1190 Setup&Installation

IndustrialIT Quality Control
Setup and Installation Manual

(Release 5.0 & later)
PROPRIETARY DATA This document contains proprietary data of ABB Inc. No disclosure, distribution (electronic or otherwise), reproduction, or other means of dissemination may be made without written permission.
Produced by QCS Product Development. Writer: Robert Macchia Illustrator: Robert Macchia Technical Contributor: Don Barger, Alan Czarnecki, Jay Johnson, Geoff Ledin, Al Luckman, Steve Lumen, and Walt Schager
1998, 2002 by ABB Inc. All rights reserved. 1190, OptiPak, and Smart Platform are trademarks of ABB Inc. ABB MasterView, Advant, and AdvaBuild are registered trademarks and service marks of ABB Inc.
April 2002 103049-001 Version B
PROPRIETARY DATA: This document contains proprietary data of ABB Inc. No disclosure, distribution (electronic or otherwise), reproduction, or other means of dissemination may be made without written permission.
Document Version History

IndustrialIT Quality Control
Setup and Installation Manual
(Release 5.0 & later)
Version Level
Effective Date
Sections Changed by Revision
Sections Added by Revision
Sections Deleted by Revision
A B
October 1998 April 2002
Original Release cover art, header, product names
103049-001
Document Version History
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Preface
This manual is designed to aid ABB field personnel in the installation, setup, and startup of the hardware and software of the 1190. For installation of platforms, sensors, and profilers; see their specific documentation. This manual only applies to 1190 Release 5.0 and Later. For earlier releases, refer to the ABB 1190 Setup and Installation Manual, 101763-002 You may need the System Software Data Book (103036-001), the System Hardware Data Book (103036-002), and the System PC Program Listing Book (103036-003). These books are specific to each site and are compiled by the project and system engineers. Other manuals that may be of use: Platform, actuator, and sensor specific documentation operator manuals (103014-00x) and tuning guides (103043-00x) S100 I/O Hardware Reference Manual, 3BSE 002 413 S800 I/O Users Guide, 3BSE 008 878 Advant Controller 450 Users Guide, 3BSE 002 415 Advant Controller 450 Product Guide, 3BSE 015 953 Master Net Users Guide, 3BSE 003 839 Advant Fieldbus 100 Users Guide, 3BSE 000 506 LCU Reference Manual, 101333-003 Radiation Safety Manual, 019406-001 1190 PMM Reference Manual, 101764-002 Computed Sensor Variables, 101766-014 AAM Technical Manual, 101033-001
103049-001
Preface
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Table of Contents
Preface ........................................................................................... i List of Figures ............................................................................ vii 1 Overview ................................................................................... 1
Compatibility .................................................................................................2 Cabinet Layout ..............................................................................................3 Processor and Communications Rack Layout...........................................5 Main Processor ......................................................................................................7 PCMCIA Flash Card ......................................................................................7 Serial Link Submodules ........................................................................................8 ABB Processor ......................................................................................................9 ABB PCMCIA Flash Card.............................................................................9 Maximum CD Actuator Count by type ........................................................10 Equipment Location....................................................................................11 Cabinet.................................................................................................................11 Operator Station...................................................................................................11
2 Preparation ............................................................................. 13
Environmental Requirements ....................................................................14 Overview .............................................................................................................14 Temperature .................................................................................................14 Humidity.......................................................................................................14 Vibration.......................................................................................................15 Altitude.........................................................................................................16 Enclosure Rating ..........................................................................................17 Contamination ..............................................................................................17 Operator Station Requirements ...........................................................................19 Cabinet and Enclosure Requirements..................................................................19 Interior Unit Requirements..................................................................................19 Platform Requirements........................................................................................20 Smart Platform .............................................................................................20 Smart Color Platform ...................................................................................20 HyperScan ....................................................................................................20 Checking Equipment Environmental Specifications...........................................22 Rectifying Adverse Environmental Conditions ........................................23 Decontamination Units........................................................................................23 Verify Necessary Utilities ...........................................................................24 Power Requirements............................................................................................24 Grounding Requirements.....................................................................................25
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iii
Air and Water Requirements ...............................................................................26 Air Quantity..................................................................................................26 Air Quality....................................................................................................26 Water Quantity .............................................................................................26 Water Quality ...............................................................................................26 Air Requirements Calculation Work Sheet for Smart Platforms ........................27 Verifying Electrostatic Discharge Control ................................................29 Receiving the Equipment ...........................................................................30
3 Hardware Installation & Setup .............................................. 31

Electronics Cabinet Installation.................................................................32 Handling the Cabinet...........................................................................................32 Mount the Cabinet ...............................................................................................32 Wiring Internal to Cabinet...................................................................................32 Connect Cables and Utilities ...............................................................................33 Platform Installation....................................................................................34 Power Distribution Panel Installation........................................................35 Mount the Power Distribution Panel ...................................................................35 Connect the Cables ..............................................................................................35 Tachometer Installation..............................................................................36 Install Flexible Couplings ...................................................................................36 Align Directly Connected Shafts.........................................................................37 Actuator Installation ...................................................................................38 Wiring Connections ....................................................................................39 Wire Power to Converter.....................................................................................40 Wire Controller to Platforms & Actuators ..........................................................41 Hardware Setup...........................................................................................44 Port Allocations ...................................................................................................44 Basic Function..............................................................................................44 Item Definitions for Class ID = Port ............................................................45 Port Type Configuration...............................................................................49 Item Definitions for Class ID = INET..........................................................50 Application Port Assignment ..............................................................................51 Hardcopy Printer Setup .......................................................................................52 I/O Subrack ..................................................................................................54 Fieldbus Information...................................................................................56 MasterBus Information ...............................................................................56
4 Software Installation & Setup ............................................... 57

Overview ......................................................................................................58 Toolbox Commands....................................................................................59 Licenses.......................................................................................................60
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Configuration & Setup Displays ................................................................61 Advant Start-Up Display .....................................................................................61 Advant Orderly Shutdown...................................................................................64 Product Code/Grade Data Setup Display ............................................................64 UPS Setup Display ..............................................................................................64 Object References................................................................................................66 Advant Procedures .....................................................................................69 CPIO Backup Procedure......................................................................................69 Station Backup Procedure ...................................................................................69 Restore Station Backup Procedure ......................................................................69 Application Dump/Load Procedures .........................................................70
5 System Startup....................................................................... 71
Startup Checklist.........................................................................................72 Smart Platform Data Setup.........................................................................73 PMM-Based Frame Data Setup ..................................................................75 Set Up Scan Speed...............................................................................................75 Set Up Coldstart Variables ..................................................................................77 Determine Fixed Home and Far EOS ..........................................................78 Determine Off-Sheet, STDZ, Single Point, Current Home EOS, and Current Far EOS Values.....................................................................................78 Determine Delta for On-Sheet Move ...........................................................78 Set Current EOS Positions ...........................................................................79 Servo Set Up........................................................................................................82 Tuning Guidelines ........................................................................................82 Tune the Single Point Measurement Mode ..................................................82 Tune the Scanning Gain ...............................................................................83 Set Up Auto Edge-Of-Sheet (AEOS) ..................................................................84 Changing Measured Sheet Width.................................................................86 Setting Sheet-Break Override..............................................................................87 Setting Global Sheet-Break Override...........................................................87 Setting Local Sheet-Break Override ............................................................88 Grade Data Setup ........................................................................................89 Changing Grade Dependent Data Grouping........................................................89 Changing System Grade Data .............................................................................91 Changing Measurement Grade Data ...................................................................92
Index ........................................................................................... 93
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List of Figures
Figure .............................................................................................................Page Figure 1-1 Figure 1-2 Figure 1-3 Figure 2-1 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 3-7 Figure 4-1 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Single Cabinet Layout ........................................................................ Typical Dual Cabinet Layout .............................................................. Rack Layout ........................................................................................ Air Requirements Calculation Work Sheet for SPs ............................ RS232/20ma Converter ....................................................................... Power Supply Out to Converter .......................................................... Power in to DIN Rail .......................................................................... Power from DIN Rail to Converter ..................................................... Point-to-Point Wiring (Converter to Client) ....................................... Sample Layout for S800 I/O ............................................................... Sample Wiring for S800 I/O ............................................................... Command Sequence ........................................................................... Frame Setup Display ........................................................................... PMM Frame Setup Display ................................................................ Frame Limits ....................................................................................... Frame Coldstart Positions on Frame and Video Profile ..................... Measurement Platform Control Panel ................................................. Auto Edge-of-Sheet Parameters .......................................................... Frame Object Display ......................................................................... Grade Grouping Display ..................................................................... Grade Data Display ............................................................................. Grade Dependent Basis Weight Display Example ............................. 3 4 6 27 39 40 40 41 43 54 55 59 74 76 77 79 81 84 88 90 91 92
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1
Overview
This chapter gives an overview of the control system and includes the following major sections: Section............................................................................................... Page Compatibility ................................................................................................. Cabinet Layout .............................................................................................. Processor and Communications Rack Layout ............................................... Equipment Location ...................................................................................... 2 3 5 11
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Overview
Compatibility
The IndustrialIT Quality Control Release 5.0 and later using the Advant Controller 450 (AC450) is compatible with the following hardware and software: On-line Builder *2.4/0 or later MV850 - FP *5.0/7 Advant OS Version: SW *1.7/1 or later ES120 & ES130 with AdvaBuild 1/3/0 or later
Note: An AC450-based system will only be connected to a ABB MasterView or PMM in an upgrade situation.
Overview
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Cabinet Layout
The Advant Controller 450 with S100 I/O are installed in RM500 cabinets. There are two different versions, RM500V1 and RM500V2, with different footprints. See Table 1-1 for the dimensions. For dual cabinet configurations, two single cabinets are bolted together. For examples of single and dual cabinet layouts, see Figure 1-1 and Figure 1-2, respectively. Cabinets used are subject to change. Table 1-1 Cabinet RM500V1 RM500V2
1Side 3Roof
Width1
Depth2
Height3 2125 mm (83.7 in) 1925 mm (75.8 in) 2225 mm (87.6 in)
800 mm (31.5 in.) 512 mm (20.1 in) 800 mm (31.5 in.) 512 mm (20.1 in) 700 mm (27.6 in.) 637 mm (25.1 in)
plates (20 mm or 0.8 inch each) are NOT included. and back plate are included. is included.
2Door
RM500V1 cabinets are provided with single or double doors (double door consists of two doors, each half the size of a single door. RM500V2 cabinets are provided with only single doors. For complete details, refer to the Advant Controller 450 Product Guide, 3BSE 015 953. Processors and Communications Rack
Modem Rack I/O Nest (if in this cabinet)
Power Supply
Figure 1-1 Single Cabinet Layout
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Overview
Processors and Communications Rack
I/O Nest
Modem Subrack Connection Units
Power Supply Power Switch and Distribution
I/O Subrack Processors and Communications Rack Modem Rack Connection Units
Power Supply Field Power Supply
Power Switch and Distribution Mains Net Filter (CE-Marked Versions Only) Figure 1-2 Typical Dual Cabinet Layout
Overview
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See Processor and Communications Rack Layout for details about specific boards. Power Supply - The power supply is a 115 Volt 15%. I/O Nest - The I/O will typically be a S100 or S800 depending on the number of I/O required for the system. Refer to the S100 I/O Hardware Reference Manual, 3BSE 002 413 or the S800 I/O Users Guide, 3BSE 008 878, respectively.
Processor and Communications Rack Layout

The processor and communications rack can contain: a main processor, a redundant main processor, four serial link carriers, two ABB processors, a power supply, a battery backup with charger, and a status card. See Figure 1-3. The power supply is a 5 volt regulator. The backup is a 5 volt RAM battery with a 12 volt charger. The status card monitors the fans. The processor and communication cards are detailed in subsections following Figure 1-3.
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Overview
Slot 2 dedicated to redundant Main Processor
Main Processor
ABB
PM 511
Serial Link Submodules

ABB
SC 510
ABB Processors
ABB
SC 510
ABB
SC 510
ABB
ABB
SC 520
PM 511
ABB
ABB
PM 511
SR 511
F RUN HLT BC F TO DUAL RUN F F F
F F F TO DUAL RUN HLT BC TO DUAL 2V 5V RUN HLT BC
1
CI ABB 532 F R X4
RUN
1
CI ABB 532 F R X4
RUN
1
CI ABB 532 F R X4
RUN
CI ABB 532 F R X4
Power Supply
X5
X5
X5
X5
Overview
1 AUTO X11 I/O
2
CI ABB 532 F R X4
2
CI ABB 532 F R X4
2
CI ABB 532 F R X4 F
2
CS 513 1 R 2 CLEAR 3 4 2 1 CLEAR 3 4 F BF TX RX F1 2AF
ABB
3 4
SB 510
ABB
TC 520
IP BP FC RUN A1 A2 AG B1 B2 BG RA RA RB RB FN S SG
X5
X5
X5
X10 SERV.
X4
X10 SERV.
X10 SERV.
Battery Backup
X11
X11 I/O
X11 I/O
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Slot
Status Card
Figure 1-3 Rack Layout
Main Processor
The main processor contains the AMPL library flash card.
ABB
PM 511
F RUN HLT BC TO DUAL
F = Fault Run = Run HLT = Halt BC = Battery Connected TO = Time Out Dual = dual processors present
P1 is normal -- L means it is loading from flash card
PCMCIA flash card
2 1 AUTO
3 4
Switch set to AutoInit (1)
X10 SERV.
Advant 130 connector Connector to local I/O bus on card
X11 I/O
PCMCIA Flash Card

This PCMCIA flash card contains the AC450 controller software load.
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Overview
Serial Link Submodules

ABB
SC 510
F RUN
1
CI ABB 532 F R X4
Each submodule consists of two RS232 ports which supports ABB serial protocol. Two submodules can be mounted in each carrier (shown at left) for a total of four ports per carrier. A maximum of five carriers can exist in the system if only one ABB Processor board is used.) This configuration provides 18 ports plus a MasterBus connection. The MasterBus submodule contains one port and takes the place of one submodule (two ports). HyperScan communication requires two ports. They must be on the same submodule. One port of a submodule can be used to communicate with a Smart Platform and the other one to communicate with a Smart Profiler or third party CD. RS232/20mA serial converters are mounted below the processor and communications rack. The bottom submodule of the last carrier will contain the appropriate card (slot 6 in Figure 1-3) for a connection to a MasterBus distributed control network. The AUI cable connects to the ethernet transceiver. See MasterBus Information on page 56.
X5
2
CI ABB 532 F R X4
X5
Overview
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ABB Processor
ABB
PM 511
F RUN HLT BC TO DUAL
F = Fault Run = Run HLT = Halt BC = Battery Connected TO = Time Out Dual = dual processors present
A 1 is normal -- L means it is loading from flash card
ABB PCMCIA flash card
2 1
CLEAR 3 4
Switch set to Clear (3)
X10 SERV.
Advant 130 connector
X11 I/O
NOT used
ABB PCMCIA Flash Card

One ABB Processor flash card contains frames, CD, and color, e.g. V1AL1103. A second ABB Processor flash card contains HyperScan, e.g. V1HS1103. All applications, except HyperScan, can exist on the same ABB Processor. Each processor can have up to 6 CD packages. The system can have a maximum of 12 CD packages (split between two nodes). ABB processor boards are interchangeable with the main processor board. The differences are on the PCMCIA flash cards (and, potentially, memory installed on the board). The system is constrained to approximately 963 AO objects (AOC and AOS) PC10 will coldstart the processor if a taskfail or boardfail has been detected. This means a reload of the flash card. Otherwise, PC10 will invoke a warmstart which does not require a reload of the flash card.
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Overview
Maximum CD Actuator Count by type

Sequential Linear Steppers Parallel Linear Steppers Smart Weight Profiler (SWP) IR Profiler ThermoProfiler Air/Water Spray ScaniValve Serial Smart Calender Profiler Dilution SWP 66 150 200 216 120 108 96 255 200 400
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Overview
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Equipment Location
Cabinet
Follow the steps below to prepare the cabinet location. 1. Install the electronics cabinet at a location predetermined by the customer and the ABB Installation Engineer. 2. Verify the cabinet is readily accessible to paper machine operating personnel and maintenance and service personnel. 3. Verify sufficient space is available for the installation of cables. 4. Verify all environmental requirements. See Cabinet and Enclosure Requirements on page 19. 5. Verify the base support structure allows the electronics cabinet to be bolted down firmly and permits cable entries from the bottom of the cabinet. 6. Refer to the cabinets Dimensional Drawing for information on specifying cable entries, securing bolt hole locations, and determining space requirements and weight specifications. 7. See Vibration on page 15 to determine if isolation mountings must be used. Note: If the electronics cabinets are located where damage may be caused by tow motors, forklift trucks, or pushcarts; some type of protective barrier must be installed.
Operator Station
Operator stations are located as required by each site.
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Overview
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Preparation
Section............................................................................................... Page Environmental Requirements ........................................................................ Rectifying Adverse Environmental Conditions ............................................. Verify Necessary Utilities .............................................................................. Verifying Electrostatic Discharge Control .................................................... Receiving the Equipment .............................................................................. 14 23 24 29 30
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Environmental Requirements
Overview
The conditions that characterize an operating environment and that are critical to the operation and reliability equipment are listed below: Temperature Humidity Vibration Altitude Enclosure Rating Contamination
Each environmental parameter has been divided into classifications that define the severity of the parameter. The classes are defined in detail so that the class number for each environmental factor can be used to describe the conditions a unit is designed to withstand.
Temperature
Temperature is defined as the maximum ambient temperature, in degrees Centigrade (C) or degrees Fahrenheit (F), where ambient refers to the air which surrounds or impacts the frame or enclosure. For a large frame or enclosure, the ambient temperature may not be uniform. In that case, the temperature specification reflects the average observed or predicted value. Factors which affect the ambient temperature include the following: Seasonal Weather Variation Location of Heat Sources Open Windows Ventilators Heat generated by system equipment and/or radiated from nearby heat sources Centigrade 19C to 27C 27C to 45C 45C to 60C Above 60C Fahrenheit 65F to 80F 80F to 110F 110F to 140F Above 140F
The four classes of temperature are as follows: Class Class 1 Class 2 Class 3 Class 4
Humidity
Humidity, also referred to as relative humidity, is the ratio, expressed as a percent, of the actual water vapor present in the air to the maximum vapor possible at the same temperature and pressure. Relative humidity values greater than 90% have little practical meaning because they are difficult to measure.
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Unless controlled by special equipment, humidity may normally vary from extremely dry (less than 10%) in the winter to saturated conditions (greater than 90%) in the summer. Uncontrolled humidity may cause the following problems: Condensation Accelerated Corrosion Changes in materials properties such as weight, dimensions, and resistivity Percent 30 to 70% Description A controlled humidity condition; typically includes devices which use paper (printer) and require humidity control. An air conditioned environment where humidity control depends on air conditioner size, heat load, and season. An uncontrolled environment, but indicates noncondensation without moisture droplets unless otherwise indicated.
The three classes of relative humidity are as follows: Class Class 1
Class2
20 to 80%
Class 3
5 to 90+%
Vibration
Vibration is specified by the following three variables: Frequency (F) in Hertz (Hz) or cycles per second Amplitude (A) in inches (peak-to-peak) Acceleration (G) in Gs (peak value) where the relationship between variables is G = 0.0511 AF2 If either amplitude or acceleration is defined in root-mean-square (rms) units, the rms units can be converted to peak value by multiplying each by 1.414. Peak value units can be converted to peak-to-peak by multiplying by 2.000. Excessive vibration may cause cyclic stressing, which can lead to fatigue failure of parts. Printed circuit board connectors may also become dislodged, causing open circuit failure or contact arcing. Vibration to sensors can cause several problems, including the following: Signal Oscillations Incomplete Standardize Unwanted Sheet Flutter Description Less than 0.01 inch (0.254 mm) amplitude (0-14 Hz) and less than 0.1 G (14 to 100 Hz) is considered normal; vibrations that are noticeable but not troublesome are in this class.
The two classes of vibration are as follows: Class Class 1
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Class 2
Greater than 0.01 inch (0.254 mm) amplitude (0-14 Hz) or greater than 0.1 gram (14 to 100 Hz) is severe enough to warrant vibration and/or shock isolation.
Altitude
Altitude is the elevation above sea level measured in feet. The relationship between altitude and atmospheric pressure is shown in Table 2-2 below. Table 2-2 Relationship between Altitude and Atmospheric Pressure Altitude in Meters 0 300 600 900 1200 1500 1800 3000 Altitude in Feet 0 985 1970 2950 3940 4920 5905 9840 Pressure in Pounds/in2 14.7 14.2 13.7 13.2 12.7 12.2 11.3 10.1 Pressure in kPa* 101.35 97.90 94.45 91.01 87.56 84.12 77.91 69.64
* Kilopascals (KiloNewtons per square meter) is the unit of measure for pressure in the international system of units. Note: Pressure will vary +0.5 psi due to weather, in addition to the altitude effect. Atmospheric pressure has a slight effect upon heat transfer, and altitude reflects atmospheric pressure. At 5,000 feet, natural convection is reduced by about 10%, and air mass flow from a fan might be reduced by about 15%. The three classes of altitude are as follows: Class Class 1 Class 2 Class 3 Description 0-900 meters (0-2,950 feet) 900-1,500 meters (2,950 - 4,920 feet) Above 1,500 meters (above 4,920 feet)
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Enclosure Rating
The enclosure rating defines enclosure resistance to common industrial environments. The four classes of ratings are as follows: Class Class 1 Class 2 Description Dust Resistant - the enclosure will resist dust to the degree specified under Particulate on page 18. Water/Oil Resistant - the enclosure will resist dust (see Class 1 above) and occasional spray of oil or water. Occasional means the equipment could be doused with oil or water less than once a week during maintenance of the process equipment. Water/Oil Proof - the enclosure will resist dust and continuous spray of oil or water. Hazardous - if the customer has a hazardous environment, special treatment is required. Normally the customer will have a defined set of requirements, such as a NEMA. Obtain these requirements from the customer.
Class 3 Class 4
Contamination
Normally there are two major categories of contamination, gaseous and particulate, as explained below. Gaseous - Gaseous contamination is measured as concentration in parts per million (ppm). Any gas which may cause metal to tarnish or corrode should be considered as gaseous. The most obvious problem with gaseous contamination is corrosion. There are a large number of electrical connectors in a system which can develop a thin layer of tarnish or oxide when exposed to certain gaseous contaminants, such as hydrogen sulfide (H2S), chlorine (CL2), and sulphur dioxide (SO2). This tarnish or oxide can act as an insulator or capacitor and greatly affect system reliability. The three classes of gaseous contamination are listed below and explained in Table 2-3 on the next page. The classes are measured in ppm. Class 1 is considered mild. Class 2 may require some type of contaminant removal. Class 3 is considered severe and/or unsafe for humans.
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Table 2-3 Classes of Gaseous Contamination Type of Gas Sulfur Dioxide Hydrogen Sulfide Hydrogen Fluoride Chlorine and Halogenated Compounds Oxides of Nitrogen (NOx) Carbon Monoxide (CO) Ammonia Aldehydes Oxidents (Ozones) Class 1 0.00-0.05 ppm 0.00-0.03 0.00-0.02 0.00-0.03 0.00-0.08 0-10 0.0-0.2 0.0-0.2 0.00-0.05 Class 2 0.05-5.00 ppm 0.03-10.00 0.02-3.00 0.03-1.00 0.08-5.00 10-50 2-50 0.2-5.0 0.05-0.10 Class 3 5+ ppm 10+ 3+ 1+ 5+ 50+ 50+ 5+ 0.1+
Particulate - Dust (paper dust, metal particles, process material) is difficult to measure and classify for a given environment. Typically, particulate contamination is either not noticeable or is severe. Dust concentrations are defined in milligrams per cubic meter (mg/m3). A high concentration of dust may cause the following problems: Increased wear on rubbing or rolling surfaces High contact resistance in plugs and connectors Shorts on printed circuit boards Increased maintenance costs for cleaning, changing filters, and repairs The three classes of particulate contamination are as follows: Class Class 1 Class 2 Measurement 0.0 - 0.3 mg/m3 0.3 - 3.0 mg/m3 Description Typical for an office environment. Typical for light manufacturing, warehouses, or facilities with bare concrete floors. All those not in Class 1 and 2; requires special consideration. The type of particulate contamination in this class (residue, quantity, size, distribution, stickiness, chemistry, and so on) should be considered and noted to the ABB Engineering Department.
Class 3
SEVERE
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Operator Station Requirements

Put operator station hardware in an enclosure with specifications as described below if the location does not meet the specifications defined by the hardware manufacturer or if it will be on the mill floor.
Cabinet and Enclosure Requirements

The following requirements are for cabinets and enclosures: Temperature: Low: non-condensing 0 C High: +40 C Gradients: 3 C/min Humidity: Relative: Absolute: Vibration: 0.075 mm, 10-57 Hz 10 m/s2, 57-150 Hz; x, y, z direction Shock: 150 m/s2 for 11ms, half sine; x, y, z direction Altitude: 2000 meters Pollution Degree: Degree 2 acc. to IEC 664 and 664A Emitted Noise: < 55 dB 5% - 95% 1 - 29 g/m3, non-condensing
Interior Unit Requirements

The following requirements are for subracks, plug-in units, and printed circuit boards: Temperature: Low: non-condensing 0 C High: +55 C Gradients: 3 C/min Humidity: Relative: Absolute: Vibration: 0.15 mm, 10-57 Hz 20 m/s2, 57-150 Hz; x, y, z direction 5% - 95% 1 - 29 g/m3, non-condensing
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Shock: 150 m/s2 for 11ms, half sine; x, y, z direction Altitude: 2000 meters Pollution Degree: Degree 2 acc. to IEC 664 and 664A
Platform Requirements
Smart Platform
Temperature: Low: non-condensing 0 C High: +40 C Gradients: 3 C/min Humidity: Relative: Vibration: 0.01 , 0-14 Hz 0.1 G, 14-100 Hz 5% - 90%
Smart Color Platform

Temperature: Low: non-condensing 0 C High: +40 C Gradients: 3 C/min Humidity: Relative: Vibration: 0.01 , 0-14 Hz 0.1 G, 14-100 Hz 5% - 90%
HyperScan
Temperature: Low: non-condensing 0 C High: +40 C Gradients: 3 C/min Humidity: Relative: Vibration: 0.01 in, 0-14 Hz 0.1 G, 14-100 Hz 5% - 95%
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Because these are general specifications, they are always superseded by job order engineering documentation. If the environment exceeds the ratings, special engineering is usually required. For more specific guidelines refer to the Advant OCS Product Guide, 3BSE 008 434 latest revision. Table 2-4 Summary of Environmental Specifications Vibration (10-57Hz / 57-150Hz) Relative Humidity (%) Altitude (meters) for 11ms) Pollution (deg.) 2 acc. 2 acc. 5000 (A/yr.) ---21
Temp. (C )
Equipment
Shock
Operator Station Enclosure Internal Units Smart Platform HyperScan Smart Color Platform Liquid Cooling Unit 0 - 40 0 - 55 0 - 80 0 - 80 0 - 80 < 43 5 - 95 5 - 95 5 - 90 5 - 95 5 -90 5 - 90
See manufacturers documentation. 0.075 mm / 10 m/s2 0.15 mm / 20 m/s2 0.01 in (0-14 Hz) / 0.1 G (14-100 Hz) 0.01 in (0-14 Hz) / 0.1 G (14-100 Hz) 0.01 in (0-14 Hz) / 0.1 G (14-100 Hz) -150 150 ----2000 2000 -----
Note: 1. Air conditioners on electronics cabinets are derated 1.6 C (3 F) per 300 meters (1,000 ft.) over 750 meters (2,500 ft.) above mean sea level. 2. Water-cooled air conditioners, when present on full electronics, allow operation in Class 3 dust environments. Normally, air conditioned offices and/or rooms housing electronic boards with air conditioners require one additional ton of refrigeration per unit to compensate for cabinet heat dissipation.
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(m/s2
Checking Equipment Environmental Specifications

Use the following measurement techniques for measuring the environment: Specification Power Air Quality Air Quantity Water Quality and Quantity Temperature Contaminant Levels Vibration Suggested Measurement Technique power line analyzer Test kit 73512-001 Test kit 73528-001 LCU only: Have site test to meet determined requirements Calibrated temperature sensing device Contamination Kits: Enclosure for samples: 121288-001 Samples: 082932-001 Use a hand held vibration monitoring device
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Rectifying Adverse Environmental Conditions

Decontamination Units
If coupon tests show greater than 300 angstroms per month (28 days), decontamination units are required. Most floor installed Advant Operator Stations (Advants in enclosures) should have decontamination units. AC450s that require decontamination units must have the sealed cabinet option (probably with air conditioning). Normally, closed cabinets have insufficient air circulation to provide proper cooling.
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Verify Necessary Utilities
The following sections contain utility guidelines. They are always superseded by job order engineering documentation.
Power Requirements
Voltage dropouts cannot exceed 10ms. Total harmonic distortion cannot exceed 5% at no load. Table 2-5 Power Requirements Equipment System Cabinet Smart Platform HyperScan (3-Phase) HyperScan (Single Phase) Smart Color Platform Actuators VAC 115 200-240 380/415 or 480/575 240 240 KVA 15/25/351 10 29/582 -1.5 Hz 60 50 or 60 50/60 50 or 60 50 or 60
Refer to specific actuator documentation
1 KVA is for one scanner/two scanners/three scanners. Exact requirement will be determined
during the development of the system configuration.

2 KVA is for 1-6 cameras and 7-11 cameras.
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Grounding Requirements
The system is designed for protected installations. All cables included in the system are tray-rated, meaning that they can be run in trays. The tray and internal shielding of the ABB cables provide protection against both high and low frequency interference. The combination of shielding and cabinets meets the requirement for interference free functionality for industrial equipment. For complete details about grounding and EMC compliance, refer to the Users Guide for Compliance with the EMC Requirements, 3BSE 009 178. For interference free operations, it is important that good grounding arrangements are maintained. All components - backplane, power supply units, power supply filters (where applicable), connection units, modems, and grounding bars must be connected directly to the chassis with screws (not long wires). The best technique to ensure a good electrical contact is to use thread cutting screws or screws with star washers under the head. Pairs of cabinets or enclosures that are used as a reference ground (chassis) must have good and permanent electrical bonding. Painted or anodized parts must also have good ground bonding. This can be achieved, for example, by scraping the surfaces or using thread-cutting screws. In aluminum, threadcutting screws must be used.
In the same way as mounting rails, all units such as subracks, power supplies, and terminal rails must be bonded to the chassis by means of approved mounting screws or short connecting wires (maximum 5 cm (2 inch) length) on both sides of the unit. Other units must be grounded in a suitable manner (maximum 5 cm long connections) to the chassis plate or to the copper grounding bar. In ABB cabinets, all these connections must be made with tapered self-tapping screws with teeth under the head. Incorrectly mounted units provide very poor protection against high frequency interference and electrostatic discharges (ESD). In the EU and EFTA countries, there must be the connection of the cable shield to the cabinet fitted by 360 connection. The latter is the place where the cables penetrate the cabinet. It is normally made by special sealing. The shields shall continue in the cabinet. In other than EU countries, the requirement on the 360 shield connection can be omitted. Shielded communication cables which are not directly grounded in the cabinet and shielded cables for analog signals with the signal circuit and shield grounded in the field are to be handled in a special way. The cable shield, in these cases, should be connected to the ground via a capacitive decoupling device located in the bottom of the cabinet.
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Air and Water Requirements

The utilities required by the system vary with the equipment you have available. Ask the ABB Installation Engineer for the options that are on your system. The utility requirements are summarized below. Refer to the specific Installation Drawings for air/water line size, type, and routing.
Air Quantity
flow rate: 10 - 60 SCFM (see Figure 2-1) line pressure: 65 - 100 PSI
Air Quality
maximum 1 ppm by weight of oil and water maximum 5 micron ppm of solid particulate temperature must be within 20 C of ambient air
Water Quantity
flow rate: 42 - 76 liters/hr (11 - 20 gal/hr) at Liquid Cooling Unit (LCU) line pressure: 138 - 551 KPa (20 - 80 psig) at device
Note: 1. Both the IR cooling units and the air conditioners require one water drain for spent cooling water and another to eliminate condensate from the air conditioner. 2. If the water supply is not cool enough, a drinking fountain water cooler may be used to pre-cool the water. temperature: 27 C (80 F) max at LCU
Water Quality
drinking water purity with pH 6.0 - 8.0 hardness: less than 85 ppm drains required below device
Note: Improper cooling and extra cooling servicing will result if dirty water (containing iron and calcium) is used. Grit may be imbedded in the rubber seats of the pressure regulator and the temperature valve of the cooling unit, or the flow control valve of the air conditioning unit, causing improper performance. Strainers may clog and stop all cooling. Excessive temperature will cause the sensor to shut off, or blockage of water flow will cause the A/C to shut off. This shut off will require resetting and correction before restarting.
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Air Requirements Calculation Work Sheet for Smart Platforms

Air Flow Per Sensor Sensor Basis Weight with Std. Air Wipe with AGC BW with CAP Smart Basis Weight IR Moisture Transmission with Std. Air Wipe with Heated Air Wipe with Std. Air Wipe with Heated Air Wipe Caliper (Single Air Bearing) Air Bearing Vacuum Plate Probe Heater Caliper (Dual Contacting) Lift-Off Tube Vacuum Plate Probe Heater Caliper (Non-Contacting) Top Air Bearing Bottom Air Bearing Caliper GT OptiPak Purge Vacuum Plate Air Bearing Plate 5.0 4.2 4.2 8.5 7.1 7.1 40 PSIG 2.0 2.0 2.0/head 3.4 3.4 2.0/head 1.0 2.0 2.0 1.7 3.4 3.4 40 PSIG 40 PSIG 30-40 PSIG 4.0 2.0 2.0 6.8 3.4 3.4 40 PSIG 40 PSIG 30-40 PSIG 5.3/wipe 5.5/wipe 5.3 5.5 9.0/wipe 9.4/wipe 9.0 9.4 10-20 PSIG 10-20 PSIG 10-20 PSIG 10-20 PSIG 4.0/wipe 5.5/wipe 4.0/wipe 4.0/wipe 6.8/wipe 9.4/wipe 6.8/wipe 6.8/wipe 40 psig <35 PSIG 10-20 PSIG SCFM M3/HR Pressure # In System Totals # Times Flow
Reflection Moisture/Coat Weight
Figure 2-1 Air Requirements Calculation Work Sheet for SPs (continued on next page)
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Air Flow Per Sensor Sensor Smart Ash Roll Hardness Gloss Air Wipes Air Purge/Sensor Sheet Guides (4) MP/SP Clutch Smart Color Microwave Single-sided Dual-sided Smoothness Normal High Temperature Temperature None 0.001 N 1.5 None 0.001 N 2.6 30 psig TOTAL = 0.18 0.18 0.3 0.3 5.0 3.5 24.0 0.0 4.0/head 8.5 5.9 40.8 0.0 6.8 40 PSIG 20 PSIG 40-50 PSIG SCFM 4.0/head 8.5 M3/HR 6.8/head 14.5 Pressure # In System
Totals # Times Flow
Figure 2-1 (continued)
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Verifying Electrostatic Discharge Control

Note: All maintenance in the cabinet is only allowed when protective ESD restrap, fitted to the cabinet is used. The equipment contains many static-sensitive devices such as transistors, diodes, integrated circuits (ICs), resistors, capacitors, and printed circuit boards. These devices must be protected from damage caused by the discharge of static electricity. Electrostatic charging is likely to occur whenever two materials are brought into contact and separated. The goal of static protection for static sensitive devices is to prevent static buildup where possible and quickly and reliably remove existing charges. This goal can be accomplished by using conductive wrist straps, work mats, and conductive bags shipped with the system. A warning label is placed in a highly visible location on all equipment containing static sensitive devices to remind you of the potential damage that can result from electrostatic discharge.
When handling a static-sensitive device such as an integrated circuit (IC) or a printed circuit board which contains ICs, you must be properly connected to ground by wearing the conductive wrist strap. The wrist strap MUST be in direct contact with bare skin. NEVER WEAR THE WRIST STRAP OVER CLOTHING. The connecting wire of the wrist strap MUST be connected to a grounded conductive bench top or system ground. A series resistor in the connecting wire at the snap protects you from electrical shock should equipment fault occur. Remember the following: The wrist strap is always FIRST ON and LAST OFF. The wrist strap MUST be attached in direct contact with bare skin, NEVER OVER CLOTHING. PC boards MUST be placed in an anti-static bag whenever removed from a cabinet. DO NOT remove wrist straps until after the board has been placed in the antistatic bag. Place the bagged PC board on the conductive work mat or attach the conductive wrist strap BEFORE removing the PC board from the anti-static bag.
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Receiving the Equipment

When equipment arrives, follow the steps below: 1. Check off all equipment and boxes on the shipping manifest. ABB personnel should be present to verify arrival conditions of the equipment. 2. Remove outer shipping covers, if present, from equipment and note any damaged or missing items before signing the manifest. 3. Notify the carrier and ABB Industrial Systems Inc. of damages and/or missing equipment. 4. If the system is to operate on 50 Hertz (Hz), verify that the applicable system units are converted to 50 Hz operation.
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3
Hardware Installation & Setup
Section............................................................................................... Page Electronics Cabinet Installation ..................................................................... Platform Installation ...................................................................................... Power Distribution Panel Installation ............................................................ Tachometer Installation ................................................................................. Actuator Installation ...................................................................................... Wiring Connections ....................................................................................... Hardware Setup ............................................................................................. I/O Subrack .................................................................................................... Fieldbus Information ..................................................................................... MasterBus Information .................................................................................. 32 34 35 36 38 39 44 54 56 56
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Electronics Cabinet Installation

Follow the general guidelines below for all electronic cabinets. For information on Master electronics cabinets, see the Advant Controller 450 Users Guide, 3BSE 002 415.
Handling the Cabinet

Special handling is required before and during installation because the operator stations and electronics cabinets contain very sensitive electronic and mechanical components which may be damaged by rough handling. Use the following guidelines when handling the cabinet. DO NOT bump or drop the cabinets. DO NOT store the electronics cabinet where it may be moved without proper supervision. DO NOT store or install the electronics cabinet in wet areas, on wet floors, or in extremely hot or cold areas. DO NOT open the door of the electronics cabinet until the unit is bolted down, braced against tipping, or partially bolted down through the front door. DO keep all doors to the electronics cabinet locked when not present.
Mount the Cabinet

To mount the electronics cabinet, follow the steps below. For detailed information, see the Advant Controller 450 Users Guide, 3BSE 002 415. 1. Transport the unit while still mounted on the shipping skid to the mounting site with a forklift truck using the quickest, safest route possible. Be careful to observe the orientation arrows on the outside of the crate. For crated shipments (all international and special domestic), transport the electronics cabinet to the mounting site while still in the crate. 2. Remove the fastening devices that secure the unit to its shipping skid and lift the unit onto the prepared mounting base. Lifting eyelets are provided on the cabinet to allow lifting from above. 3. Open the front door to access the securing bolt holes. 4. Bolt the cabinet down securely to prevent it from tipping or sliding.
Wiring Internal to Cabinet

Refer to the ABB Conduit/Cable Summary and System Wirelist for termination information. Point-to-point and connection diagrams may be provided instead of the conduit/cable summary and system wirelist.
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Connect Cables and Utilities

Follow the steps below to connect the cables and utilities. 1. Use the slides in the bottom of the cabinet for cable entry. See the Advant Controller 450 Users Guide (3BSE 002 415) for information on connecting cables in the cabinets. CAUTION
Do not allow metal chips to scatter within the cabinet. Do not use hole saws, sabre saws, or other cutting devices that would create excessive vibration of the internal circuitry.
Avoid contact with the internal wiring and terminals. 2. Pull and terminate all cables. All wiring to the electronics cabinet is shown on the point-to-point drawing in the System Hardware Data Book which is shipped with your system. 3. Seal the cable entries to the cabinet to prevent contamination and to allow more efficient operation of the air conditioning and decontamination units. 4. Verify that all internal power cables are connected to the local load center as described in the System Hardware Data Book.
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Platform Installation
Several types of platforms are used to support/position the various sensors of the quality control system. Each platform is equipped with various sensor configurations depending upon the system application. Installation information for all platforms is in the appropriate platform manual. Smart Platform 700 Smart Platform 1200 HyperScan 101764-004 101764-003 103045-001 CAUTION
Special handling and care of platforms is required before and during installation. The platforms receive critical alignment and adjustment at the factory prior to shipment. Special precautions must be taken during shipping, handling, and installation to preserve the integrity of these adjustments. These precautions are outlined in the applicable platform manual.
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Power Distribution Panel Installation

Follow the guidelines below for Power Distribution Panel (PDP) installation techniques.
Mount the Power Distribution Panel

Wall-mount the power distribution panel close to the full-size operator station in an area where it will be protected from water spray and excessive dust. Mounting should be done in accordance with standard electrical practices and local code specifications.
Connect the Cables

Cabling and connection of AC power from the customers source to the system units is made through the power distribution panel. Before beginning the cabling and utilities connections to any of the system units, verify that the customer power source and earth ground meet the requirements. Power cabling to and from the power distribution panel should be wired in accordance with the point-to-point drawings in the System Hardware Data Book. Wiring should be made first from the power distribution panel to the system units, and then to the customer power disconnect switch or breaker. Power cabling must be in accordance with local code specifications.
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Tachometer Installation
For more information on the DSDP170 Pulse Board, refer to the S100 I/O Hardware Reference Manual, 3BSE 002 413. For best accuracy, tachometers should be driven by positive drives, including any of the following: Gearing Timing belt Direct shaft coupling
The type of drive takeoff you use should be determined by the desired ratio of tachometer speed to shaft speed. If the ratio is not in unity, then use a timing belt drive. With a unity ratio, use direct shaft flexible couplings. If you use a timing belt, make sure that belt tension is not excessive, since very little torque is required to turn the tachometer. Belts over 3/8 inch wide are not recommended. The tachometer can normally be directly belted off the machine or sectional drive motor shaft. However, if the distance between the machine and tachometer is so great that excessive belt tension is required, consider using a jack shaft arrangement. If direct shaft coupling is used, use flexible coupling and align the shafts as accurately as possible. Regardless of which type of drive is used, make sure that the tachometer is not subjected to any axial thrust and as little side thrust as possible. In order to maintain a long and trouble-free life for the tachometer, you must minimize vibration and bearing load due to misalignment, end float, or over-hung load. Because of the tendency to under-design this aspect, we are providing the following installation guidelines.
Install Flexible Couplings

1. Accomplish a direct connection between two shafts using flexible couplings. 2. Size the flexible couplings to permit a light interference fit to the shafts for installation. CAUTION
Do not drive or force the couplings onto the tachometer shaft because damage to its bearing may result. 3. Shaft ends should not meet or, in the case of Thomas couplings, extend beyond the face of the shaft-mounted hub.
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Align Directly Connected Shafts

Make four measurements on each of the following coupling installations: 1. Shaft Runout - Using a dial indicator mounted to a base common to the machine frame, set the indicator tip on a ground portion of the shaft, near the shaft end. Rotating the shaft through 360 will indicate the shaft runout. Note: Shaft runout must be held to less than 0.001 inch. 2. Parallel Misalignment - With the tachometer on its mounting pad, attach the dial indicator to the shaft of the tachometer. The dial indicator tip is allowed to contact the machine shaft as near the bearings as possible (to eliminate runout). The tachometer shaft and dial indicator should then be rotated, and the high or low spots noted. Note: A V block facilitates this setup. Use shims between the tachometer and mounting bracket. 3. Angular Misalignment - Set up according to the instructions for parallel misalignment. 4. End Play - With the tachometer mounted on its pad and the dial indicator on the end of the machine shaft, clamp the machine shaft with the suitable nomarring device (for example,V block and clamp) and manually attempt to move the shaft in and out of the machine, noting dial indicator movement. When conditions make it impossible to check alignment in this manner, make it with a straight-edge and feeler gauge. Check for angular misalignment by inserting the feeler gauge between the faces of the coupling hubs at four equidistant points. Check for runout by placing a straight-edge across the ground or closely machined diameters of both coupling hubs. This method is not recommended unless a check with a dial indicator is impossible.
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Actuator Installation
See appropriate Actuator documentation. Smart Weight Profiler Smart CoatWeight Profiler Smart Calender Profiler Smart Consistency Profiler 101794-003 103007-003 103020-002 103046-002
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Wiring Connections
The RS232/20ma converter is the bridge between the controller and the platforms and actuators. The converter is used for bi-directional signal conversion (transmission rate determined by the interface with the lower capacity) and long distance transmission. It is located below the processor and communications rack. You need one converter for each port (two per submodule). The cable connects from the submodule port to the RS232 connection on the converter (#1, see Figure 3-1), the cable from the client (e.g. Smart Platform or Smart Actuator) is connected to the 8 screw terminals (#4) along the bottom of the converter (labeled TTY). 24 volt DC power is connected to the converter via two terminal strips (#5) on the top left of the unit.
24 V DC power
UNUSED
Yellow LED = transmit Green LED = receive UNUSED to communications submodule port
8 screw terminals for 20 mA loop Figure 3-1 RS232/20ma Converter
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Wire Power to Converter

1. Wire power from the power supply to the converter. See Figure 3-2.
Figure 3-2 Power Supply Out to Converter 2. Connect wiring from power supply to DIN rail. See Figure 3-3.
from Power Supply
GROUND WIRE
Figure 3-3 Power in to DIN Rail 3. Tighten the connector that ties 1,2, and 3 together (3-screw bar near center).
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4. Tighten the connector that ties 4,5, and 6 together (3-screw bar near center). 5. Connect power from DIN rail to each converter. See Figure 3-4. Connect one wire from any of the 24V terminals available on the DIN rail to the 24V screw terminal on the top left of the converter. Connect one wire from any of the 0V terminals available on the DIN rail to the 0V screw terminal on the top left of the converter.
0V
24V
Figure 3-4 Power from DIN Rail to Converter 6. Connect ground for each converter. See Figure 3-3.
Wire Controller to Platforms & Actuators
CAUTION
You cannot use the terminal strip AND the CORRESPONDING 9-pin connector at the same time. 1. Plug in 9-pin connector at the submodule. 2. Plug in 9-pin connector at the converter (RS232). Shielding takes place via the connector frame, which is permanently connected to the ground terminal. If needed, see the pin assignments in Table 3-1.
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Table 3-1 RS-232 Pin Assignments Description Supply Voltage Transmit Data Receive Data Clear to Send Request to Send Functional Ground Data Terminal Ready Data Set Ready Ground Abbreviation 24 V 0V TxD RxD CTS RTS GND STR DSR -Screw Terminal (from left) pin 1 pin 2 pin 4 pin 5 pin 6 pin 7 pin 8 --See note. 9-pin Connector --pin 3 pin 2 pin 8 pin 7 pin 5 pin 4 pin 6 Shield
Note: The ground connection is actually the screw on the RS-232 9-pin connector. 3. If necessary, set the DTE/DCE switch to DTE (factory default). Switch S1 is used to cross the TxD and RxD connection internally, allowing the adaptation to be carried out conveniently. If the connected interface type is unknown, you can determine the correct configuration by trial and error. 4. Leave CTS/RTS jumper AS IS (4-2). The control wires CTS/RTS can be jumpered on the jumper field X7 or as an option actively set to logical 1. The control lines DSR/DTR are permanently bridged internally. This requires the RS-232 cable to have these lines wired as well. 5. Connect wiring from client (i.e. Smart Platform, Smart Actuator, etc.) as described in Figure 3-5 and Table 3-2. Note: DONT forget to set the S1+ to T+ jumper.
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Note: The ground connection is actually the screw on the TTY 9-pin connector.
Figure 3-5 Point-to-Point Wiring (Converter to Client)
Table 3-2 TTY Pin Assignments Description current source 2 neg. polarity current source 2 pos. polarity current source 1 neg. polarity current source 1 pos. polarity transmit data neg. polarity transmit data pos. polarity receive data neg. polarity receive data pos. polarity Ground Abbreviation S1S1+ S2S2+ TT+ RR+ -Screw Terminal (from right) pin 3 pin 4 pin 1 pin 2 pin 7 pin 8 pin 5 pin 6 See note. 9-pin Connector pin7 pin 3 pin 9 pin 5 pin 6 pin 2 pin 8 pin 4 Shield
Note: The ground connection is actually the screw on the TTY 9-pin connector.
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Hardware Setup
The following PORT and INET definitions are current as of the release date of this manual. Other IDs may have been added since then. The existing IDs will not have changed.
Port Allocations
This section describes a facility within the ABB Processor that defines the location and nature of the communication ports accessible from all ABB Processors in an AC450 node. This port configuration is performed by application AMPL software within the AC450.
Basic Function
Per communication port, an ABB Processor object of the class PORT is defined in the ABB Processor where a device handler will manage the communication port. Each such object is populated by an AMPL application with all the information required to define external communication paths also called logical ports. Communication handlers in the ABB Processor locate and examine the object to determine what functionality is required. Examples of communication ports are RS232 serial links attached to a submodule on the FutureBus or to a daughterboard on the ABB Processor, and TCP/IP connections likewise via a submodule or a daughterboard. The requirements to configure each port differ, so some dedicated items and a set of general purpose items are allocated to allow for expansion, ideally, without changing this definition. In the case of TCP/IP connections, logical ports can share physical ports; but each logical port will require a different device handler in the ABB Processor. However, because of the AC450 architecture, all logical ports on the same TCP/IP physical port must be assigned to the same ABB Processor for device handling. TCP/IP connections require an ABB Processor object of the class INET to define the submodules IP address. This address is the same for all logical ports assigned to that submodule.
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Item Definitions for Class ID = Port

Table 3-3 Port Item Definitions Item PORT TYPE Type I I Port logical ID (1 - 255) Type: 1 = ABB standard serial via FB+ 2 = AccuRay Direct serial via FB+ 3 = Time-based serial via FB+ (output only implemented) 4 = ABB Standard Protocol - ASI/AD emulation 5 = AccuRay Sockets Interface client via FB+ 6 = AccuRay Sockets Interface server via FB+ Slot no. & subModule no. of physical port (decimal SM) Physical port no. on submodule (1 or 2) or local TCP/IP port number Baud rate (150 to 38400) Number of data (character) bits (7 or 8) Number of stop bits: 5 = .5 stop bit 1 or 10 = 1 stop bit 15 = 1.5 stop bits 2 or 20 = 2 stop bits Parity: 0 = no parity 1 = odd parity 2 = even parity 3 = parity 0 (force low) 4 = parity 1 (force high) Configuration parameter 1 Type 1 serial setup options: 0 = ABB standard (use defaults: CHAR=8, PRTY=2, STOP=1) 1 = user-defined (use all BAUD, CHAR, STOP, PRTY inputs) Type 2 (or 4) serial setup options: 0 = AccuRay Direct standard (use defaults: CHAR=8, PRTY=0, STOP=1) 1 = user-defined (use all BAUD, CHAR, STOP, PRTY inputs) Type 6 ASI server maximum clients supported CFG2 I Configuration parameter 2 Type 1: Use new hardware settings flag (when value changed) Type 2 (or 4): Maximum queued input messages (defaults to 50 if set to 0) Description
SLOT LPRT IP BAUD CHAR STOP
I I L I 1
C16 TCP/IP address of remote port in dot notation
PRTY
CFG1
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Item CFG3
Type I Configuration parameter 3
Description Type 4 host side connection: 0 = AccuRay Sockets Interface (TCP/IP) 1 = AccuRay Direct Interface (serial)
CFG4 CFG5 CFG6 STS
L L L I
Configuration parameter 4 Configuration parameter 5 Configuration parameter 6 Port status: 0 = OK 1 = Port type code error 2 = Instance limit exceeded for this device handler 3 = Device handler signal channel creation failure 4 = Device handler task creation failure 5 = Instance limit exceeded for transceiver drivers 6 = Transceiver driver task creation failure 7 = Device could not be initialized (perhaps nonexistent) 8 = No response from submodule 9 = bad client count 10 = No INET class defined 11 = No INET object defined 12 = Network setup failure (reported by port doing the setup) 13 = Network is not setup (reported by port not doing the setup) 14 = No connection to remote server
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Item ERR
Type I
Description Last communication error code $0001 = IORB busy $0002 = device not found $0003 = bad port ID $0004 = no response from device (timeout seconds expired) $0005 = invalid operation for defined protocol variant $0006 = no response from device handler (5*timeout secs. expired) $0007 = unsolicited input handler already defined $0008 = message too large $0009 = invalid request $000A = device handler transmission time-out $000B = no path to device formed (check PORT object STS for error) $000C = transceiver signal queue full $000D = logical port disabled $000E = slave request timeout (timeout + 1 secs. expired) $000F = transceiver signal failure (timeout + 1 secs. expired) $0010 = no start-of-message (SOM) character received $0011 = no end-of-message (EOM) character received $0012 = block checksum error $0013 = wrong device responded (device ID mismatch) $0014 = unrecognizable response $0015 = input data count differs from expected $0016 = UART reported overrun error $0017 = UART reported parity error $0018 = UART reported framing error $0019 = no block checksum after end-of-message (EOM) $001A = device queue full $001B = invalid slave protocol model $001C = invalid slave request $001D = slave failed to be initialized $001E = slave UART setup failed $001F = communication manager is offline $0020 = no slave buffer available for request $0021 = slave unable to spawn asynchronous task $0022 = device returned an ACK/NAK code (between driver and slave) $0023 = duplicate AccuRay Direct field number $0024 = serial emulation pass thru message bad command field $0025 = serial emulation pass thru message missing data $0026 = no AccuRay Direct connection (link is down) $0027 = undefined AccuRay Direct group $0028 = unimplemented AccuRay Direct function $0029 = undefine AccuRay Direct function $002A = unable to queue AccuRay Direct request
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Item ERR (cont)
Type I
Description $002B = (undefined) $002C = AccuRay direct packet error $002D = AccuRay Direct packer format error $002E = serial emulation field type differs from groups type already defined $002F = serial emulation bad field conversion type $0030 = bad group reference (AccuRay Direct device reported an error) $0031 = bad field reference (Accuray Direct device reported an error) $1yxx = device responded with command-not-accepted (CNA) y = reason code 1 = invalid command byte 2 = buffer overflow (AMS) 4 = too much data (AMS) 5 = access violation (AMS) 6 = invalid CFN (AMS) or block number (DIU) 7 = data locked (AMS) or invalid block offset (DIU) 8 = length exceeds block (DIU) or file (AMS) boundary xx = received command code $2yxx = device responded with not-accept/negative-acknowledge (NAC) y = reason code 0 = none provided 2 = buffer overrun xx = 01, message too long 02, buffer not available 3 = format error (too much data) xx = received data byte count 5 = overrun error 6 = parity error 7 = character framing error 8 = block checksum error xx = received block checksum character (BCC) $30xx = device responded with error code xx = error code C8 = operation cannot be performed in offline mode C9 = initialization required other = single byte ACK/NAK code (usually expected) $400D = AccuRay Direct disconnect just occurred $400E = no AccuRay Direct messages currently available
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Item HIST
Type L11
Description Activity history array: Total IORB signals received Total output messages Total output bytes Total input messages Total input bytes Total flushed input messages Total flushed input bytes Total retries Total timeout errors Total physical errors reported by the device Total protocol errors
Port Type Configuration

The following configuration parameters are required for ports of a particular type. Type 1: ABB Standard Protocol LPRT physical port number on CI532V09 (1 or 2) BAUD many applications override this baud rate with their own (see CFG1) CHAR number of data bits (default per CFG1) STOP number of stop bits (default per CFG1) PRTY parity (default per CFG1) CFG1 0 = ABB standard (use defaults: CHAR=8, PRTY=2, STOP=1) 1 = user-defined (use all BAUD, CHAR, STOP, PRTY inputs) CFG2 use new hardware settings flag when this value changes (permits runtime changes) Type 2: AccuRay Direct LPRT physical port number on CI532V09 (1 or 2) BAUD baud rate (see CFG1) CHAR STOP PRTY CFG1 number of data bits (default per CFG1) number of stop bits (default per CFG1) parity (default per CFG1) 0 = AccuRay Direct standard (defaults: CHAR=8, PRTY=0, STOP=1) 1 = user-defined (use all BAUD, CHAR, STOP, PRTY inputs)
CFG2 maximum queued input messages (defaults to 50 if set to 0) Type 3: BIOS serial LPRT physical port number on CI532V09 (1 or 2) BAUD CHAR STOP PRTY baud rate number of data bits number of stop bits parity
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Type 4: ABB Standard to AccuRay Direct emulation CFG3 0 = AccuRay Sockets Interface (TCP/IP) (must also set type 5 parameters) 1 = AccuRay Direct (serial) (must also set type 2 parameters) CFG4 timeout override in seconds (defaults to applications serial timeout) Type 5: ASI client side LPRT remote IP port number of server IP remote server IP address CFG2 maximum queued input messages (defaults to 50 if set to 0) Type 6: ASI server side LPRT local IP port number of server CFG1 maximum clients supported (defaults to 1 if set to 0)
Item Definitions for Class ID = INET

Table 3-4 INET Item Definitions Item SLOT IP MASK GATE NAME STS I Type I Description Slot number & subModule number of physical port (decimal SM)
C16 IP address of local port in dot notation C16 Subnet mask in hexadecimal long format (e.g. FFFF0000) (optional) C16 IP address of default gateway in dot notation (optional) C16 Name of local host (optional) Network setup status: 0 = OK 1 = port type conflict Subnet masking default to one of the standard IP address classes (A, B, or C). If a nonstandard mask is used, see Table 3-5 for conversion from decimal to hexadecimal. each of the octets in the dot notation corresponds to a pair of hexadecimal digits in the subnet mask format reading from left to right. For example, 255.255.128.0 = FFFF8000. Table 3-5 Decimal to Hexidecimal Conversions
Decimal
255 254 252 248 240 224 192 128 0
Binary
11111111 11111110 11111100 11111000 11110000 11100000 11000000 10000000 00000000
Hexidecimal
FF FE FC F8 F0 E0 C0 80 00
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If ABB applications need to connect to IP ports on another subnet, a router must be attached to the local network. This router is known as a gateway and must be assigned a local network IP address. Networking software will automatically direct all TCP packets with the IP addresses not matching the local network address through this default gateway. It is not necessary to provide a host name for this submodule, unless a remote user will try to connect to this IP address by host name.
Application Port Assignment

The association of application to serial port object is implemented within each application where the application port number uniquely maps one-to-one to the port ID item in the port class. To avoid having to change port configuration parameters in the target system, match the software to the customer hardware during configuration. If you need to change/ look up the baud rate, it can be found in each applications code. Frame ports are configured via table parameter xFM.TLRNIO. Generally, row number = frame number value = (port #) 256 + 1 HyperScan requires two ports. Their configuration resides at the following locations: PC11.1.211:5 PC11.1.211:6 D=5 D=6 FFS1_Port1 FFS1_Port2
Actuator ports are set at the following locations: IR Profiler (CDIR) Parallel Linear Stepper (CDWT) Water Spray (CDAW) ScaniValve (CDGN) Smart Calender (CDTP) Serial (CDSR) Smart Weight (CDWT) xPNy.PRT1NM xPSy.PRT1NM xPWy.PRT1NM xPGy.PRT1NM xPYy.PRT1NM xPZy.PROTID xPXy.PRT1NM xPXy.PRT2NM xPSy.PRT2NM
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Hardcopy Printer Setup

To connect an HP Deskjet 1600 network printer to an Advant Station (OS 1.7 or later), perform the following steps: From the printer: 1. Printout the Printer Setup Page. From the Advant: 2. Press System Config. 3. Press Settings (D6). 4. Press Printer Config (D3). 5. If Hardcopy printer exists in the printer list, remove it. a. Select Hardcopy printer. b. Select Actions-->Remove printer. Answer the warnings OK. 6. Select Actions -->Add Printer Connected to HP JetDirect.... 7. Press OK in pop-up note. The following window will appear:
8. Select 1 (Create printer configuration in BOOTP/TFTP database). 9. Enter LAN Hardware address. 12 character name shown on the Printer Setup Page. 10. Enter the network printer name or IP Address. 11. If you enter a name you may be asked to enter the IP Address now. Do so. 12. Press y to Add [printername] and [IP address] to /etc/hosts. 13. Enter 1 for ethernet connection. 14. Select q when done to exit back to the configuration utility.
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15. Select 3 (Add printer to local spooler). 16. Enter network printer name or IP address (from step 10.). 17. Select 1 (LP destination name). 18. Type Hardcopy. To set up a postscript printer instead, type Postscript. 19. Press 4 to turn the job monitor off. 20. Press 6 (Additional printer configuration). 21. Press 1 (Model script). 22. Type net_lj4x (default value). To set up a postscript printer instead, type postscript. 23. Press 0 to configure. 24. For any other station you can now omit steps 8-14.
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I/O Subrack
For complete information on the S800 I/O refer to S800 I/O Users Guide, 3BSE 008 878 latest revision. See Figure 3-6 and Figure 3-7.
AC450 Cabinet CI522 TK515 Hardware Installation & Setup 103049-001 TC512 Modem TC505 TC501 V150
AI810 MTU835
AI810 MTU835
AI810 MTU835
AO810 MTU830
AO810 MTU830
DI820 MTU831
DI820 MTU831
DO820 MTU831
DO820 MTU831
SD812 24VDC 5A
CI810 Station 2 TC501V150 TC505 AF100 SD812 24VDC 5A
AI810 MTU835
AI810 MTU835
AI810 MTU835
AI810 MTU835
AO810 MTU830
AO810 MTU830
AO810 MTU830
AO810 MTU830
AO810 ... MTU830
up to J6
Figure 3-6 Sample Layout for S800 I/O
TB807
TB807
54
CI810 Station 1 TC501V150 TC505 AF100
#12WH
#12GR
Power Distribution Panel 120 VAC 3C/12 AWG

#12BLK #12WH
#12BLK
NEU GND #12GR 120 VAC
SD812 24VDC 5A 3C/12 AWG

+24 VDC 0 VDC DC OK L+ L- SA L+ L- SB
AI810 MTU835
+ -
AI810 MTU835
AI810 ... MTU835
+ -
#12BLK
SH
SH
SH
SH
NEU GND Hardware Installation & Setup 55
#12WH #12GR #12BLK
TC505
+ -
#12WH
#12GR
SH
SH
SD812 24VDC 5A
+24 VDC 0 VDC DC OK L+ L- SA L+ L- SB
AI810 MTU835
+ -
AI810 MTU835
AI810 ... MTU835
+ -
Located in back of cabinet
SH
SH
SH
SH
as necessary
Figure 3-7 Sample Wiring for S800 I/O
TB807
1P/22AWG AF100 <2450 ft (750 m)
L (120 VAC) N (Neutral) PE (Ground)
CI810 Station 2
TB807
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L (120 VAC) N (Neutral) PE (Ground)
CI810 Station 1
Fieldbus Information
For Fieldbus information, refer to the Advant Fieldbus 100 Users Guide, 3BSE 000 506 latest revision.
MasterBus Information
For Masterbus infomation, refer to the Master Net Users Guide, 3BSE 003 839 latest revision.
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Software Installation & Setup
Note: This chapter contains general procedures and overview information. For details, refer to the READMEs; first.mex, syread.mex, avfirst.mex; the 1190 Production Toolbox with Advant; and the 1190 Software Configuration Spec. All documents are available on the ABB Information Exchange (ABBIE). The READMEs are also loaded with the software. Section............................................................................................... Page Overview ....................................................................................................... Toolbox Commands ....................................................................................... Licenses ......................................................................................................... Configuration & Setup Displays ................................................................... 58 59 60 61
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Overview
For the build of the controller to be smooth, it is important that the following steps be performed in order. 1. Modify the system scan table cycle times with APP command. a. Change interpreter C cycle time from 250 to 500 ms. b. Change interpreter B cycle time from 50 to 100 ms. c. Change interpreter A cycle time from 10 to 20 ms. 2. Dimension database using report generated from DIM1190 command. 3. Dimension PC from available feature data. 4. Create I/O boards (optional) This allows AI, AO, DI, DO to reside in the beginning of the database. The customer tagnames must be added using MDB. Note if the customer I/O is added by hand, it must be removed from the Level 1 Database. 5. Load system database source code using the command file TRANSDB.CF. Note SY01.BA is the first database to be translated. The Level 1 database created using the type circuits should be included. The Level 1 database may include the customers I/O, provided step 3 was not performed. Otherwise, the customers I/O should be removed from this database. 6. Load all required MP logical dumps (.LD). 7. Translate all PC programs using the command file TRANSPC.CF. 8. Do necessary configurations and modifications. 9. Create AAB_FILES and load the LICENSE and PMM files. License is 1 file element at 1 kb size. 10. Create TTD logs in the controller.
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Toolbox Commands
The following commands should be performed in the order shown. cfg1190jonnnn cfglvl1jonnnn bld1190jonnnn bldlvl1jonnnn dim1190jonnnn cmp1190jonnnn trs1190jonnnn configure a job order configure level 1 I/O and control for job order build a job order build level 1 I/O and control for job order scan all of the node source and produce dimensioning reports compress the node source build execute command files for database and AMPL PC programs
where jonnnn = job order identifier (It is used to select correct job order directory.)
cfg1190
bld1190 dim1190 comp1190 trs1190
cfglvl1
bldlvl1 Figure 4-1 Command Sequence
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Licenses
The AC450 license file is downloaded to the ABB Processor board in the AC450, where it will be decrypted and enforced. If the license file is not downloaded and/ or properly installed, the ABB Processor will randomly halt with a code 66. The license database file exists in the MP database as an AAB_FILE element. One AAB_FILE element should be dimensioned for the license file. The AAB_FILE is created using CRDB. The name is LICENSE and property ALL_SIZE is 1 kb. The license file will be generated by the system manufacturing process when a system order is placed. The file is an encrypted binary file and should be downloaded (ftp) and/or copied into the MA220 project. The file is then loaded into the MP database elements with the MA220 command: LAABF SRCE:<download filename>.DD,<AAB_FILE name> The same license file should be loaded into all nodes in a multi-node system. License files should always be loaded in P2 mode. If a new license is being loaded and one was previously loaded, all ABB Processors should be given an INIT (with the INIT button) before trying to run the system.
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Configuration & Setup Displays

The following sections describe the start-up, shutdown, and several other setup displays used by control system Advant station.
Advant Start-Up Display

1. Turn the station on. When the Advant station is starting up, you will see the following window:
2. Enter the necessary information. If you select help, you will see the following window:
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3. Press OK. The start up will continue until the following screen appears.
If you select help, you will get the following window:
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4. Select the desired workstation mode and press OK. Startup will continue, until you see the following screen.
5. Select the startup mode. 6. Select the user name
7. If necessary, enter the password. The workstation will finish its startup. The basic display will appear.
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Advant Orderly Shutdown

To shutdown the advant station, perform the following steps: 1. Open a terminal window. 2. Type: su [Enter] 3. Type the password and press [Enter]. 4. Change to the root directory, type: cd/ [Enter] 5. Type: shutdown-h0 [Enter] After the system has shutdown, you may turn off the machine.
Product Code/Grade Data Setup Display

See Figure 5-8 on page 90. See Chapter 5 Startup, IndustrialIT Quality Control Operator Manual Advant Stations, 103014-001, and IndustrialIT Quality Control Basic Controls Tuning Guide Release 4.x & later, 103043-001 for information about setting up grade data.
UPS Setup Display

To turn the UPS function on or off, perform the following steps: 1. Select System Config. 2. Select Settings (D6). (continued on next page)
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3. Select Station Settings (D2). The following window appears.
4. Turn UPS on or off as desired by selecting the appropriate diamond and pressing OK.
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Object References
To find unresolved object references perform the following steps. You can also perform other object reference actions from the window shown in step 4. 1. Select System Config. 2. Select Maintenance (D8). 3. Select Object References (D6). 4. Enter password. You will see the following window:
(continued on next page)
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5. Select List. You will see the following window:
6. Set Reference Status to Unresolved. (continued on next page)
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7. Press OK. If any objects are listed here, you have a problem in the system. Contact your application engineer for help resolving these objects. The results of your search will appear in the following window:
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Advant Procedures
CPIO Backup Procedure
A CPIO backup tape is a copy of the whole disk, but it is not a bootable tape. At the UNIX prompt, become superuser and then change directory to root. Put a tape in the drive and do the cpio. When finished (1 hr.), be sure to mark the number of blocks on the tape label along with the date, hostname, etc. 1. Type: su [Enter] 2. Enter the password [Enter]. 3. Change to root directory. Type: cd/ [Enter] 4. Insert tape into DAT drive. 5. Type: find.|cpio-ocxB>/dev/rmt/0m [Enter] Where: -o -c -x -B tells it to output writes header in ASCII format handles special (device) files block input/output at 5120
Station Backup Procedure

To backup the Advant station, perform the following steps: 1. Select System Config. 2. Select Maintenance. 3. Select Station Backup. 4. Enter password. 5. Highlight backup you wish to perform. 6. Select Action-->Start Program.
Restore Station Backup Procedure

To restore a backup of the Advant station, perform the following steps: 1. Select System Config. 2. Select Station. 3. Select Function Restart. 4. When asked to select workstation mode, select Backup Restore mode. 5. Highlight the backup you wish to restore. 6. Select Action-->Start Program.
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Application Dump/Load Procedures

To dump or load the application software, follow the steps below: 1. Open the On-Line Builder. 2. Connect to the controller. 3. To dump the software, type: DUAPfilename 4. To load the software, type: LOAPfilename
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5
System Startup
Chapter Three discusses System Startup, including the major sections listed below. Section............................................................................................... Page Startup Checklist ........................................................................................... Smart Platform Data Setup ............................................................................ PMM-Based Frame Data Setup ..................................................................... Set Up Scan Speed .................................................................................. Set Up Scan Speed .................................................................................. Set Up Coldstart Variables ...................................................................... Servo Set Up ........................................................................................... Set Up Auto Edge-Of-Sheet (AEOS) ..................................................... Setting Sheet-Break Override ................................................................. Grade Data Setup ........................................................................................... Changing Grade Dependent Data Grouping ........................................... Changing System Grade Data ................................................................. Changing Measurement Grade Data ....................................................... 72 73 75 75 75 77 82 84 87 89 89 91 92
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Startup Checklist
Complete the following tasks, in the order given, to start up the system. Power-up the air conditioner and decontamination unit. Power-up the PMM (1190 PMM Reference Manual, 101764-002) or AAM (Technical Manual, 101033-001). Power-up the hardcopy printer. Power-up the Advant Controller and Advant Operator Station. Refer to the Installation Commissioning and Service Manual, 7650-043-205. Power-up the cooling unit. Refer to the Liquid Cooling Unit Reference Manual, 101333-003. Power-up the Smart Platform as detailed in the SP 700 / SP1200 manuals. Power-up the sensor hardware. See the appropriate sensor manual. Verify that each component listed above is running. Perform radiological procedures. See the Radiation Safety Manual, 019406-001. Setup frame data. See Smart Platform Data Setup on page 73 or PMM-Based Frame Data Setup on page 75. Perform initial static verification for each sensor. Refer to the appropriate sensor manual(s). Setup grade data. See Grade Data Setup on page 89. Perform initial process measurement verification. Refer to the appropriate sensor manual(s).
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Smart Platform Data Setup

For each frame, collect the following information and enter it as indicated below. Scan time: This scan time is for Independent Mode operation only. Number of profile points - on the Frame Setup Page. Default Standardize: clean or dirty Conditioned weight and bone dry weight factors: refer to the Computed Sensor Variables Manual, 101766-014.
See Figure 5-1 on page 74. The following procedure assumes an Advant Operator Station. MasterView setup is similar except you must enter Max Dialog and put the scanner in Manual mode after steps 4. and 12. 1. Select the SP Frame Setup Page. 2. Select the frame number field. 3. Enter the desired frame number and press SEND. 4. Select the Read Setup diamond. 5. Refresh the display. 6. Select the Scan Time field. 7. Enter the desired scan time (in seconds). 8. Select the # Profile Points field. 9. Enter the desired number of profile points. 10. Select the Default Standardize field. 11. Enter the desired default standardize. 0 = dirty; 1 = clean 12. Select the Save Setup diamond. 13. Select Frame Overview display. 14. Select desired frame. 15. Select Extend (D5). 16. Select Frame Reload (D6).
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Figure 5-1 Frame Setup Display
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PMM-Based Frame Data Setup

For each frame, collect the following information and enter it as indicated below. Scan time: Set Up Scan Speed on page 75. This scan time is for Independent Mode operation only. Number of profile points: on the PMM Frame Setup display. Conversion factors: refer to the Computed Sensor Variables Manual, 101766014, and the 1190 PMM Reference Manual, 101764-002. Conditioned weight and bone dry weight factors: refer to the Computed Sensor Variables Manual, 101766-014. Type of basis weight/conditioned weight target entries: refer to the Computed Sensor Variables Manual, 101766-014, and the 1190 PMM Reference Manual, 101764-002.
Set Up Scan Speed

See Figure 5-2 on page 76. The following procedure assumes an Advant Operator Station. MasterView setup is similar except you must enter Max Dialog after steps 3. and 9. 1. Select the PMM Frame Setup Page. 2. Select the desired frame. 3. Place the cursor in the Read Setup diamond and press SELECT. 4. Put the frame in Manual. 5. Refresh the display. 6. Select the Scan Time field. 7. Type the value for scan time (in seconds). 8. Press SEND. 9. Select the Save Setup diamond. 10. Select Frame Overview display. 11. Select desired frame. 12. Select Extend (D5). 13. Select Frame Reload (D6).
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Figure 5-2 PMM Frame Setup Display
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Set Up Coldstart Variables

Fixed Far Edge-of-Sheet (EOS) and Fixed Home EOS (the maximum scan limits) define the resolution of the available data boxes in the video display. It is important that all scanning is done within these limits, and all frames on the same line have approximately the same limits. All frames on a multi-frame installation must be aligned with each other so they share the same sheet center line. The scan limits should be symmetrical about the center line. See Figure 5-3. Frame Position Variables are defined in Table 5-1.
Max Trim LFEOS Frame 2 Frame 1 Center of Sheet LHEOS
Figure 5-3 Frame Limits Table 5-1 Frame Position Definitions Position Off-sheet STDZ Single Point Definition Position on the frame, next to the process, where maintenance will be performed on the sensor heads Position on the frame, just off the process sheet edge, where sensor standardization takes place The default single point position where the sensor heads stop whenever this mode is entered The scanning home edge-of-sheet position that is closest to the off-sheet position; this must be within the maximum trim limits (Fixed Home and Fixed Far EOS) The scanning edge-of-sheet position farthest from the off-sheet position; this must be within the maximum trim limits (Fixed Home EOS and Fixed Far EOS) Determines the minimum limits of Current Home EOS Determines the maximum limits of Current Far EOS The additional distance the heads will travel when first coming on-sheet to assure that sheet contacting sensors, such as caliper, are fully on-sheet before making contact; the heads will then back up to the Current Home EOS position to start scanning
Current Home EOS
Current Far EOS Fixed Home EOS Fixed Far EOS
Delta for On-sheet Move
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Determine Fixed Home and Far EOS

1. Position the heads using the jog controls on the frame so the measurement window center line is lined up with the edge of a nearby roll. 2. Record the head position in A/D units (Fixed Home EOS and Fixed Far EOS) for both ends of the roll. 3. Enter the Fixed Home EOS and Fixed Far EOS onto the Frame Setup display. 4. Permanently mark the frames with electrical tape or a suitable substitute to identify where Fixed Home EOS and Fixed Far EOS are set. This mark makes it easier to check these limits later during routine maintenance.
Determine Off-Sheet, STDZ, Single Point, Current Home EOS, and Current Far EOS Values
1. Disable automatic edge-of-sheet, if enabled. 2. Put the frame in Local from the frame control panel. The Local indicator should illuminate. 3. Press JOG on the frame control panel until the sensor heads are at the selected head position (Off-Sheet, STDZ, single point, current home EOS, and current far EOS). 4. Read and record the measured head position in A/D units. 5. Repeat Steps 3 and 4 for each variable. 6. Enter the recorded integer values onto the Frame Setup display.
Determine Delta for On-Sheet Move

If the sensor package contains contacting sensors such as the MK5 Caliper, it may be desirable to start the scanning inside the scan limits in order to reduce the possibility of a sheet-break by coming down on the edge of the sheet. Delta for Onsheet Move will force the heads initial measurement of the sheet to start a safer distance from the edge. Subsequent scans go to Current Home EOS limit. 1. Verify that the current edge-of-sheet limits (Current Home EOS and Current Far EOS) are set inside the maximum limits (Fixed Home EOS and Fixed Far EOS). See Figure 5-4 for the frame coldstart positions.
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Sheet
KHEOS OFF STDZ LHEOS DHEOS
KFEOS LFEOS
Video
Figure 5-4 Frame Coldstart Positions on Frame and Video Profile
2. Jog the sensor heads to the desired on-sheet READY-TO-MEASURE position. 3. Read and record the integer position value. 4. Jog the sensor heads to the Current Home EOS HOME position. 5. Read and record the integer position value. 6. Subtract the integer value of Step 3 from the integer value of Step 2. The difference is the value of Delta for On-Sheet Move. 7. Enter the integer value onto the Frame Setup display. Note: Larger values of Delta for On-Sheet Move are useful if the heads sometime hang up when auto edge-of-sheet is used.
Set Current EOS Positions

To manually set up edge-of-sheet (EOS) positions, complete the following steps using the controls on the frame control panel. Figure 5-5 on page 81 shows the control panel found on the ABB scanning Measurement Platforms. Note: Make sure you do not exceed the maximum scan limits when performing the following steps. An entry error will result if the scan limits are exceeded. 1. Take the frame off-sheet. 2. Put the frame in Local. 3. Press and hold JOG FORWARD until the sensor reaches the desired far edgeof-sheet position.
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CAUTION
This position must be less than or equal to the far edgeof-sheet limit and greater than the current home EOS. 4. Press FORWARD LIMIT. 5. Press and hold JOG REVERSE until the sensor reaches the desired home edgeof-sheet position. CAUTION
This position must be greater than the home edge-ofsheet limit and less than the current far edge-of-sheet limit. 6. Press REVERSE LIMIT. 7. Put the frame in remote. 8. Put the frame on-sheet. CAUTION
EOS limits moved in far enough to drop a logical zone require a system restart. Note: The maximum number of data boxes is determined by the scan limits Fixed Far EOS and Fixed Home EOS. Moving the current edge-ofsheet positions inside the limits causes the end data boxes to be empty.
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SOURCE CLOSED
SOURCE OPEN A red indicator lamp that lights when the radiation source shutter on the sensor head is OPEN.
ON-SHEET
A green indicator lamp that is ON when the radiation source shutter on the scanning head is CLOSED.
OFF-SHEET
This push button causes the sensor package to move off-sheet. When you press the button, scanning is not under computer control until you press the ONSHEET push button.
This push button allows the sensor package to move onsheet and enables computer control of scanning.
LOCAL
Press to transfer control of the platform from computer to manual so you can use the jogging function.
JOG REVERSE
REMOTE
Press to transfer control to the host system.
Press to manually drive the scanning head backward.
JOG FORWARD
Press to manually drive the scanning head forward.
REVERSE LIMIT
Press to set the reverse scanning limit.

CALIBRATE SAMPLE
FORWARD LIMIT
Press to set the forward scanning limit.

SAMPLE CHECK
Enables special sensor data collection. Use it in conjunction with lab tests at the completion of a reel. Reserved for Future Use
Press to activate scanning head measurement circuitry when the head is off-sheet. It allows you to make a sample check measurement. Reserved for Future Use
Figure 5-5 Measurement Platform Control Panel
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Servo Set Up
A Direct Digital Control (DDC) loop in the Programmable Microcomputer Module (PMM) Frame/Sensor coordinator controls the positioning of the head. The DDC scanning constants compensate for different frame lengths on the same system. The constants for the DDC are transferred to the PMM at load time. The following sections explain how to set up the DDC servo.
Tuning Guidelines
Use the following overall guidelines for tuning: Ensure that the motor controller on the frame is correctly adjusted according to the instructions in the appropriate frame manual. Perform Tune the Single Point Measurement Mode. Tune one frame at a time on any system that has multiple frames. Adjust one variable at a time to minimize interactions between variables.
Tune the Single Point Measurement Mode

Follow the steps below to tune the servo constants in single point mode. 1. Select the Frame Setup display. See Figure 5-2 on page 76. 2. Select the desired frame. 3. Select READ SETUP. 4. Determine the Positioning Gain to achieve smooth and quick positioning with little overshoot using the guidelines below. The default value of Positioning Gain is 10. Avoid changing the dead band. The initial value of dead band should be -128. Positioning Gain is the Inverse Servo Gain. Eight indicates a higher gain than 9. Typical values are 4 to 12 for the Measurement Platform. If the servo is sluggish, decrease the value of Positioning Gain. If the servo is unstable, increase the value of Positioning Gain. The negative dead band is in A/D units. Typical values are -128 to -40 units, where -128 represents a wider dead band than -40. If the servo has trouble with position complete, make dead band wider. If the servo has inaccurate positioning, make dead band narrower. 5. Enter the new values for POSITIONING GAIN and NEGATIVE DEAD BAND in the SERVO SETUP section. 6. Use the following guidelines to adjust the INTEGRAL GAIN to achieve quick position complete. Make changes to INTEGRAL GAIN in increments of 1000 decimal. The default value of INTEGRAL GAIN is 2000 decimal.
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The INTEGRAL GAIN term is scaled by the proportional gain. During the scan mode this scaling results in reduced effects due to the integral gain.
7. Write the gain and dead band values to the database by selecting WRITE SETUP. These values will be used when a PMM reload is performed. 8. Reload the PMM.
Tune the Scanning Gain

Use the following procedure to tune the scan measurement mode: 1. Select the Frame Setup display. See Figure 5-1 on page 74. 2. Adjust MULTIPLIER FOR EOS DELTA to achieve a smooth scan at the edgeof-sheet position. Typical values are between 2 and 5. 3. Adjust the SCANNING GAIN to provide smooth and even scanning. SCANNING GAIN is active when the target velocity is non-zero. The default value of SCANNING GAIN is 8. 4. Write the gain and dead band values to the database by selecting WRITE SETUP. These values are used when a PMM reload is performed. 5. Reload the PMM. Note: In some cases, you may need to readjust the Positioning Gain to provide smooth and even scanning. This adjustment results in some overshoot when operating in single point mode.
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Set Up Auto Edge-Of-Sheet (AEOS)

Follow the steps below to make AEOS entries on the Frame Setup Page. 1. Determine the customer units (inches or centimeters) for the trim measurement. 2. Obtain a precise measurement of L1, L2, E1, E2, S1, and S2 within an accuracy of 1/16 inch (0.16 cm). See Figure 5-6 and Table 5-2. CAUTION
If AEOS is disabled for the frame that was selected for measured sheet width, then the active trim source is an operator entry.
L2 S2 E2 Sensor Measurement Head
L1 S1 E1 Sensor Measurement Head
D2
D1
D2
D1
Far Edge of Sheet
Measure Window Scan Width Trim Width
Home Edge of Sheet
AEOS Dimensional Relationships to Process Edges
Figure 5-6 Auto Edge-of-Sheet Parameters
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Table 5-2 AEOS Frame Setup Entries AEOS Entry L1 Description Required Values
Distance between center of the Home Edge-of- Must be greater than 9.9 Sheet HEOS detector (D1) and head reference inches (in) or 25.2 line in customer units centimeters (cm) Distance between center of the Far Edge-ofSheet (FEOS) detector (D2) and head reference line in customer units Must be greater than 6.4 in or 16.3 cm
L2
E1
Distance in customer units between center of Must be between S1/2 HEOS detector (D1) and home sheet edge when and S1-D1 head is positioned at the desired home edge-ofsheet position at the off-sheet end of the frame Distance in customer units between center of Must be between S2/2 FEOS detector (D2) and far edge-of-sheet when and S2-D1 head is positioned at the desired far edge of sheet position Distance between the center of the HEOS detector (D1) and the HEOS side (M1) of the sensor cluster Distance between the center of the FEOS detector (D2) and the FEOS side (M2) of the sensor cluster Sheet width computation offset in customer units Must be less than L1-2.4 in (6.1 cm) Must be less than L2-2.4 in (6.1 cm) Determined by any consistent errors that occur in calculation of sheet width 0 = Disable 1 = Enable
E2
S1
S2
SWO
ENABLE
Enables or disables AEOS
Note: A compromise must be reached in determining the S and E dimension. Bringing the window area edge close to the sheet edge decreases the size of the scan adjustment sensitivity dead band, which is twice the S and E distance. If S and E is small, there will be frequent scan limit changes resulting in longer waits at EOS in order to re-compute the scan speed and data box arrangement. The measurement window area will also be close to the sheet edge. If S and E is large, the measurement window area will not be close to the sheet edge, but there will be few, if any, scan limit changes occurring. This condition is a problem if sheet wander brings the sheet out from under the measure windows. Therefore, in setting up the E dimension, make sure the anticipated sheet wander will not exceed S and E.
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3. Enter the values for L1, L2, E1, E2, S1, and S2 in customer units on the Frame Setup Page under the column Auto Edge of Sheet Setup. See Table 5-3. Table 5-3 Setup Limits of the AEOS Variables Variable E1 E2 L1 L2 S1 S2 Nominal 12.1 (30.7 cm) 8.6 (16.8 cm) 16.5 (41.9 cm) 11.0 (27.9 cm) 14.1 (35.8 cm) 8.6 (21.8 cm) Minimum S1/2 S2/2 9.9 (25.1 cm) 6.4 (16.3 cm) E1 + D8 E2 + DB Maximum S1 - D1 S2 - D2 N/A N/A L1 - 2.4 (6.1 cm) L2 - 2.4 (6.1 cm)
4. Take the frame off-sheet from the Frame Object Display Page. 5. Reload the PMM to make the entries active. See the 1190 PMM Reference Manual, 101764-002.
Changing Measured Sheet Width

Measured sheet width is a feature of auto-edge-of-sheet. The system can receive the value for the sheet width the following two ways: As an operator entry of trim As input from AEOS sheet edge detectors on a frame that has AEOS enabled CAUTION
When the sheet width source width is changed from measurement to operator entry, the Trim Next Reel must be entered by the operator. The new trim will be activated at the next reel turnup or grade change. The system computes measured trim in customer units at each edge-of-sheet. It uses the value for active trim. The factor to convert from DAC units to customer units will be the slope of the frame position. The slope is computed from the fixed home and far EOS positions in EU (customer engineering units) and the fixed home and far EOS positions in A/D units. There is also a factor to compensate for the measurement offset. The slope automatically computes at startup after the procedures are completed.
86
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103049-001
Follow the steps below to change measured sheet width. 1. Move the heads to the fixed home EOS. 2. Record the distance in customer units from the endcasting of the frame to the center of the window. 3. Mark the sensor head position if it is not already marked. 4. Move the sensor head to the Fixed Far EOS. 5. Record the distance in customer units from the endcasting of the frame to the center of the window. 6. Mark the sensor head position if it is not already marked. 7. Enter these numbers in Customer Engineering Units (EU) on the Frame Setup display as Fixed Far EOS and Fixed Home EOS. 8. Perform a PMM reload. See the PMM Reference Manual, 101764-002.
Setting Sheet-Break Override

The sheet-break override feature allows you to request or cancel a sheet-break override. You can request a sheet-break override for one specific frame or for any number of frames. There are two types of sheet-break overrides: Local: Operates only at the PMM level and allows operation of the frame without affecting control functions. Global: Operates at both the microcomputer and the PMM levels and affects all system functions that occur during a sheet-break, including report data.
Setting Global Sheet-Break Override

Follow the steps below to request a sheet-break override for all frames. The following procedure assumes an Advant Operator Station. MasterView setup is similar except you must enter Max Dialog after step 2. 1. Select the desired frame object. 2. Press OBJ. DISP. See Figure 5-7. 3. Press D6 (MAINT CODE). 4. Enter the code. 5. Press the D-key that corresponds toMORE CMDS. 6. Press D10 (Keyboard). 7. Press the D-key that corresponds to GLOBAL SBO.
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87
Setting Local Sheet-Break Override

Follow the steps below to request a sheet-break override for an individual frame. The following procedure assumes an Advant Operator Station. MasterView setup is similar except you must enter Max Dialog after step 2. 1. Select the desired frame. 2. Press OBJ. DISP. See Figure 5-7. 3. Press D6 (MAINT CODE). 4. Enter the code. 5. Press D10 (Keyboard). 6. Press the D-key that corresponds to LOCAL SBO.
Figure 5-7 Frame Object Display
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Grade Data Setup

Grade Data Setup involves the following: Changing Grade Dependent Data Grouping Changing System Grade Data Changing Measurement Grade Data
Changing Grade Dependent Data Grouping

The following procedure explains how to change grade dependent data grouping. The following procedure assumes an Advant Operator Station. MasterView setup is similar except you must enter Max Dialog after step 3b. 1. Select the Grade Grouping display. See Figure 5-8. 2. Select the numbers beside the words PRODUCT CODE and enter the desired grade number. 3. Enable save, if necessary, by doing the following: a. Select the Enable Save box. b. Select D1 (Block Input). c. Select D10 (Keyboard). d. Select D1 (On) 4. Select the group you want to change. 5. Enter the new group number. 6. Press SEND. 7. Select the SAVE diamond to save your changes.
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89
Figure 5-8 Grade Grouping Display
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Changing System Grade Data

The following procedure explains how to change system grade data, including trim standard, reel standard, run time standard, machine speed standard, ream size standard, rush/drag set point, and machine speed target. 1. Select the Grade Data display. See Figure 5-9. 2. Select the GROUP number. 3. Enter the group number you want to view. 4. Select the GET diamond to retrieve the data for that group. 5. Enter the new system data by selecting the numbers beside the words, entering the information, and pressing the SEND key. 6. Select the SAVE diamond to save the data.
Figure 5-9 Grade Data Display
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91
Changing Measurement Grade Data

The following procedures explain how to change grade dependent data for measurements. Basis weight is used here as an example. 1. Select the Measurement Grade Data display. See Figure 5-10. 2. Select the GROUP number. 3. Enter the group number you want to view. 4. Select the GET diamond to retrieve the data for that group. 5. Enter the new measurement data by selecting the numbers beside the words, entering the information, and pressing the SEND key. 6. Select the SAVE diamond to save the data.
Figure 5-10 Grade Dependent Basis Weight Display Example
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Index
Numerics
20ma converter, 39
D
Deconamination units, 23 Delta for On-Sheet Move, 78 Direct Digital Control Setup, 82
A
Actuators, 10 installation, 38 power, 24 Air calculations, 27 requirements, 26 Altitude, 16
E
Edge-of-Sheet auto, 84 current far, 78 current home, 78 current position, 79 fixed far, 78 fixed home, 78 Electronics Cabinets, 10 connecting cables and utilities, 33 handling, 32 mounting, 32 Electrostatic Discharge (ESD), 29 Enclosure rating, 17 requirements, 19 Environment, 14 altitude, 16 cabinet, 19 checking, 22 contamination, 17 enclosure rating, 17 humidity, 14 HyperScan, 20 operator station, 19 rectifying, 23 Smart Color, 20 Smart Platform, 20 summary, 21 temperature, 14 vibration, 15
B
Backup software, 69
C
Cabinet environment, 19, 23 I/O rack, 5 installation, 32 cables, 33 utilities, 33 layout, 3 location, 11 power, 5, 24 processor & communications rack, 5 Cables connecting, 33 Communications rack, 5 layout, 6 main processor, 7 submodules, 8 Compatibility, 2 Configuration port, 49 Contamination, 17 Converter RS232/20ma, 39 wiring, 39
F
FieldBus, 56 Flexible Couplings installing, 36
103049-001
Index
93
G
Grade data setup, 89 Grounding, 25
Port allocations, 44 assignment, 51 configuration, 49 definitions, 45 Power cabinet, 5 distribution panel (PDP), 35 grounding, 25 requirements, 24 Printer setup, 52 Processor ABB, 9 main, 7 Processor rack See Communications rack, 5
H
Hardware installation, 32 printer, 52 setup, 44 Humidity, 14 HyperScan, 8, 9 environment, 20 installation, 34 power, 24
I
I/O, 5 layout, 54 wiring, 55 Installation actuator, 38 cabinet, 32 electronics cabinets, 32 hardware, 32 HyperScan, 34 power distribution panel, 35 preparation, 29 scanning frames, 34 Smart Platform, 34 software, 5860 tachometer, 36 utilities requirements, 24 verifying electrostatic discharge, 29
R
RS232, 8 converter, 39
S
Setup grade data, 89 hardware, 44 PMM-based frame, 75 printer, 52 Smart Platform, 73 software, 61 Smart Color environment, 20 power, 24 Smart Platform environment, 20 installation, 34 power, 24 setup, 73 Smart Platforms air calculation, 27 Software backup, 69 dump/load, 70 installation, 5860 setup, 61 Startup, 72 Submodule, 8 connection, 39 System Grade Data, 91
M
MasterBus, 8, 56 Mounting cabinet, 32
O
Operator station backup, 69 environment, 19, 23 location, 11
P
PCMCIA, 7, 9
94
Index
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T
Tachometer, 36 Temperature, 14
V
Vibration, 15
U
Utilities air, 26 power, 24 water, 26
W
Water requirements, 26 Wiring cabinet, 32 I/O, 55
103049-001
Index
95
Blank Page
User Comments Request Form

We appreciate your comments on this manual. Please call or send comments to: ABB Inc. Attention: Documentation 650 Ackerman Road P.O. Box 82650 Columbus, Ohio 43202-0650 (614) 261-2000
Comments can also be sent via FAX to: Documentation (614) 261-2113
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1190 Setup&amp;Installation

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IndustrialIT Quality Control

Setup and Installation Manual

April 2002 103049-001 Version B

Document Version History

Sections Changed by Revision

Sections Added by Revision

Sections Deleted by Revision

October 1998 April 2002

Original Release cover art, header, product names

Document Version History

3 Hardware Installation & Setup .............................................. 31

4 Software Installation & Setup ............................................... 57

Modem Rack I/O Nest (if in this cabinet)

Figure 1-1 Single Cabinet Layout

Processors and Communications Rack

Modem Subrack Connection Units

Power Supply Power Switch and Distribution

Power Supply Field Power Supply

Processor and Communications Rack Layout

Slot 2 dedicated to redundant Main Processor

Serial Link Submodules

F RUN HLT BC F TO DUAL RUN F F F

F F F TO DUAL RUN HLT BC TO DUAL 2V 5V RUN HLT BC

Figure 1-3 Rack Layout

F RUN HLT BC TO DUAL

P1 is normal -- L means it is loading from flash card

PCMCIA flash card

Switch set to AutoInit (1)

Advant 130 connector Connector to local I/O bus on card

PCMCIA Flash Card

Serial Link Submodules

F RUN HLT BC TO DUAL

A 1 is normal -- L means it is loading from flash card

ABB PCMCIA flash card

Switch set to Clear (3)

Advant 130 connector

ABB PCMCIA Flash Card

Maximum CD Actuator Count by type

The three classes of relative humidity are as follows: Class Class 1

The two classes of vibration are as follows: Class Class 1

Operator Station Requirements

Cabinet and Enclosure Requirements

Interior Unit Requirements

Smart Color Platform

Checking Equipment Environmental Specifications

Rectifying Adverse Environmental Conditions

Verify Necessary Utilities

Refer to specific actuator documentation

during the development of the system configuration.

Air and Water Requirements

Air Requirements Calculation Work Sheet for Smart Platforms

Reflection Moisture/Coat Weight

Totals # Times Flow

Figure 2-1 (continued)

Verifying Electrostatic Discharge Control

Receiving the Equipment

Hardware Installation & Setup

Electronics Cabinet Installation

Handling the Cabinet

Mount the Cabinet

Wiring Internal to Cabinet

Hardware Installation & Setup

Connect Cables and Utilities

Hardware Installation & Setup

1190 Setup&Installation

1190 Setup&Installation