Knitter to inspect the machine. If the
machine is not inspected by the second inspection cycle, the machine is
stopped and a missed inspection is counted.
Mid-Roll Flush 0 – 99999 The piece revolutions that the machine will begin the oil flush in the middle
of the roll.
Oil Flush Duration 0 - 99 The duration of an oil flush

Pre-Doff Clean 0 - 999 The number of revolutions before the end of the roll that the machine will be
stopped and the machine will display the Pre-Doff Clean message.
Pre-Doff Flush 0 - 999 The number of revolutions before the end of the roll that begins the end of
the roll oil flush.
RPM Tolerance 0-9 The allowable amount of RPM tolerance.

Max Defects/Roll 0 - 99 The maximum defects allowed per piece.

ISO 3593_00_Display Operator Manual 25

 Figure 11: Add/Edit Cycle Settings

3.2.5 Add/Edit Knitters

Use this window to control the knitter database. (See Figure 12) Typed data must be saved by clicking ‘Save’. Knit-
ters must be added to groups to be scheduled in knitter sets. If no groups are selectable, or the desired group is not
an option, go to add/edit groups to create and modify groups.

Figure 12: Add/Edit Knitters Window

3.2.6 Add/Edit Fixers

Use this window to control the fixer database. (See Figure 13) This window operates similarly to the knitter window with the excep-
tion of groups. Typed data must be saved by clicking ‘Save’.

ISO 3593_00_Display Operator Manual 26

 Figure 13: Add/Edit Fixers Window

3.2.7 Add/Edit Groups

Use this window to organize knitters into shift groups. (See Figure 14) To create a new group, click ‘New’ and input the group
name. It will appear in the dropdown box. Add knitters to the group by selecting the group, then selecting knitters and clicking the
‘>>’ button. To ungroup a knitter, select a knitter and click the ‘<<’ button. To delete a group, select it and click ‘Delete’. All knitters
in a deleted group will be ungrouped.

Figure 14: Add/Edit Groups Window

3.2.8 Shift Schedule

The ‘Shift Schedule’ window allows for the creation of a diverse plant schedule. The schedule is built in a modular format. (See
Figure 15)

ISO 3593_00_Display Operator Manual 27

 Figure 15: Extended Shift Planning Window

Begin by ‘building days’. Click on the ‘Build Day’ button. The day layout constructor is displayed. (See Figure 16)To create
a new shift, click ‘New’. After entering the name of the day, you must enter the shift data. There can be up to four shifts in
one day. If you only have 2 shifts, only select ‘Active’ on the first and second shift. Select the start and end time of each
shift and the group of knitters that will be working that shift. Finally, click on the day color to select a custom color for that
day. Click ‘Save’ to save the day. To create more days, click ‘New’ again.

ISO 3593_00_Display Operator Manual 28

 Figure 16: Build Day Window

Now that we have build days, we can build weeks with those days. From the main schedule window click the ‘Build Week’ button to
display the week layout constructor. (See Figure 17)To create a new week, click the ‘New’ button. After naming the week, you must
populate the week with previously build days. Click ‘Save’ to save changes. If not every week is the same, create additional weeks.
(If you are on a four week rotation, you need four weeks. If on a two week rotation, you need 2 weeks.)

Figure 17: Build Week Window

Now that we have build days and weeks, we can build four week segments. Click on ‘Build Four Weeks’ to display the four week
layout constructor. (See Figure 18)Similarly to building days and weeks, to create a new four week layout, click ‘New’. If you are on
a four week rotation, select week1, week2, week3, and week4. If on a two week rotation, select week1, week2, wee1, week2. Click
‘Save’ to save the layout.

ISO 3593_00_Display Operator Manual 29

 Figure 18: Build Four Week Layout Window

Once the layouts have been constructed, return to the main schedule window and select the radio button beside the layout you
want to apply. Next select the number of consecutive layouts you want to apply. Finally click ‘Set’ to apply the layout. For exam-
ple if you want to set ‘Day1’ for 10 days, click the days radio button, select ‘Day1’ then input 10 into the number of days. If you
want to apply a 2 week rotation for a year, select the four week radio button, select your four week layout, then input the number
of four week periods in a year. (About 12) Hit set. You can even schedule for 10 years, just input 120 instead of 12.

After you have the general structure of your schedule, you can make small changes by double clicking on the day and altering it,
or selecting single or multiple days and clicking delete. Details about selected days are displayed below in the list box.

3.3 Display Menu

The display menu contains the machine icon display options: ‘Shift Efficiency’, ‘Knitter Efficiency’, ‘Log Status’, and ‘Style Informa-
tion’. It also contains a link to the ‘Declarations’ window and the ‘Display Setup’ submenu. The display setup submenu contains
links to ‘Efficiency Parameters’, ‘Declaration Colors’, and ‘Fault Colors’. (See Figure 19)

ISO 3593_00_Display Operator Manual 30

 Figure 19: Display Menu

3.3.1 Shift Efficiency

Selecting this option causes the machine icons to display the shift efficiency in the main display panel and the knitter efficiency, log
status, and style information in the tool tip. (See Figure 20)

Figure 20: Display and Tooltip with Shift Efficiency Selected

3.3.2 Knitter Efficiency

Selecting this option causes the machine icons to display the knitter efficiency in the main display panel and the shift effi-
ciency, log status, and style information in the tool tip. (See Figure 21)

ISO 3593_00_Display Operator Manual 31

 Figure 21: Display and Tooltip with Knitter Efficiency Selected

3.3.3 Log Status

Selecting this option causes the machine icons to display the log status in the main display panel and the shift efficiency, knitter
efficiency, and style information in the tool tip. (See Figure 22)

Figure 22: Display and Tooltip with Log Status Selected

3.3.4 Style information

Selecting this option causes the machine icons to display the style information in the main display panel and the shift efficiency,
knitter efficiency, and log status in the tool tip. (See Figure 23)

ISO 3593_00_Display Operator Manual 32

 Figure 23: Display and Tooltip with Style Information Selected

3.3.5 Current Declarations

Clicking the ‘Declarations’ button displays a window with all the current declarations in the plant. (See Figure 24)

Figure 24: Current Declarations Screen

3.3.6 Efficiency Parameters

Clicking the ‘Efficiency Parameters’ button displays the current efficiency parameters. This window controls the shift efficiency per-
centage below which the background color of a machine window will change color to a color you choose. Click on the colored box
to change the color.

Figure 25: Efficiency Parameters Window

ISO 3593_00_Display Operator Manual 33

 3.3.7 Declaration Colors
Custom colors can be set for each declaration, but this is not required. To set a single declaration’s color, click the colored box be-
side it. To set multiple colors simultaneously, check the box beside the declaration and click ‘Set’. Choose the color and hit ‘OK’.
(See Figure 26)

Figure 26: Declaration Colors Window

3.3.8 Fault Colors

Custom colors can be set for machine faults exactly the same as declarations. (See 3.3.7 Declaration Colors, Figure 1)

Figure 27: Fault Colors Window

ISO 3593_00_Display Operator Manual 34

 3.4 Administration Menu
This menu contains links to knitters sets, machine sampling, PM logging, and security. (See Figure 28)

Figure 28: Administration Menu

3.4.1 Knitter Sets

Clicking the knitter sets menu option transforms the main window into a knitter set planning window. (See Figure 29) Knitter sets
assign knitters, styles and priorities to specific machines during a specific group’s shift.

To create a knitter set for specific day and group, that day and group must already be scheduled using the schedule planner. (See
3.2.8 Shift Schedule) To select a day, use the date time picker. Then use the drop down box to select the group that you want to
plan for that day.

Now you must assign a knitter, priority, and style to each machine you want to plan. It is not important the order you assign them.
You can also do partial plans that do not include every machine or plans that only have style and priority and not knitter.

ISO 3593_00_Display Operator Manual 35

 Figure 29: Knitters Sets Window

To assign a knitter, select the knitter in the drop down box. (If a knitter outside of the scheduled group is needed, check the box
‘Show all knitters’.) Once the knitter is selected, click the ‘assigned knitter’ panel of every machine that knitter will run. (See Figure
30) A random color will be assigned to that knitter to help distinguish them from other nearby knitters. To unassigned a knitter, right
click on the assigned

Next Page

ISO 3593_00_Display Operator Manual 36

 knitter panel. To assign a different knitter, simply select them and left click the assigned knitter panel. The knitters ‘value’ is
displayed along with his current assigned value. If his assigned value exceeds his set value, his assigned value turns red. Ma-
chine values are displayed at the bottom of their icon.

Styles are added in the same way as knitters. Simply select the style and click the style panel of the machine icon. To un-
assign a style, right click it. To assign another style, select the new style and left click the style panel.

Priorities are applied in the same manner as knitters and styles. Simply click the colored box of the priority you want to apply
and click the priority panel of the machine icon.
Once a machine is fully defined, the style panel’s background turns from white to green.

Figure 30: Knitter Set Machine Icon

To speed up the creation of knitter sets, you are able to copy and paste them. If you complete a knitter set for a certain group, you
can click ‘Copy Set’ to save the set into memory. You can then select a new day and group and hit ‘Quick Paste’ to insert the set
once. Alternatively, you can click ‘Multi Paste’ to paste the set for multiple days quickly. (See Figure 31)

Simply select a range of days and a shift and click ‘Add’. When you have added all the days and shifts you want to paste to, click
‘Paste’.

Figure 31: Multi Paste Window

ISO 3593_00_Display Operator Manual 37

 3.4.2 Machine Sampling
Machine sampling settings control how the machine samples real time data. (See Figure 32) Number of seconds between sam-
ples is defaulted to 300. (5 minutes) Days to maintain old samples is defaulted to 365. (1 year) Hour interval of weekly average
updates is defaulted to 1 hour. This means the server will update the average efficiency and RPM of the previous 7 days using
samples taken in that time interval every hour. Machine window connection timeout is the amount of time (in minutes) that a ma-
chine will appear to still be connected after it has last checked in.

Figure 32: Machine Sampling Window

3.4.3 PM Logging
The PM logging window allows for the documentation of PMs performed on machines. When you select a machine number, the
current number of revolutions are populated in the ‘Revs:’ textbox. The number of revolutions can be changed in case the PM was
performed earlier. Select the fixer that performed the PM from the fixer database and the date the PM was performed. Finally, se-
lect the description of the PM that was performed from the PM database. ‘Vendor’ and ‘Notes’ are optional. Click ‘Save’ to save
changes. (See Figure 33)

ISO 3593_00_Display Operator Manual 38

 Figure 33: Periodic Maintenance Logging Window

3.4.4 Security
The security window allows administrators to manage client users. New users can be added, existing users can be removed, exist-
ing users can have their security profile changed, passwords can be reset, and security profiles can be defined and changed.

3.4.4.1 Add Users

The add users tab allows new users to be added. (See Figure 34) Each user must have a unique username. To add a new user,
input the username, select the desired security profile, input their password and retype the password to confirm it. Finally, click add
user. If the desired user security profile is not present or there are no user security profiles, see section: 3.4.4.5 Manage Security
Profiles.

ISO 3593_00_Display Operator Manual 39

 Figure 34: Security Window; Add Users Tab

3.4.4.2 Reset User Password

To reset an existing user’s password, navigate to the reset user password tab of the security panel and select the username from
the list box. Next type in the new password and retype it to confirm and click reset. (See Figure 35)

Figure 35: Security Window; Reset User Password Tab

3.4.4.3 Delete Users

To delete existing users, simply navigate to the ‘Delete Users’ tab and select the username to delete. Click ‘Delete’. (See Figure 36)

ISO 3593_00_Display Operator Manual 40

 Figure 36: Security Window; Delete Users Tab

3.4.4.4 Change User Security Profile

To change a user’s security profile, navigate to the ‘Change User Security Profile’ tab. Select the desired username and then select
the desired security profile. Click ‘Save’. (See Figure 37)

Figure 37: Security Window; Change User Security Profile Tab

3.4.4.5 Manage Security Profiles

To create and modify security profiles, navigate to the ‘Manage Security Profiles’ panel. To add a new security profile, type its name
into ‘New Profile Name” and click ‘Add”. To delete an existing security profile, select the profile in the list box and click ‘Delete’. To
change the permissions associated with a security profile, select the
Profile from the list boxes next to areas available to that profile. (See Figure 38 next Page)

ISO 3593_00_Display Operator Manual 41

 Figure 38: Security Window; Manage Security Profiles Tab

ISO 3593_00_Display Operator Manual 42

 3.5 Log ON/OFF Menu

The log on/off menu allows users to log on or off. (See Figure 39)

Figure 39: Log ON/OFF Menu

3.5.1 Log On

The log on menu item is only selectable if no user is currently logged in. To log in as a different user, the
current user must log off. (See 3.5.2 Log Off) The log on window automatically appears when the program
starts or when a user logs off. (See Figure 40) If closed, it can be reopened with the log on menu item.

Figure 40: Log ON Window

3.5.2 Log Off

The log off option is only available when a user is logged on. This menu item logs a user off and allows an-
other to log on.

ISO 3593_00_Display Operator Manual 43

 3.6 Reports
Clicking the reports menu item brings up an open file dialogue that asks you to choose the desired report
file. (See Figure 41) Once the desired report is selected, click ‘Open’ and the report will be opened.

Figure 41: Open File Dialogue for Reports

If there is any information required by the report, you will be asked to input it at this time. Afterward, the report will be displayed in
the ‘Report Viewer’. An outline of the current report’s main groups are listed to the left of the report and can be clicked on as short
cuts to their location in the report. The report can have many pages and can be navigated by using the arrows at the top of the win-
dow. The report can be refreshed to update it as new information comes in from machines. The report’s print option can also be
found at the top of the screen. Clicking the menu item ‘Open Report’ will allow you to open a new report from within the current re-
port viewer.

ISO 3593_00_Display Operator Manual 44

 Figure 42: Report Viewer Window

3.7 Send Menu

The send menu has the option to open the send style window and to view the current send style queue. (See Figure 43)

Figure 43: Send Menu

ISO 3593_00_Display Operator Manual 45

 3.7.1 Send Style
The send style window is very similar to the add/edit style window except the style data is not able to be modified. (See Figure
44) Once the desired style to be sent is displayed, you can either send the style to one machine by clicking ‘Send Once’ or
several at the same time by clicking ‘Send Many’.

Figure 44: Send Style Window

Clicking the ‘Send Once’ button brings up the send once dialog. (See Figure 45) Only machines that are setup for the selected style
will be available. If no machines are displayed, then there are no matching machines in the database. Select the machine and click
‘Send’.

Figure 45: Send Style Once Window

Clicking the ‘Send Many’ button brings up the send many dialog. (See Figure 46) Only machines that are setup for the se-
lected style will be available. If no machines are displayed, then there are no matching machines in the database. Select sev-
eral machines by holding down ‘CTRL’ and clicking them or select a range of machines by holding ‘SHIFT’ and clicking the
beginning and of the range. When all desired machines are selected, click ‘Send”. The sent machines should then appear in
the queue.

ISO 3593_00_Display Operator Manual 46

 Figure 46: Send Style Many Window

3.7.2 View Queue

The view queue menu option displays the current send style queue. (See Figure 47) This is the list of styles waiting to be sent to
specific machines. Styles are sent as soon as the machine tries to communicate, so if a machine stays on this list for an extended
period of time there may be a connection error. The list is set to auto refresh by default, but if this lags the system, the auto refresh
can be deactivated by un-checking the box and manually refreshing with the ‘Refresh’ button. To delete a style before it is sent,
select it and click ‘Delete’.

ISO 3593_00_Display Operator Manual 47

 Figure 47: View Queue Window

3.8 Help Menu

The help menu currently contains only the ‘View Manual’ option. (See Figure 48)

Figure 48: Help Menu

3.8.1 View Manual

The view manual menu item displays this manual.

3.8.2 About
The ‘About’ window displays version info about the software. (See Figure 49)

ISO 3593_00_Display Operator Manual 48

 Figure 49: About Window

4 First Time Startup

Many features of the knit monitoring software have prerequisites from other areas of the software. For example, to create a style,
you must have yarns and yarn vendors input already. As a result, the first time the software is used several areas must be initial-
ized in a specific order.

4.1 Security Profiles

It is possible to restrict certain areas of the software from lower level users. You must first determine how many different security
profiles you need. Each profile corresponds to a certain level of access that the administrator defines. If you want everyone to have
the same level of access, only one profile is needed. However, if you want administrators to have full access, fixers with slightly
limited access, and knitters with very limited access, you would need three different profiles.

Once you determine the number of profiles needed, they must be created using the manage security profiles tab of the security
window. (See 3.4.4.5 Manage Security Profiles) Create each security profile and assign them their corresponding permissions.

4.2 Users

Now that security profiles have been created, users must now be added. Each user must be added before they can use the soft-
ware. To add users, see ‘3.4.4.1 Add Users’.

ISO 3593_00_Display Operator Manual 49

 4.3 Styles
Now that yarn types and yarn vendors have been fully populated, styles can be created. To create a style, see ‘3.2.2 Add/Edit
Styles’. Styles are required to create knitter sets and track style data for reports.

4.4 PMs
PMs or periodic maintenance descriptions must be created before they can be assigned to machines and tracked or logged as
completed. (See ‘3.2.3 Add/Edit PMs’)

4.5 Cycles
Machine cycle presets must be created before they can be assigned to machines. (See ‘3.2.4 Add/Edit Cycle’)

4.6 Machines
Machines data can now be fully added to the database. (See ‘3.2.1 Add/Edit Machines’)

4.7 Align Machine Icons

Once all machines have been created, they appear in a stack in the upper left corner of the window and must be arranged on the
virtual knitting floor. (See ‘3.1.2 Floor Layout’)

4.8 Knitters
Knitters must be created before knitter sets can be made. (See ‘3.2.5 Add/Edit Knitters’)

4.9 Fixers
Fixers must be created before they can log PMs. (See ‘3.2.6 Add/Edit Fixers’)

4.10 Groups
Groups must be created before shifts can be scheduled. (See ‘3.2.7 Add/Edit Groups’) After the groups are created, add the appro-
priate knitters to each group.

ISO 3593_00_Display Operator Manual 50

 4.11 Schedule
Now that groups have been created, the shift schedule must be created. Create the shift schedule according to ‘3.2.8 Shift Sched-
ule’.

4.12 Knitter Sets

Now that knitters, groups, styles, machines, and schedules have been created, knitter sets can be created. Create knitter sets ac-
cording to ‘3.4.1 Knitter Sets’.

4.13 Colors
Verify that alert colors are appropriate according to ‘3.3.6 Efficiency Parameters’, ’3.3.7 Declaration Colors’, and ’3.3.8 Fault Col-
ors’.

4.14 Machine Sampling

Verify that machine sampling settings are appropriate according to ‘3.4.2 Machine Sampling’.

ISO 3593_00_Display Operator Manual 51

 APPENDIX A – Report Examples

ISO 3593_00_Display Operator Manual 52

ISO 3593_00_Display Operator Manual 53
ISO 3593_00_Display Operator Manual 54
ISO 3593_00_Display Operator Manual 55
 KNIT MONITORING SOFTWARE
NEW SOFTWARE INSTALLATION SETUP
After the new installation of the software certain parameters need to be set in order for the software to work correctly.

Many features of the knit monitoring software have prerequisites from other areas of the software. Such as entering the knitting
operators name and or ID number, creating the shift schedule, adding fixers, adding styles and machine data.

Note: As a result, the first time the software is used several areas must be initialized in a specific order.

First Time Startup

Start by clicking on the icon VPL DB icon from the desktop computer and a screen will appear as follows.

Click the Log On/Off drop down box and enter in the user name and password that was given when purchasing the soft-
ware.
After entering the default user name and password; this will give full access to all the menus.

Log On/Off

ISO 3593_00_Display Operator Manual 56

 Start by entering machine data.

Add/Edit Machines

All machines that will be monitored must first be entered into the database using this window.
To add new machines, click ‘New’. You will be prompted to enter the machine number and Serial Number. After this is entered, you
will be shown the newly created machine’s blank entry that must be populated. After entering in the machine’s data, click ‘Save’.
The machine data window contains several fields that must be populated for full functionality of the knit monitoring software. The
left side of the window contains several general pieces of data about the machine: Manufacturer (Vanguard, etc.), Models (SJ4A,
SJ3A), Type (Jersey, Rib), Cylinder Size (Inches), Cut, Number of Needles, Number of Feeds, RPM Tolerance (How much the ma-
chine can deviate from the prescribed RPM before it shuts down.), Roll Weight (Pounds), Speed Factor and Machine Value (For
Knitter assignments).

ISO 3593_00_Display Operator Manual 57

 The machine window also contains four individual PM counters. These counters decrease with each revolution of the machine it is
associated with. Each PM counter has a warning count level, a negative count level, a run prevention selection and a description
associated with it.
When any of the PM counters drop below its respective warning level count, a declaration is triggered. The declaration indicator on
the associated icon turns blue. If the pointer arrow is over the indicator, a pop-up caption will be displayed. The caption will display
‘PM Needed’ with the counter number and description of the PM level as entered in the machine database. When any of the PM
cycle counters drop to zero the ‘D’ in the declaration indicator flashes.
When any of the PM cycle counters drop below their respective negative level count with the run prevention selection checked, that
particular machine is stopped until the PM is taken care of and correctly logged into the PM Logging window. The machine data-
base also has a selection for showing or hiding the machine icon on the screen. When adding machines to the knit monitoring floor
layout, the ‘Show Icon’ must be check marked. The check mark can be removed to remove the icon from the floor layout.

The PM descriptions are custom preset PMs that are created by you. If you have no selectable PM descriptions or the one you
want is not an option, you must add that PM with the Add/Edit PMs window.
The machine window also displays cycle presets. These cycle presets are settings that you create with the Add/Edit Cycles win-
dow. If no cycles are selectable or the desired cycle is not an option, you must create it.

Finally the machine must be setup for Yarn/Belt matching. There can be up to 4 belts and 4 yarns. Multiple belts can use the same
yarn type but only one yarn type can be put on a belt. For example if you want YARN1 to be used on belts 1 and 2 and YARN2 to
be used on belt 3 and belt 4 is out of use, check belts 1, 2 and 3 and select YARN 1 for belts 1 and 2 and select YARN 2 for belt 3.

ISO 3593_00_Display Operator Manual 58

 GROUPS
Groups must be created before shifts can be scheduled. After the groups are created, add the appropriate
knitters to each group.

Click on the setup menu then scroll down to groups.

Groups can be created and saved in this menu.

Start by selecting “New” then enter groups.

Example: Groups 1, 2, 3, 4 or A, B, C and D.

Use this window to organize knitters into shift groups. To create a new group, click ‘New’ and input the group name. It will appear
in the dropdown box. Add knitters to the group by selecting the group, then selecting knitters and clicking the ‘>>’ button. To un-
group a knitter, select a knitter and click the ‘<<’ button. To delete a group, select it and click ‘Delete’. All knitters in a deleted group
will be ungrouped.

Add/Edit Knitters
Click the setup drop down box and select Add/Edit Knitters.

ISO 3593_00_Display Operator Manual 59

 Add/Edit Knitters

Use this window to control the knitter database. Typed data must be saved by clicking ‘Save’. Knitters must
be added to groups to be scheduled in knitter sets. If no groups are selectable, or the desired group is not an
option, go to add/edit groups to create and modify groups.
Typed data must be saved by clicking ‘Save’. Knitters must be added to groups to be scheduled in knitter sets. If no groups are
selectable, or the desired group is not an option, go to Add/Edit Groups to create and Modify Groups.

When entering the knitters name and or ID number select the group that was created then check ‘Active’ and save.

If active is not checked the knitters name will not show up on the data base.

If the value of the knitter is Un-Know, then leave this window blank. This value will be determined by the work load of the machines.

Add/Edit Styles

All the fabric styles used on the Knitting Floor can be entered into the Fabric Styles Data-
base using this window. To create a style, you must have the style name, the number of
yarn types it uses, the stitch of each of those yarns, the type of each of the yarns and the
vendor of each yarn. Click ‘New’ to create a new style. After entering the style name, you
must populate the style data. Changes are saved automatically.
To send a fabric style to a machine, left-click the ‘Send’ button. The ‘Send Style’ window will be displayed. Select the machine (s)
that are scheduled for a fabric style change. Click the ‘>>’ button to add them to the list of machines to receive that style. Any ma-
chines mistakenly added can be removed by selecting them and clicking ‘<<’. Once you are satisfied with the list of selected ma-
chines, click ‘Send’ to populate the send style queue. These machines will be sent the new style next time they connect to the
server.

ISO 3593_00_Display Operator Manual 60

 Style Window

Add/Edit Yarn

Send Style Window

3.2.4 Add/Edit Vendors

Use this form to enter yarn vendor information including account number, address, phone number and notes. Data is saved auto-
matically as you type. To create a new vendor, click ‘New’. To delete a Vendor, select it and click ‘Delete’. These Vendors are used
to populate Yarn Vendor options in the style window.

ISO 3593_00_Display Operator Manual 61

 Add/Edit Vendors Window

3.2.5 Add/Edit PMs

Enter PM descriptions into this form to populate selectable PMs in the Add/Edit Machine Window. You must click ‘Save’ to save
typed data.

Add/Edit PMs

ISO 3593_00_Display Operator Manual 62

 3.2.6 Add/Edit Cycle
Use this window to pre-program cycles according to Table 1 below.

Figure 14: Add/Edit Cycle Settings

3.2.7 Add/Edit Knitters

Use this window to control the knitter database. Typed data must be saved by clicking ‘Save’. Knitters must be added to groups to
be scheduled in knitter sets. If no groups are selectable, or the desired group is not an option, go to Add/Edit groups to create and
modify groups.

Available Style Parameters

Parameter Name Range Description
Inspection Cycle 0 – 99999 Cycle counter that indicates to the Knitter to inspect the machine. If the
machine is not inspected by the second inspection cycle, the machine is
stopped and a missed inspection is counted.

Mid-Roll Flush 0 – 99999 The piece revolutions that the machine will begin the oil flush in the middle
of the roll.
Oil Flush Duration 0 - 99 The duration of an oil flush
Pre-Doff Clean 0 - 999 The number of revolutions before the end of the roll that the machine will
be stopped and the machine will display the Pre-Doff Clean message.

Pre-Doff Flush 0 - 999 The number of revolutions before the end of the roll that begins the end of
the roll oil flush.
Doff Revs 0 – 99999 The preset amount of revolutions in a piece.
Expected RPM 0 - 999 The expected RPM of the machine.
RPM Tolerance 0-9 The allowable amount of RPM tolerance.
Counts/12hr Shift 0 – 999999 The engineered amount of revolutions in a 12 hour shift.
# of Belts 1-4 Number of belts to measure the ravel.
Rate Tolerance 0-9 The allowable amount of ravel tolerance.
Belt #1 (in/r) 0 - 999 The expected ravel for Belt 1.
Belt #2 (in/r) 0 - 999 The expected ravel for Belt 2.
Belt #3 (in/r) 0 - 999 The expected ravel for Belt 3.
Belt #4 (in/r) 0 - 999 The expected ravel for Belt 4.
Max Defects/Roll 0 - 99 The maximum defects allowed per piece.

ISO 3593_00_Display Operator Manual 63

 3.2.7 Add/Edit Knitters

Use this window to control the knitter database. Typed data must be saved by clicking ‘Save’. Knitters must be added to groups to
be scheduled in knitter sets. If no groups are selectable, or the desired group is not an option, go to Add/Edit Groups to create and
Modify Groups.

Add/Edit Knitters Window

3.2.8 Add/Edit Fixers

Use this window to control the fixer database. This window operates similarly to the knitter window with the exception of groups.
Typed data must be saved by clicking ‘Save’.

3.2.9 Add/Edit Groups

Use this window to organize knitters into shift groups. To create a new group, click ‘New’ and input the group name. It will appear in
the dropdown box. Add knitters to the group by selecting the group, then selecting knitters and clicking the ‘>>’ button. To ungroup
a knitter, select a knitter and click the ‘<<’ button. To delete a group, select it and click ‘Delete’. All knitters in a deleted group will be
ungrouped.

Add/Edit Groups Window

ISO 3593_00_Display Operator Manual 64

 3.2.10 Shift Schedule
The ‘Shift Schedule’ window allows for the creation of a diverse plant schedule. The schedule is built in a modular format.

Extended Shift Planning Window

22 Begin by ‘building days’. Click on the ‘Build Day’ button. The day layout constructor is displayed. To create a new shift, click
‘New’. After entering the name of the day, you must enter the shift data. There can be up to four shifts in one day. If you only have 2
shifts, only select ‘Active’ on the first and second shift. Select the start and end time of each shift and the group of knitters that will
be working that shift. Finally, click on the day color to select a custom color for that day. Click ‘Save’ to save the day. To create
more days, click ‘New’ again.

Build Day Window

Now that we have build days, we can build Weeks with those days. From the main schedule window click the ‘Build Week’ button to
display the Week layout constructor. To create a new week, click the ‘New’ button. After naming the Week, you must populate the
Week with previously build days. Click ‘Save’ to save changes. If not every Week is the same, create additional Weeks. (If you are
on a four Week rotation, you will need four Weeks. If on a two Week rotation, you will need 2 Weeks.)

ISO 3593_00_Display Operator Manual 65

 Build Week Window

Now that we have build Days and Weeks, we can build four Week segments. Click on ‘Build Four Weeks’ to display the four Week
layout constructor. Similarly to building Days and Weeks, to create a new four Week layout, click ‘New’. If you are on a four week
rotation, select Week1, Week2, Week3 and Week4. If on a two Week rotation, select Week1, Week2, Week1 and Week2. Click
‘Save’ to save the layout.

Build Four Week Layout Window

Once the layouts have been constructed, return to the main schedule window and select the radio button beside the layout you
want to apply. Next select the number of consecutive layouts you want to apply. Finally click ‘Set’ to apply the layout. For example if
you want to set ‘Day1’ for 10 days, click the days radio button, select ‘Day1’ then input 10 into the number of days. If you want to
apply a 2 Week rotation for a Year, select the four Week radio button, select your four Week layout then input the number of four
Week periods in a year. (About 12) Hit set. You can even schedule for 10 years, just input 120 instead of 12.

After you have the general structure of your schedule, you can make small changes by double clicking on the day and altering it, or
selecting single or multiple days and clicking delete. Details about selected days are displayed below in the list box.

ISO 3593_00_Display Operator Manual 66

 4.2.6.3.5 Signal Start Val:

Choosing this option prompts you to enter a new value for the signal start value:

Input the value corresponding to the desires signal start value for auto calibration and press enter to proceed.

4.2.6.3.6 Gain Start

Choosing this option prompts you to enter a new value for the gain start value:

Input the value corresponding to the desires gain start value for auto calibration and press enter to proceed.

ISO 3593_00_Display Operator Manual 67

 4.2.6.3.7 Threshold
Choosing this option prompts you to enter a new value for the threshold value:

Input the value corresponding to the desired threshold value below which scanner values will not be displayed
during manual calibration.

4.2.6.4 Add Max. De-

Choosing this option displays a screen with the number of defects on the current roll of cloth:

If the number of max defects has been reached, this option will add 5 to the number of defects allowed for the
current roll. Otherwise, if the maximum number of defects per roll has not been reached, the screen only dis-
plays information about the current number of revolutions and defects in the current roll.

ISO 3593_00_Display Operator Manual 68

 4.3 Start Auto Cal.:

This option begins the scanner automatic calibration routine. By default, the scanner will automatically cali-
brate when each cloth roll has reached 200 revolutions without using this option. If that calibration fails, the
display will show a “Scanner Err.” fault. The cloth will need to be manually inspected for defects and after con-
firmation of good cloth, use this option to attempt calibration again.

4.4 Defect Type:

This option is only visible in the place of auto calibration when a defect has been detected and the machine
has stopped:

Choosing this option gives access to the fabric defect type menu:

Input the value corresponding to the observed defect and press enter to proceed.

ISO 3593_00_Display Operator Manual 69

 5 Faults:
YRM X INCORRECT – “X” can be 1-4. Ravel length on belt number “X” is outside of tolerance.
OVER TEMP. – Machine temperature exceeds set point. (See 4.2.5 Temperature)
SCANNER ERR. – Scanner returning an error. Possible failed calibration. (See 4.3 Start Auto Cal.)
NO OPERATOR LOG – There is no knitter logged into the machine.
SER.STP.PM/OTHER – The server has stopped the machine, possibly for periodic maintenance.
PRE-DOFF CLEAN – The machine has been stopped to allow for pre-doff cleaning.
NO COUNTER PULSE – The machine is running but is not receiving counter pulses.
NO FIXER LOG – There is not fixer logged in to repair a declaration.
MISSED INSPECT – The number of revolutions for inspection has been doubled and the machine must now
be inspected.
DOFF MACHINE – The cloth roll is complete and is stopped for doff.
INSPECT MACHINE – the number of revolutions for inspection has passed and the machine should now be
inspected.
TOO MANY DEFECTS – The number of defects in this roll of cloth has exceeded the maximum allowable
number of defects per roll for this style. (See 4.2.6.4 Add Max. Defects)
FABRIC DEFECT; ENTER DEFECT– The scanner has detected a fabric defect and must be entered. (see 4.4
Defect Type)
NO COM LINK – The panel has no established com link with the machine.
PRESS STOP P.B.; FOR RESET – The stop button must be pressed to reset the machine.
FILTER FLOW FILTER CLOGGED – The machine air filter is clogged.
JOG P.B. FAULT – The jog push button has faulted and must be reset. Press and release button to proceed.
START P.B. FAULT - The start push button has faulted and must be reset. Press and release button to pro-
ceed.
STOP P.B. FAULT - The stop push button has faulted and must be reset. Press and release button to pro-
ceed.
NO H24VAC POWER – The machine is not being supplied with high current 24 volt power.
NO 24VAC POWER – The machine is not being supplied with low current 24 volt power.
INVERTER FAULT – The inverter is faulting.
COWLING OFF – The machine’s cowling is not detected. Replace cowling to proceed.
TAKE/UP FAULT – Take-up rail arms are not latched correctly.
GATE IS OPEN – A machine gate is open. Close all gates to proceed.
LOW AIR WARNING – Machine is not receiving sufficient pressure from compressed air.
LOW OIL WARNING – Machine is not receiving sufficient oil flow.
NO RUN SIGNAL – Machine is running but not receiving a run signal.
CLOTH DETECTOR – The cloth detector has been tripped. Confirm cloth is rolling in take-up correctly.
NEEDLE DETECTOR –Needle detector has tripped.
FEEDER INPUT – Feeder input detector has tripped. Check for a yarn break before feeder.
FEEDER OUTPUT – Feeder output detector has tripped. Check for a yarn break between feeder and ma-
chine.

ISO 3593_00_Display Operator Manual 70

 Scanner Status

Fabric Scanner Status

On the main screen the fabric scanner status will be displayed.
SCN: DIS = Fabric Scanner is disabled.

SCN: USER = Fabric Scanner has been manual set (Auto-calibration was not used)

SCN: KNIT = Fabric Scanner is waiting for the machine to run so that the auto-calibration can start or con-
tinue.

SCN: X = The “X” will rotate during auto-calibration.

SCN: OK = The Fabric Scanner has completed the auto-calibration and is monitoring the fabric.

SCN: ERR! = The Fabric Scanner is not communicating to the machine. Check the wiring of the Fabric
Scanner head.

6 Appendix A – VPL fabric scanner settings:

VPL Fabric Scanner Settings

Single Knit Double Knit

SETPOINT 126 126

CAL. MIN 90 90

CAL MAX 95 95

SIGNAL START VAL. 30 26

GAIN START VAL 10 7

THRESHOLD 85 85

ISO 3593_00_Display Operator Manual 71

 This Page Intentionally Left Blank

ISO 3593_00_Display Operator Manual 72