ATHENA AQUACHRON 2G SYSTEM

SCLAVOS
ATHENA AQUACHRON 2G DYEING MACHINE

AQUACHRON 2G CONTINUOUS RINSING SYSTEM & CONTROLLER

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CONTENTS
1. 1.1. 1.1.1. 1.1.2. 1.1.3. 1.1.4. 1.1.5. 1.2. 1.2.1. 1.2.2. 1.2.3. 1.2.4. 1.2.4.1 1.2.4.2 1.2.4.3 1.2.4.4 1.2.4.5 1.2.4.6 1.2.4.7. 1.2.4.8 2. 2.1 2.2 2.2.1 3. 3.1.1. 3.1.2. 3.1.3. 3.1.4. 3.2. 3.3

ATHENA AQUACHRON 2G
INTELLIGENT TWIN SOFT FLOW What is the Twin Soft Flow System How does the Twin Soft Flow (TSF) System work? Elbow Plaiter Liquor By Pass High Volume Low Pressure Pump AQUACHRON 2G Automatic Machine Settings Continuous Flow Dosing Smart Liquor Ratio AQUACHRON 2G AQUACHRON 2G Components and Parameters Wash Temperature Gradient / Min Lt / min / chamber Litres / Kg Wash Level Water Type Salt (gr / lt.) 3 3 3 3 4 4 5 5 5 6 6 7 7 8 8 9 10 10 10

ATHENA CONTROLLER-SCLAVOS 5500

General Features Controller Multi Screen Functions Menu 11 11 13

CREATING A PROGRAM FOR ATHENA

List of functions Options of Algorithms List of Chemicals Create a new program QUICK PROGRAMMING REFERENCE GUIDE TYPICAL ATHENA AQUACHRON 2G PROCESS-COTTON 100% CONTROLLER PROGRAMMING CONTROLLER PROGRAM STEPS FOR COTTON 100% 14 15 16 16 17 18 21 21 27 27

4. 5.

RUN A BATCH IN ATHENA MODIFICATIONS DURING RUNNING A BATCH

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1. ATHENA AQUACHRON 2 1.1.

ND

GENERATION (2G)

INTELLIGENT TWIN SOFT FLOW

WHAT IS THE TWIN SOFT FLOW SYSTEM? This is a worldwide patented fabric transport and storage dyeing system, which represents a totally new concept in dyeing via the use of two soft flow nozzles and a unique plaiting system. HOW DOES THE TWIN SOFT FLOW (TSF) SYSTEM WORK? Water flow is equally distributed from the main water inlet to the two nozzle outlets. Due to the design of the nozzles, the water pressure is significantly reduced before the contact of the bath with the fabric rope. As the water flow is equally distributed to each nozzle, the pressure of water is also equally divided, ensuring that the fabric passage through the TSF is uniform and without tension. This is important because if the water pressure from the two nozzles was not equal, i.e. the second nozzle having greater water pressure than the first one, then the fabric would be pulled causing mechanical abrasion i.e. pilling, excessive tension. Because of the twin nozzle's configuration and design, the water pressure in each nozzle is half of the pressure delivered from the pump. In a single nozzle machine, after the fabric leaves the nozzle, it decelerates and, in order to maintain the fabric speed, the pressure of the nozzle has to be increased. In the TSF, this is overcome by the fact that the fabric comes in contact with the liquor at two different points along its path. Therefore, after the fabric leaves the first nozzle, it joins the water flow of the second nozzle. In this way, the natural deceleration of the fabric after it exits the first overflow is eliminated as the fabric reaches the second overflow. The new reel design is effectively improving the running behavior of the fabric. The new reel due to its big diameter is embracing the fabric, eliminating any slipping effects to the minimum. Consequently, high fabric speeds can be achieved at very low inlet water pressures (maximum of 0.3 bar at maximum speed of 320m/min.). Speed and smoothness of the fabric movement can be adjusted to meet the requirements of virtually any type of fabric. Hence, special fabrics such as synthetics and their blends with lycra can be processed as effectively as cotton, without any pilling or crease mark problems. Moreover, higher speed facilitates the processing of lighter fabrics. This leads to a significant reduction in mechanical abrasion on the surface of the fabric as well as, 100% increase in liquor and fabric interchange, resulting in safer dyeing conditions and reduced dyeing times. Unlike other systems, the nozzles of the TSF System do not have to be changed or to be altered in any way to accommodate particular types of fabric. All fabric weights and constructions, whether in body or trim form, knitted or woven, heavy or light, can be processed even in the same rope without altering any part of the TSF System of the machine. ELBOW PLAITER Correct storage and fabric placement in the J-Box is one of the most important elements in reducing tension and creasing of fabric and ensuring a smooth tangle free operation throughout the process. There must be no built up of fabric in one place and no vacant areas in the chamber into which the plaint fabric can fall. On the other hand the undisturbed storage of the fabric in the J-Box, is crucial for

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avoiding any surface quality issues especially in synthetic fabrics. To accomplish this, SCLAVOS designed a low speed plaiting system that uses the entire width of the JBox thus eliminated blind parts and therefore the possibility of entanglement. The Elbow Plaiting system plaits the fabric precisely and predictably revolution by revolution. The swinging motion is synchronized with the fabric speed allowing the plaiter to plait from 0 to 11.6 full strokes per minute. Therefore, the fabric is plaited precisely at low speed and it is stored in an orderly way. Due to the unique design of the elbow plaiter and the wide rectangular section at the end of the Elbow Plaiter, a further reduction in the twist effect of the fabric is achieved. The correct placement of the fabric at the back of the J-box ensured the smooth traveling of the fabric at the front part with, only the weight of the fabric, resulting the tensionless lift of the fabric from the reel. LIQUOR BY PASS The plaiter incorporates liquor by pass that directs large amount of the dye bath away from the J-Box and the stored fabric. Consequently, prevents interference of the surface and ensures orderly storage of the fabric, eliminating crush marks. Furthermore, it increases the liquor circulation, since the by passed liquor can return directly to the pump for re-circulation and does not have to 'be filtered' through the stored fabric. This condition is rather important especially during the dyeing process (dosing, heating, cooling etc.) and, of course, any other process that could affect the fabric quality. HIGH VOLUME LOW PRESSURE PUMP The special pump design permits a high volume liquor flow, with complete bath circulation in maximum 45 seconds, at low operating nozzle pressures of 0.07 to 0.3 bar. This high volume circulation via the intensive zones, means that the liquorfabric contacts at a given fabric speed are much more than in other machines and, therefore, level dyeing can be achieved at relatively low fabric speeds. This is a major advantage in the dyeing of delicate fabrics. In both intensive zones, the liquor spray interacts with the fabric with sufficient intensity to break the boundary layer of liquor carried by the fabric. This causes much greater liquor-fabric interchange on every revolution of the fabric. Conversely, the high liquor to goods interchange can be used to shorten the dyeing processes. At high fabric speeds, the rates of temperature change can be increased without impairment of levelness.

T W IN

S O F T

F L O W

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All the above enable the processing of very light and sensitive fabrics, such as 100% cotton, cotton blends, wool, elastomerics etc. at low liquor ratios with an unmatched leveling.

1.2 AQUACHRON 2G
Aquachron 2G is the culmination of SCLAVOS dyeing technology, built-in in ATHENA. Aquachron 2G is a self-thinking system providing global control over the dyeing process. Aquachron 2G receives the batch parameters as input and provides the optimum dyeing environment, by automatically tuning all the machine settings, including pump, TSF, reel, plaiter, cycle-time and WR Rinsing (washing parameters). ATHENA equipped with Aquachron 2G provides always the same optimum dyeing conditions. The Dyer does not need to worry about tuning the dyeing machine any more, since ATHENA with Aquachron 2G is automatically tuned. He can concentrate on the chemical process, since ATHENA will always be performing in the same manner. ATHENA with Aquachron 2G can guaranty constant fabric treatment conditions irrespective of loading throughout the loading range resulting in batch-to-batch reproducibility and shade matching. 1.2.1. AUTOMATIC MACHINE SETTINGS This is a unique and totally new concept and can not be found in any other dyeing machine. The main objective of the auto-settings is the optimization of the fabric treatment and dyeing conditions for each fabric quality and loading, in order to achieve batch to batch reproducibility, shade matching and top quality dyed fabric throughout the loading and fabric-type range. The only required parameters for the machine is the Fabric weight the LR and the weight per linear meter. Then the machine calculates and applies throughout the batch the optimal reel and pump operating conditions and consequently the plaiter strokes. 1.2.2. CONTINUOUS FLOW DOSING ATHENA is especially equipped with Continuous Flow Dosing that is an analogue dosing system developed by SCLAVOS, which secures the even application of the dosing liquor to the fabric. The pre-dissolved in the side tank(s) chemicals or dyestuffs are transferred into the inlet of the main pump suction nozzle, at a continuous, adjustable and precisely controlled flow rate. The result is an efficient dilution of all additions before their interaction with the fabric as well as an instantaneous distribution in the process bath. Further more, the system provides the ability of continuous dosing in a large variety of dosing curves (e.g. linear, progressive and digressive) according to the dyers needs. The side tanks can now work either independently or linked together during dosing. This means that in case of a very large quantity of dyestuff where one side tank is not enough for proper dilution, the two (0,5 LR each) side tanks can be used and analogue dosing of the content of both tanks at the same time can be performed. It has to be mentioned that if the reel for any reason is stopped, dosing stops also automatically for better protection of the fabric in case of entanglement.

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1.2.3. SMART LIQUOR RATIO ATHENA calculates through SEDOMAT Controller the LR (initial and addition of dyes and chemicals) according to the batch loading. The water quantity used for the dilution of dyes and chemicals throughout the process has to be calculated with the maximum possible accuracy in order dyeing LR to be kept within certain narrow limits. That is why an analogue level sensor system has been installed in each of the two side tanks. The machine automatically calculates the amount of water needed, without any operator involvement. This system uses an algorithm based on the load capacity of each particular batch. As a result, the quantity of liquor inside the machine and the final LR can be calculated even before the loading of the batch with up to 1% accuracy. This calculated LR is recorded and presented continuously in the screen of the SCLAVOS controller. 1.2.4. AQUACHRON 2G With water becoming more of a valuable commodity, together with increased labor costs and overheads, water management is becoming extremely important. Industry is mainly focused on saving both water and time in order to reduce costs, increase productivity and meet the challenges of ever-increasing legislative pressures as well as foreign competition. The two basic methods for washing off a fabric are the classical drain-fill method and the continuous rinsing method, with the later providing superior quality and being the ideal for every one, but difficult to manufacture and control. SCLAVOS has been a pioneer in this subject by introducing AQUACHRON, the first efficient and fully controllable in all aspects continuous rinsing system. After extended research and development and using the experience gained from the application of AQUACHRON, SCLAVOS has surpassed the needs of industry by introducing the AQUACHRON 2G. ATHENA is able, without human interference, to monitor, control and interact with all process parameters ensuring guaranteed reproducible results irrespective of the loading. Two of the new main features are the very low volume of remaining contaminated bath during rinsing down to 300lt/port and the water consumption calculation in terms of LT of water per KG of fabric which makes easy to standardize the rinsing process irrespectively of the batch loading. AQUACHRON 2G allows the entire process from loading to unloading to be performed without stopping either the liquor or the fabric circulation. AQUACHRON 2G does not aim to modify either the bleaching or dyeing process in order to obtain savings, but concentrates on rinsing, where most time and water is consumed during processing. By using the simple techniques described in this manual, AQUACHRON 2G is easily implemented and the advantages of the system can be immediately realized. There after, the customer is free to experiment and to fine-tune the process for maximum profitability.

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1.2.4.1 AQUACHRON 2G COMPONENTS & PARAMETERS AQUACHRON 2G uses several components and parameters in order to function. A major component of the system is the "TWIN SOFT FLOW SYSTEM" and the "EXCESS LIQUOR BY-PASS". During AQUACHRON 2G the fresh water entering the vessel is channeled via the heat exchanger and arrives directly at the two soft flow nozzles where maximum interchange between the water and the fabric takes place. AQUACHRON 2G controls the flow rate of incoming water in order to achieve maximum effect with minimal wastage. Large amount of bath within the "TWIN SOFT FLOW SYSTEM" is then channeled through the "EXCESS LIQUOR BY-PASS". This ensures that the fabric will not be decontaminated by the bath and allows a portion to be siphoned off to the drain. AQUACHRON 2G controls the drain rate to ensure that bath level is maintained at the minimum without stopping the pump running. The benefit of maintaining pump circulation is that, incoming fresh water is able to pass through the heat exchanger. AQUACHRON 2G enables to preheat the incoming water to the desired process temperature, regardless of flow rate and incoming water temperature, before the water arrives at the fabric. In this way, quality problems, which may arise due to thermal shock, are avoided and the ideal fabric environment is always obtained. Rinsing can therefore take place without cooling, draining, filling and re-heating the liquor, thereby considerably reducing process times. Besides, being able to rinse whilst maintaining the temperature, AQUACHRON 2G enables the rinsing with cooling gradient. This dual-purpose function does not only save time but also allows more rapid cooling to be achieved, especially at lower temperatures. The operation of AQUACHRON 2G is controlled by two functions: The AQUACHRON 2G RINSING and the AQUACHRON CTRL function. The parameters of the function A AQUACHRON 2G RINSING are the following: Wash temperature Gradient / min Lt. / min / chamber Liters/kg Salt AQUACHRON CTRL are the following: The parameters of the function A Wash level Water type AQUACHRON 2G RINSING The dyer can modify all parameters when creating A commands. 1.2.4.2 WASH TEMPERATURE Total temperature control is achieved during the AQUACHRON 2G rinsing. In other words, the set temperature is maintained throughout the whole AQUACHRON 2G process, regardless the steam supply of the factory. It is clear that the rinsing effect can be improved at high rinsing temperature.

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AQUACHRON 2G enables cooling at a set temperature according to a specific gradient. Normally the set temperature is programmed with a value either to maintain the current temperature or to cool to a lower one. AQUACHRON 2G can be performed at temperatures up to 105C, when special conditions exist, otherwise, at 95C. It is important to point out that, in case of set temperature 0C the AQUACHRON 2G is controlled only by the calculated amount of water. This amount of water is calculated by internal calculations and the parameter LT/KG which is explained below. In other words, the AQUACHRON 2G will be executed for as long as required to consume the defined amount of water, irrespectively of the temperature achieved. 1.2.4.3 GRADIENT /MIN AQUACHRON 2G can be also executed during the cooling step. Having selected a gradient, AQUACHRON 2G will be performed achieving the required gradient control. The ability to maintain the programmed gradient during cooling depends on the following factors: At higher machine temperatures the ability to cool the machine is greater whilst at lower temperatures it is reduced. That means, by which cooling is obtained, is from the rinse water entering the machine. Therefore, the two major factors, which will affect cooling, are the flow rate and the temperature of the water that enters the machine. 1.2.4.4 LT / MIN / CHAMBER This parameter sets or calculates (in the case that algorithm has been used) the desired flow of the rinse water entering the machine. The programmer can insert the volume of lt./min/chamber and, according to the number of chambers, the required flow in lt/min is calculated. Since the supply of the water for AQUACHRON 2G RINSING is through the main supply pipe of the machine, the capability of the AQUACHRON 2G RINSING water flow is practically limited only from the factory supplies. The general idea is that since we know the required amount of water for each AQUACHRON 2G RINSING step, then the higher is the water flow the less is the process time. As a general rule the following values should be used. 180-200 lt./min/chamber (as a higher value), when the factory has hot water or the machine is equipped with SHR and very good steam supplies. 150 lt./min/chamber (as a lower value), when there is no SHR or the steam supplies are simply satisfactory.

Other intermediate values of water flow are also valid depending on the specific conditions of each dye house. In case of simultaneous cooling and rinsing the algorithm option should be used. In that case the total required amount of water is calculated using batch weight and Liters/Kg. According to the required gradient the machine calculates the time

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needed to get to the required temperature and the flow of water is adjusted automatically. It is clearly concluded that the higher the flow rates the more efficient the AQUACHRON 2G process, resulting in the decrease of the total rinsing time. However, the controller can vary the selected flow rate during the AQUACHRON 2G. In cases that the steam supply is not sufficient to heat the incoming water up to the set temperature, resulting in temperature drops, the controller decreases the flow rate of the incoming water in order to maintain the set temperature. By setting the new flow rate, the controller checks, within a default time, whether the temperature is controlled to the target (set temperature). If, although the decreased flow, the temperature can not be set to the target, then the flow rate is reduced again. The checking is repeated. In case that, even now, the temperature can not be set to the desired one, then the controller pause the function by closing the associated Aquachron valves unless the temperature achieve the programming target. When the flow of the incoming water is less than the desired one, then the controller increases the flow in order to reach the first selected flow, where at the same time maintains the temperature. The return to the desired flow is achieved by gradual open of the valve. 1.2.4.5 LITERS / KG In this step, we introduce the number of LITERS of water per KG of fabric that we have decided it would be consumed within the whole AQUACHRON 2G RINSING step. This is one of the key parameters of AQUACHRON 2G RINSING and secures the repeatability of the rinsing stages no matter what are the fluctuations of the water and steam supplies and the batch loading. Of course it is clear that by having constant and high water and steam supply, there will be no need of process prolongation. This parameter is used for calculating the total amount of water to be consumed by using internal calculations and the batch weight. If for example we dye in ATHENA 250, 240 kg of fabric and the parameter Liters/Kg is 10 then the total water consumption would be 2400 liters. For the same fabric, shade and program but 180 kg of fabric, we should keep the same value for the parameter Liters / Kg, 10. Then the total water consumption shall be 1800 liters, and we get the same quality results avoiding increased water consumption. The main benefit here is that we get repeatable results from batch to batch without having any having any consequences on the process control e.g. different pH values. Regarding the required volume of water for AQUACHRON 2G step, this depends on the purpose of the rinsing process. In the following pages, two characteristic examples are presented as guidelines to the way a program in ATHENA should be built (see chapter 2.3.1, From process diagram to structured program). Along with the AQUACHRON 2G parameters already described, there are also some other factors important for the operation of the AQUACHRON 2G process.

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These factors are included in the A AQUACHRON CTRL function (see Parallel functions, p.20) and have as follows: Wash level Water type

1.2.4.6 WASH LEVEL Significant savings in water can be achieved by setting the proper conditions during rinsing. One of them is the water level of the machine. In case of ATHENA machine, where we never drain, we need to minimize the contaminants circulating in the machine, taking into consideration the minimum pump operating level. The recommended minimum pump operating level for AQUACHRON 2G is as follows: MINIMUM LEVEL Units (LU) WITH PUMP RUNNING

TYPE OF MACHINE ATHENA AQUACHRON 2G

1 300

2 600

CHAMBERS 3 4 900 1200

6 1800

100

So, during AQUACHRON 2G, the machine will automatically drain (without stopping the fabric revolution) and will maintain the aforementioned machine levels throughout the AQUACHRON 2G process, resulting in significant savings in time and water consumption. 1.2.4.7 WATER TYPE According to the factory supplies, two or more options appear on this parameter. These could be soft cold, soft hot, hard or blend water filling. In case of blend filling, it is possible to choose the temperature of the incoming water used during AQUACHRON 2G 1.2.4.8 SALT (GR/LT.) Specially for reactive dyeing the A AQUACHRON 2G RINSING step for removing the salt from the dye bath, can be precisely controlled using this parameter and the conductivity measuring system supplied by SCLAVOS. The conductivity systems measure the conductivity of the dye bath in ms/cm. So if we introduce a value in this parameter (different than zero), then AQUACHRON 2G RINSING will end irrespectively with the total water consumption at this moment and provided of course that the target temperature has been reached. Please note that the A AQUACHRON CTRL function should always be programmed along with the AQUACHRON 2G RINSING function.

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2.

ATHENA CONTROLLER-SCLAVOS 5500

2.1 GENERAL FEATURES

SCLAVOS Sedomat 5500 controller is based at Windows CE operating system, with 12.1 TFT colour display 800x600 pixels, touch screen and internal PLC with PROFIBUS DP world wide accepted standard field bus for the connection of automation components like remote PLC I/O boards. Windows CE is a robust operating system tailored for industrial applications. This system is suitable for machine control against any computer virus and Trojans. Controller offers a windows user interface with icons for a simple and intuitive programming operation. Animated multi screens of the machine improve the process overview. A graphical user interface consist a user friendly and simple operation, with touch screen soft buttons for manual control of the machine peripherals, like addition tanks and the dry salt system (optional). It is compatible with SM5000 dye programs. All alarms and pre-defined operator messages are displayed in text format. Several system text languages and character sets (e.g. Spanish, Chinese) are supported. It is equipped by USB interface for inexpensive devices like memory stick, for copy/save dye programs, batch history (curves) and machine backup data. It use Ethernet TCP/IP network for link to SedoMaster central system.

2. 2 CONTROLLER MULTI SCREEN

Switching on the ATHENA machine with the main power switch, the controller will also be activated. It will be necessary to wait for a few seconds while the controller initializes and the machine graph (see page below) appears on the screen. This is the main screen of the controller (for HT or AT machine) and will be referred to as the Main Machine Screen throughout this manual. The main screen represents the machine including some touch screen buttons which you can focus to several animation screens like graphic display showing the fabric dye cycle, the Liquor Ratio, the water consumption, the flow into pipes and the status of the valves. Further informations are displayed at the top of the screen in the so-called Status Area. The status area is always updated and gives the following information: 1. 2. 3. 4. 5. Status of the program. Batch identification. Number and name of the program being executed. Alarms and operator messages. Process values like actual and theoretical machine temperature, remaining time for the active step, total water consumption, LR recording.

For further details please refer to the SM5500 User manual. Below they are showed some screens of the mentioning controller.

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ATHENA AQUACHRON 2G SYSTEM

SM5500 ATHENA ATMOSPHERIC Main Screen

SM5500 ATHENA HIGH TEMPERATURE Overview Screen

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2.2.1 Functions Menu

Along the bottom and right side of the screen, the available choice menu is listening in some touch screen function keys. The functionality of these keys is described in the SM5500 user manual. A short explanation is given below:

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3.
3.1.1

CREATING A PROGRAM FOR ATHENA

LIST OF FUNCTIONS

The process curve in diagram form (temperature vs time) is commonly used to describe the steps of the process that will be followed. The process curve is used irrespectively of the machine type. This type of diagram can be easily understood from all the dyers. The important point is to change the process curve into controller functions so that the process curve to be executed exactly with the way presented in the diagram. In order to create the basic program steps, the dyer has to be fully aware of the functions and parameters of the ATHENA SCLAVOS controller. The description of the functions available can be readied at the General Guide to Machine Functions section including in this manual. The list has as follows1:

Main Filling Draining AQUACHRON 2G RINSING Heat / Cool Hold time Save L:R Recall L:R

Parallel Prepare Tank Control Off Fill Add Tank Dosing Tank Transfer Tank AQUACHRON CTRL Cycloclean Recirculation Tank Heat Tank (Un)load Salt Prepare (optional) Salt Transfer (optional) Salt Pump Clean (opt) pH Adjust (optional) pH Check (optional)

Data Pump Speed Reel Speed pH monitor (optional) VAT Dyeing Prepare Prod. Wait Prod. Check Prod.

Special Prog. Start Prog. End Operator Call Label Funct Jump Next Batch

It must be mentioned that the Main, Data and Special functions are inserted in the first column. As far as the Parallel functions are concerned, these are inserted in the three parallel columns. Please note that in the Operation Manual General Guidance, all the aforementioned functions are analytically described. In case that the machine is equipped with second additional tank, the relevant tank functions are presented, similar to the ones already mentioned for the first additional tank. Optional functions like pH or Salt functions are operational when the suitable equipment support the machine. VAT dyeing function is available only for HT machine.

In the machine screen, the special functions are not included on the list. However, they are presented here so that, to have a complete list of the available categorized functions.

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At Operator Call step, the operator can proceed to load/unload, check pH, seam detect, manual transfer of salt etc. During Unloading, when the associated Function Stop is programmed (seam one by one or All seam detection), then Seam Detector can also be activated and the machine automatically search to find the seams. 3.1.2 OPTIONS OF ALGORITHMS

Although the analysis of the algorithms is done in SM5500 User Manual, it is important to describe the options of algorithms that have been developed for ATHENA machine and which functions accept algorithms. These are the followings:

FUNCTION FILLING FILL TANK1 AQUACHRON 2G RINSING AQUACHRON CTRL FILL TANK2 PUMP SPEED REEL SPEED HOLD TIME DOSING T1 DOSING T2

ALGORITHM Fill Alg - Liters Add 1 Level Level AQUACHRON lt./min/port 2G FLOW Flow

AQUACHRON 2G RINSING Level Wash Level Add 2 Level - Level Pump speed - % Speed - Meters / min Cycles - Time (minutes) Cycles Dos 1 Time (minutes) Cycle Dos 2 Time (minutes)

Every algorithm includes a number of calculations using the batch information introduced at the beginning of the batch. In the ATHENA operational manual, where an analytical explanation of all the functions is done, the calculations used for each of the above mentioned parameters are clearly analyzed. In case that the algorithm option is preferred, choose the relevant option of the function. After selecting it, the relevant box will be updated automatically. A good example of how important the use of the algorithms in the program could be is the control of the water in the side tanks during the process. For example, at the beginning of each batch, we have to calculate the quantity of the water that will be introduced from the additional tanks for the process. That comes to be a nightmare, considering that it is depended on the loading and the machine capacity, whereas the operator interference is critical. The function of the algorithm command is as follows: you introduce the required coefficient, which takes values from 1 to 5. This number is divided, automatically, by 10 and multiplied by the loading of the batch. The result of these calculations is the quantity of water (fresh or run back) in liters that will fill the additional tanks. With this automatic and simple way, you can create a program that can be easily copied in the other machines, irrespective of the machines size and with no need to change any parameters of the program.

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3.1.3

LIST OF CHEMICALS

The following list of chemicals is the one developed for the users of ATHENA machine. Please note that the machine user can not change the list presented below. It is only an authorized person by SCLAVOS that can do any changes required by the customer.

EDIT MACHINE FUNCTION / PREPARE ADDS MESSAGE : CHEMICALS 1. Chemicals 2. Salt 3. Detergent 4. Silicon 5. Fixer 6. Dyes 7. Acid 8. Sequesterant 9. Soap 10. Wetting 11. Soda 12. Alkali 13. Softener 14. Detergent / Sequesterant 15. Peroxide Killer 16. Wetting / Sequesterant 17. Perydrol 18. Hydrosulphit 19. Scouring 20. Ammonium 21. Stabilizer 22. Chlorine 23. Caustic 24. Carbonate 25. Bisulphite 26. Dispersing 27. Chemical 1 28. Chemical 2 29. Chemical 3 30. Chemical 4 31. Chemical 5 32. Chemical 6

3.1.4

CREATE A NEW PROGRAM

There are three (3) program groups: PROCESS (Main Programs). TREATMENT (Sub Programs). ADDITION (Addition Programs). In regards to the difference of the aforementioned kinds of programs, please refer to the SM5500/2500/1800 User manual. When we select the edit screen, it automatically defaults to the Main Program section. Having selected the type of the program you want to work with, please proceed to the program creation, as this is described in the SM5500/2500/1800 User manual, Entering a program. Insert the relevant functions in order to create the program according to the process curve.

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3.2

QUICK PROGRAMMING REFERENCE GUIDE

Start from the main machine screen.

Having completed the information, press Execute. Automatically, the beginning of the program will appear on the screen. Insert the required functions according to the instructions given in SM5500/2500/1800 User manual. FROM PROCESS DIAGRAM TO STRUCTURED PROGRAM The procedure on page 18 is an actual process for cotton fabric 100% run on a ATHENA T2 (500 kg) machine and will be used as an example throughout this section to explain how to structure a program using AQUACHRON 2G RINSING. The machine is equipped with two additional tanks Dry Salt System and SCLAVOS Heat Recovery System. Both the bleaching and the dye cycle are according to the customers existed processes. By using AQUACHRON 2G RINSING, no modifications should be done to those parts of the process or furthermore to the desired LR, in order to achieve significant savings in both time and water. The recipe is the following: Drimarene Yellow HF-R Drimarene Red HF-3B Glauber Salt 80 gr/lt Soda Ash 5 gr/lt. Caustic flakes 1.15 gr/lt 0.54% 3.0%

This is a typical process for cotton 100% fabric dyed to brilliant RED shade (Prebleaching, dyeing, and rinsing with open width 178 cm and 165 gr/cm2. In the following pages, you can see the process curve (temperature vs time) as well as the step by step with the total process time. According to this diagram, the structured program is created in chapter 3, Controller programming, p29.
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ATHENA AQUACHRON 2G SYSTEM

TYPICAL ATHENA Aquachron 2G RINSINGPROCESS-COTTON 100%

Step 1 P r e b l e a c h i n g 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Process Filling Machine 1:5 Heat to 60C with max. Rate While transf. Aux. (Fresh 1:0.2) And Load Fabric Hold Time Save L.R Heat to 70C with max. Rate While Transfer Caustic (Runback 1:0.2) Heat to 95C with max. Rate While Transfer Peroxide (Fresh 1:0.2) Hold Time Cool to 90C with Rate 2/min AquaCron 2G Rinse to 55C( rate 4C/min ) with 6Lts/Kg Recall L.R Hold Time while Transfer Acid Hold Time while Transfer Killer Check Peroxide Heat/Cool to 60C with max. Rate while transfer Auxiliaries (Fresh 1:0.2) Hold Time While Transfer Salt Dose Dyes Linear (Fresh 1:0.4) Hold Time Dose Alkali Progress 3 (Fresh 1:0.4) Hold Time Operator Call Sample AquaCron 2G Rinse to 60C With 3Lts/Kg Recall L.R Hold Time While Transfer Acid (Fresh1:0.2) Check Ph Heat to 80C With max. Rate AquaCron 2G Rinse to 80C With 8Lts/Kg Recall L.R Heat to 95C With max. Rate While Transfer Soap (Fresh 1:0.2) Hold Time AquaCron 2G Rinse to 85C( rate 2/min )With 9Lts/Kg AquaCron 2G Rinse to 70C( rate 3/min )With 3Lts/Kg Draining Filling Machine 1:2 With Control OFF Hold Time While Run Cycloclean Seams Detect Unload Draining PROGRAM END Step Time Run Time Temp (Min) (Min) (C) 3 6 6 1 2 5 20 3 9 1 6 10 2 1 10 20 15 40 40 5 5 1 7 3 4 11 1 3 8 13 5 3 3 3 5 10 3 3 9 15 16 18 23 43 46 54 55 61 71 73 74 84 104 119 159 199 204 209 210 217 220 224 235 236 239 247 260 265 268 271 274 279 289 292 292 30 60 60 60 70 95 95 90 55 55 55 55 55 60 60 60 60 60 60 60 60 60 60 61 80 80 80 95 95 85 70 50 50 50 50 50 30

D y e i n g

R i n s i n g

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ATHENA AQUACHRON 2G SYSTEM

100

Process Diagram 100% Cotton

90

80

70

Temperature

60

50

40

30

20

10

PreBleaching

Dyeing

Rinsing

20

40

60

80

100

120

140

160

180

200

220

240

260

280

300

AquaChron 2G

Time (min)

Process 292 min

Hereafter there are some tips for this particular batch: According to the fabric characteristics, the automatic settings will adjust the reel speed to 285 m/min and the pump to 95%. The cycle time shall be 3 minutes. During the different steps of AQUACHRON 2G RINSING the water level inside the machine was adjusted to 400lt/port and the flow of fresh water used was: Step 9: Step 22: Step 28: Step 32: Step 33: 180 lt./min/chamber 150 lt./min/chamber 180 lt./min/chamber 180 lt./min/chamber 150 lt./min/chamber

This was a typical pre-bleaching process. In order to structure the rinsing processes during pre-bleaching you need to keep in mind the operational temperature of the peroxide killer and of course the temperature that dyeing starts. In the example used in this section, the peroxide killer was an enzyme which can be used effectively between 40 and 60 C. Since the dyeing temperature was 60 C we performed AQUACHRON 2G down to 55oC (step 9) and then added the enzyme. Another two important tips is that generally the action of the enzymes is not affected by the salt and if they remain in the dye bath, the dyestuffs are not influenced. These two points are reflected in the steps 12 to 16 of the process.

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ATHENA AQUACHRON 2G SYSTEM

At the end of the dyeing, the rinsing process starts. The rinsing time needs to be adjusted according to the depth of shade and, therefore, the concentration of the electrolyte in the bath. After soaping, in the conventional method, we would use drop/fill process. In ATHENA 2 we use AQUACHRON 2G RINSING, a continue process without intermediate drop and fill. In contrast to the conventional method AQUACHRON 2G RINSING process has the following advantages: a) Faster processes due to more efficient washing effect and elimination of drain, fill, heating and cooling time. b) Less water consumption due to the continuous washing process in a low liquor Ratio at the optimum temperature for each AQUACHRON 2G RINSING step which ensures better water utilization. c) Better fabric quality, due to absence of stoppages for drain-fill, which results to temperature shock effects. d) Precise calculation of water consumption. e) No need for special adjustments, as the system is automatically set and controlled. f) Less energy consumption. The use of CYCLOCLEAN II is recommended in order to keep the internal parts of the machine clean.

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ATHENA AQUACHRON 2G SYSTEM

3.3 CONTROLLER PROGRAMMING CONTROLLER PROGRAM STEPS FOR COTTON 100% RED PROCESS
STEP MAIN FUNCTION 1 2 PROG_START PUMP SPEED > PUMP SPEED :PUMP SPEED PRETREATMENT PROCESS 3 FILLING WATER TYPE : COLD LITERS : FILL ALG Wt LIQ RATE : 5 4 HEAT/COOL TEMPERATURE : 60 GRAD/MIN : 0 5 PUMP SPEED > PUMP SPEED :PUMP SPEED NORMAL PROCESS 6 HOLD TIME TIME : 6 CYCLES : 2 7 8 SAVE L:R HEAT/COOL TEMPERATURE : 70 GRAD/MIN : 0 9 HEAT/COOL TEMPERATURE : 95 GRAD/MIN : 0 10 HOLD TIME TIME : 20 CYCLES : 7 11 HEAT/COOL TEMPERATURE : 90 GRAD/MIN : 2 12 AQUACHRON 2G RINSING WASH TEMP : 55 GRAD / MIN : 4 Lt/min/champ : 150 LITERS / kgr : 6 SALT : 0 13 RECALL L:R PREPARE SALT AQUACHRON CTRL WATER TYPE : COLD WASH LEVEL: AQCHR LEVEL FILL ADD T2 WATER : COLD LEVEL : ADD2 LEVEL LEVEL ALG : 2 PREPARE T2 MESSAGE : ACID MAX TIME : 5 TRANSFER T1 TRANSFER T2 PREPARE T1 MESSAGE : PEROXIDE MAX TIME : 5 FILL ADD T2 WATER : RUNBACK LEVEL : ADD2 LEVEL LEVEL ALG : 2 PREPARE T2 MESSAGE : ALKALI MAX TIME : 5 FILL ADD T1 WATER : COLD LEVEL : ADD1 LEVEL LEVEL ALG : 3 REEL SPEED > METERS/MIN : REEL SPEED TRANSFER T1 PREPARE T1 MESSAGE : WETTING MAX TIME : 5 FILL ADD T1 WATER : COLD LEVEL : ADD1 LEVEL LEVEL ALG : 2 (UN)LOAD REEL SPEED > METERS/MIN : 100 PARALLEL 1 PARALLEL 2 PARALLEL 3

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ATHENA AQUACHRON 2G SYSTEM

14

HOLD TIME TIME : 6 CYCLES : 1

TRANSFER T2

PREPARE T1 MAX TIME : 5

FILL ADD T1 LEVEL : ADD1 LEVEL LEVEL ALG : 2 PREPARE T2 MESSAGE : CHEMICALS MAX TIME : 5

MESSAGE: PEROX/ KILLER WATER : RUNBACK

15

HOLD TIME TIME : 10 CYCLES : 3

TRANSFER T1

FILL ADD T2 WATER : RUNBACK LEVEL : ADD2 LEVEL LEVEL ALG : 2

16

OPERATOR CALL CHECK PEROX

OPERATOR CALL CHECK PEROX TRANSFER T2

OPERATOR CALL CHECK PEROX

OPERATOR CALL CHECK PEROX

17

HEAT/COOL TEMPERATURE : 60 GRAD/MIN : 0

18

HOLD TIME TIME : 6 CYCLES : 2

TRANSFER SALT

FILL ADD T1 WATER : COLD LEVEL : ADD1 LEVEL LEVEL ALG : 4

PREPARE T1 MESSAGE : DYES MAX TIME : 5

19

DOSING T1 DOS TIME : 20 DOS CURVE: LINEAR CYCLES DOSING : 5 DOS1+DOS2 : NO

20

HOLD TIME TIME : 20 CYCLES : 5

FILL ADD T1 WATER : COLD LEVEL : ADD1 LEVEL LEVEL ALG : 4 DOSING T1 DOS TIME : 40 DOS CURVE: PROGRESS 3 CYCLES DOSING : 7 DOS1+DOS2 : NO

PREPARE T1 MESSAGE : ALKALI MAX TIME : 5

21

22

HOLD TIME TIME : 40 CYCLES : 10

FILL ADD T2 WATER : COLD LEVEL : ADD2 LEVEL LEVEL ALG : 2 OPERATOR CALL SAMPLE AQUACHRON CTRL WATER TYPE : COLD WASH LEVEL: AQCHR LEVEL OPERATOR CALL SAMPLE

PREPARE T2 MESSAGE : ACID MAX TIME : 5 OPERATOR CALL SAMPLE

23 24

OPERATOR CALL SAMPLE AQUACHRON 2G RINSING WASH TEMP : 60 GRAD / MIN : 0 Lt/min/champ: AQCHRFLOW LITERS / kgr : 3 SALT : 0 RECALL L:R HOLD TIME TIME : 7 CYCLES : 2

25 26

TRANSFER T2

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ATHENA AQUACHRON 2G SYSTEM

27 28

OPERATOR CALL SAMPLE HEAT/COOL TEMPERATURE : 80 GRAD/MIN : 0

OPERATOR CALL SAMPLE

OPERATOR CALL SAMPLE FILL ADD T1 WATER : COLD LEVEL : ADD2 LEVEL LEVEL ALG : 2

OPERATOR CALL SAMPLE PREPARE T1 MESSAGE : SOAP MAX TIME : 5

29

AQUACHRON 2G RINSING WASH TEMP : 80 GRAD / MIN : 0 Lt/min/champ : 180 LITERS / kgr : 8 SALT : 0

AQUACHRON CTRL WATER TYPE : COLD WASH LEVEL: AQCHR LEVEL

30 31

RECALL L:R HEAT/COOL TEMPERATURE : 95 GRAD/MIN : 0 TRANSFER T1

32

HOLD TIME TIME : 8 CYCLES : 2

33

AQUACHRON 2G RINSING WASH TEMP : 85 GRAD / MIN : 2 Lt/min/champ: AQCHR FLOW LITERS / kgr : 9 SALT : 0

AQUACHRON CTRL WATER TYPE : COLD WASH LEVEL: AQCHR LEVEL

34

AQUACHRON 2G RINSING WASH TEMP : 70 GRAD / MIN : 3 Lt/min/champ: AQCHR FLOW LITERS / kgr : 3 SALT : 0

AQUACHRON CTRL WATER TYPE : COLD WASH LEVEL: AQCHR LEVEL

35 36

DRAINING TIME : 1 FILLING WATER TYPE : COLD LITERS : FILL ALG Wt LIQ RATE : 2 CONTROL OFF

37

HOLD TIME TIME : 3 CYCLES : 2

CYCLOCLEAN TIME : 3 OPERATOR CALL SEAMS DETECT (UN)LOAD OPERATOR CALL SEAMS DETECT OPERATOR CALL SEAMS DETECT

38 39 40 41

OPERATOR CALL SEAMS DETECT

DRAINING TIME : 1 PROGR-END

The next few pages are blank for your practice when creating your own programs.

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ATHENA AQUACHRON 2G SYSTEM

PROGRAM NAME: PROGRAM No: NOTES:

STEP MAIN FUNCTION 1 PROG_START PARALLEL 1 PARALLEL 2

DATE: MACHINE No:

PARALLEL 3

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ATHENA AQUACHRON 2G SYSTEM

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ATHENA AQUACHRON 2G SYSTEM

PROG-END

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ATHENA AQUACHRON 2G SYSTEM

4. RUN A BATCH IN ATHENAUSING AN EXISTING

PROGRAM
Note: Before starting a new batch, the previous running program must reach to the end. It is very important for the best performance of the controller either to reach the step "Program-End" at the end of the executed program or read the step "ProgramStart" at the beginning of the program. For more information regarding the loading of the batch, kindly refer to the SM5500/2500/1800 User Manual. In this paragraph, it is important to mention the batch parameters that will be encountered in ATHENA machine. These have as follows: 1. 2. 3. 4. Batch loading in kgs. Liquor ratio (L:R). In this parameter we have to insert the value for the initial liquor ratio. This value will be used for the algorithm calculation of the first machine filling. Weight of the fabric (gr/Lm). This is the linear weight of the treated fabric. AQUACHRON 2G Level. In reference to the AQUACHRON 2G Rinsing values, please refer to the chapter of this manual AQUACHRON 2G Rinsing System Components and Parameters.

5. MODIFICATIONS DURING RUNNING A BATCH

Please consider the SM5500/2500/1800 User manual Interventions.

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