IndustrialIT Quality Control Installation & Setup Manual ...

IndustrialIT Quality ControlSetup 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 MacchiaIllustrator: Robert MacchiaTechnical 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.

V

Document Version HistoryIndustrialIT Quality Control

Setup and Installation Manual(Release 5.0 & later)

ersionLevel

EffectiveDate

Sections Changedby Revision

Sections Addedby Revision

Sections Deletedby Revision

A October 1998 Original Release

B April 2002 cover art, header, product names

103049-001 Document Version History

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PrefaceThis 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 User’s Guide, 3BSE 008 878

• Advant Controller 450 User’s Guide, 3BSE 002 415

• Advant Controller 450 Product Guide, 3BSE 015 953

• Master Net User’s Guide, 3BSE 003 839

• Advant Fieldbus 100 User’s 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 i

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103049-001

Table of Contents
Preface ........................................................................................... i
List of Figures ............................................................................ vii

1 Overview ................................................................................... 1Compatibility .................................................................................................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 ............................................................................. 13Environmental 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

Table of Contents iii


iv

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 .............................................. 31Electronics 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 ............................................... 57Overview ......................................................................................................58

Toolbox Commands....................................................................................59

Licenses.......................................................................................................60

Table of Contents 103049-001


103049-001

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....................................................................... 71Startup 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

Table of Contents v

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103049-001

List of FiguresFigure .............................................................................................................Page

Figure 1-1 Single Cabinet Layout ........................................................................ 3

Figure 1-2 Typical Dual Cabinet Layout .............................................................. 4

Figure 1-3 Rack Layout ........................................................................................ 6

Figure 2-1 Air Requirements Calculation Work Sheet for SPs ............................ 27

Figure 3-1 RS232/20ma Converter ....................................................................... 39

Figure 3-2 Power Supply Out to Converter .......................................................... 40

Figure 3-3 Power in to DIN Rail .......................................................................... 40

Figure 3-4 Power from DIN Rail to Converter ..................................................... 41

Figure 3-5 Point-to-Point Wiring (Converter to Client) ....................................... 43

Figure 3-6 Sample Layout for S800 I/O ............................................................... 54

Figure 3-7 Sample Wiring for S800 I/O ............................................................... 55

Figure 4-1 Command Sequence ........................................................................... 59

Figure 5-1 Frame Setup Display ........................................................................... 74

Figure 5-2 PMM Frame Setup Display ................................................................ 76

Figure 5-3 Frame Limits ....................................................................................... 77

Figure 5-4 Frame Coldstart Positions on Frame and Video Profile ..................... 79

Figure 5-5 Measurement Platform Control Panel ................................................. 81

Figure 5-6 Auto Edge-of-Sheet Parameters .......................................................... 84

Figure 5-7 Frame Object Display ......................................................................... 88

Figure 5-8 Grade Grouping Display ..................................................................... 90

Figure 5-9 Grade Data Display ............................................................................. 91

Figure 5-10 Grade Dependent Basis Weight Display Example ............................. 92

viiList of Figures

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103049-001

1Overview

This chapter gives an overview of the control system and includes the following major sections:

Section............................................................................................... Page

Compatibility ................................................................................................. 2Cabinet Layout .............................................................................................. 3Processor and Communications Rack Layout ............................................... 5Equipment Location ...................................................................................... 11

1Overview


2

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 ABBMasterView or PMM in an upgrade situation.

Overview 103049-001


103049-001

Cabinet LayoutThe 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

1Side plates (20 mm or 0.8 inch each) are NOT included.2Door and back plate are included.3Roof is included.

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.

Figure 1-1 Single Cabinet Layout

Cabinet Width1 Depth2 Height3

RM500V1 800 mm (31.5 in.) 512 mm (20.1 in) 2125 mm (83.7 in)

800 mm (31.5 in.) 512 mm (20.1 in) 1925 mm (75.8 in)

RM500V2 700 mm (27.6 in.) 637 mm (25.1 in) 2225 mm (87.6 in)

Processors

Communications

Power Supply

and

Rack

Modem

I/O Nest

Rack

(if in thiscabinet)

3Overview


4

Figure 1-2 Typical Dual Cabinet Layout

Processors

Communications

Power Supply

I/O Nest

and

Rack

Connection Units

Power Switchand Distribution

Modem Subrack

Processors andCommunications

Rack

Power Supply

Power Switchand Distribution

Mains Net Filter(CE-MarkedVersions Only)

I/O Subrack

Connection

Field Power Supply

Units

Modem Rack

Overview 103049-001


103049-001

• 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 User’s Guide, 3BSE 008 878, respectively.

Processor and Communications Rack LayoutThe 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.

5Overview

PRO

PRIETAR

Y DATA: This docum

ent contains proprietary data of ABB Inc. No disclosure, distribution (electronic or otherw

ise),reproduction, or other m

eans of dissemination m

ay be made w

ithout written perm

ission.

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verview103049-001

X11

IP

BP

FC

F

BF

F1

2AF

ABB SB510

RUN

A1A2AGB1B2BGRARA

SSG

RBRBFN

ABB TC520

M

Battery Backup

S Status Card

Figure 1-3 Rack Layout

ABB SR511

F

2V

5V

RUN

ABB PM511

F

HLT

BC

TO

DUAL

2 3

1 4

SERV.X10

X11I/O

AUTO

RUN

ABB PM511

F

HLT

BC

TO

DUAL

2 3

1 4

SERV.X10

X11I/O

CLEAR

RUN

ABB PM511

F

HLT

BC

TO

DUAL

2 3

1 4

SERV.X10

X11I/O

CLEAR

RUN

ABB SC520

F

F R

TX RX

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CS

513

RUN

ABB SC510

F

1

2

X4

X5

F R

ABBCI532

X4

X5

F R

ABBCI532

RUN

ABB SC510

F

1

2

X4

X5

F R

ABBCI532

X4

X5

F R

ABBCI532

RUN

ABB SC510

F

1

2

X4

X5

F R

ABBCI532

X4

X5

F R

ABBCI532

X4

X5

F R

ABBCI532

1

2

ain Processor Serial Link Submodules ABB Processors

Power Supply

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103049-001

Main Processor

The main processor contains the AMPL library flash card.

PCMCIA Flash Card

This PCMCIA flash card contains the AC450 controller software load.

RUN

ABB PM511

F

HLTBC

TO

DUAL

2 3

1 4

SERV.X10

X11I/O

AUTO

P1 is normal

Switch set to AutoInit (1)

PCMCIA flash card

Advant 130 connector

Connector to local I/O bus on card

-- L means it is loading from

F = FaultRun = RunHLT = HaltBC = Battery ConnectedTO = Time OutDual = dual processors present

flash card

7Overview


8

Serial Link Submodules

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.

RUN

ABB SC510

F

1

2

X4

X5

F R

ABBCI532

X4

X5

F R

ABBCI532

Overview 103049-001


103049-001

ABB Processor

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.

RUN

ABB PM511

F

HLTBC

TO

DUAL

2 3

1 4

SERV.X10

X11I/O

CLEAR

A 1 is normal

Switch set to Clear (3)

ABB PCMCIA flash card

Advant 130 connector

NOT used

-- L means it is loading from

F = FaultRun = RunHLT = HaltBC = Battery ConnectedTO = Time OutDual = dual processors present

flash card

A

9Overview


10

Maximum CD Actuator Count by type

• Sequential Linear Steppers 66

• Parallel Linear Steppers 150

• Smart Weight Profiler (SWP) 200

• IR Profiler 216

• ThermoProfiler 120

• Air/Water Spray 108

• ScaniValve 96

• Serial 255

• Smart Calender Profiler 200

• Dilution SWP 400

Overview 103049-001


103049-001

Equipment LocationCabinet

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 cabinet’s 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 causedby tow motors, forklift trucks, or pushcarts; some type of protectivebarrier must be installed.

Operator Station

Operator stations are located as required by each site.

11Overview

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103049-001

2Preparation

Section............................................................................................... Page

Environmental Requirements ........................................................................ 14Rectifying Adverse Environmental Conditions ............................................. 23Verify Necessary Utilities .............................................................................. 24Verifying Electrostatic Discharge Control .................................................... 29Receiving the Equipment .............................................................................. 30

13Preparation


14

Environmental RequirementsOverview

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

The four classes of temperature are as follows:

Class Centigrade Fahrenheit

Class 1 19°C to 27°C 65°F to 80°F

Class 2 27°C to 45°C 80°F to 110°F

Class 3 45°C to 60°C 110°F to 140°F

Class 4 Above 60°C Above 140°F

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.

Preparation 103049-001


103049-001

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

The three classes of relative humidity are as follows:

Class Percent Description

Class 1 30 to 70% A controlled humidity condition; typicallyincludes devices which use paper (printer) and require humidity control.

Class2 20 to 80% An air conditioned environment where humidity control depends on air conditioner size, heat load, and season.

Class 3 5 to 90+% An uncontrolled environment, but indicates non-condensation without moisture droplets unless otherwise indicated.

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 G’s (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

The two classes of vibration are as follows:

Class Description

Class 1 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.

15Preparation


16

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

* 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 altitudeeffect. Atmospheric pressure has a slight effect upon heat transfer,and altitude reflects atmospheric pressure. At 5,000 feet, naturalconvection is reduced by about 10%, and air mass flow from a fanmight be reduced by about 15%.

The three classes of altitude are as follows:

Class Description

Class 1 0-900 meters (0-2,950 feet)

Class 2 900-1,500 meters (2,950 - 4,920 feet)

Class 3 Above 1,500 meters (above 4,920 feet)

Altitude in Meters

Altitude inFeet

Pressure inPounds/in2

Pressure in kPa*

0 0 14.7 101.35

300 985 14.2 97.90

600 1970 13.7 94.45

900 2950 13.2 91.01

1200 3940 12.7 87.56

1500 4920 12.2 84.12

1800 5905 11.3 77.91

3000 9840 10.1 69.64



103049-001

Enclosure Rating

The enclosure rating defines enclosure resistance to common industrial environments. The four classes of ratings are as follows:

Class Description

Class 1 Dust Resistant - the enclosure will resist dust to the degree specified under “Particulate” on page 18.

Class 2 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.

Class 3 Water/Oil Proof - the enclosure will resist dust and continuous spray of oil or water.

Class 4 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.

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.

17Preparation


18

Table 2-3 Classes of Gaseous Contamination

• 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 Measurement Description

Class 1 0.0 - 0.3 mg/m3 Typical for an office environment.

Class 2 0.3 - 3.0 mg/m3 Typical for light manufacturing, warehouses, or facilities with bare concrete floors.

Class 3 SEVERE 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.

Type of Gas Class 1 Class 2 Class 3

Sulfur Dioxide 0.00-0.05 ppm 0.05-5.00 ppm 5+ ppm

Hydrogen Sulfide 0.00-0.03 0.03-10.00 10+

Hydrogen Fluoride 0.00-0.02 0.02-3.00 3+

Chlorine and Halogenated Compounds

0.00-0.03 0.03-1.00 1+

Oxides of Nitrogen (NOx) 0.00-0.08 0.08-5.00 5+

Carbon Monoxide (CO) 0-10 10-50 50+

Ammonia 0.0-0.2 2-50 50+

Aldehydes 0.0-0.2 0.2-5.0 5+

Oxidents (Ozones) 0.00-0.05 0.05-0.10 0.1+



103049-001

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 °CHigh: +40 °CGradients: ±3 °C/min

Humidity:

Relative: 5% - 95%

Absolute: 1 - 29 g/m3, non-condensing

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

Interior Unit Requirements

The following requirements are for subracks, plug-in units, and printed circuit boards:

Temperature:


Humidity:

Relative: 5% - 95%

Absolute: 1 - 29 g/m3, non-condensing

Vibration:

±0.15 mm, 10-57 Hz

20 m/s2, 57-150 Hz; x, y, z direction

19Preparation


20

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:


Humidity:

Relative: 5% - 90%

Vibration:

0.01 ιν, 0-14 Hz0.1 G, 14-100 Hz

Smart Color Platform

Temperature:


Humidity:

Relative: 5% - 90%

Vibration:

0.01 ιν, 0-14 Hz0.1 G, 14-100 Hz

HyperScan

Temperature:


Humidity:

Relative: 5% - 95%

Vibration:

0.01 in, 0-14 Hz0.1 G, 14-100 Hz



103049-001

Eq

uip

men

t

Operator S

Enclosure

Internal U

Smart Pla

HyperSca

Smart ColPlatform

Liquid CoUnit

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

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 meansea 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 electronicboards with air conditioners require one additional ton of refrigerationper unit to compensate for cabinet heat dissipation.

Tem

p. (

° C )

Rel

ativ

e H

um

idit

y (%

)

Vib

rati

on

(1

0-57

Hz

/ 57-

150H

z)

Sh

ock

(m/s

2 fo

r 11

ms)

Alt

itu

de

(met

ers)

Po

lluti

on

(d

eg.)

tation See manufacturer’s documentation.

0 - 40 5 - 95 ± 0.075 mm / 10 m/s2 150 2000 2 acc.

nits 0 - 55 5 - 95 ± 0.15 mm / 20 m/s2 150 2000 2 acc.

tform 0 - 80 5 - 90 0.01 in (0-14 Hz) / 0.1 G (14-100 Hz)

-- -- 5000 (A/yr.)

n 0 - 80 5 - 95 0.01 in (0-14 Hz) / 0.1 G (14-100 Hz)

-- -- --

or 0 - 80 5 -90 0.01 in (0-14 Hz) / 0.1 G (14-100 Hz)

-- -- --

oling < 43 5 - 90 -- -- -- --

21Preparation


22

Checking Equipment Environmental Specifications

Use the following measurement techniques for measuring the environment:

Specification Suggested Measurement Technique

Power power line analyzer

Air Quality Test kit 73512-001

Air Quantity Test kit 73528-001

Water Quality and QuantityLCU only: Have site test to meet determined requirements

Temperature Calibrated temperature sensing device

Contaminant Levels

Contamination Kits:

Enclosure for samples: 121288-001

Samples: 082932-001

Vibration Use a hand held vibration monitoring device



103049-001

Rectifying Adverse Environmental ConditionsDecontamination 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.

23Preparation


24

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

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.

Equipment VAC KVA Hz

System Cabinet 115 15/25/351 60

Smart Platform 200-240 10 50 or 60

HyperScan (3-Phase)380/415 or

480/575 29/582 50/60

HyperScan (Single Phase) 240 -- 50 or 60

Smart Color Platform 240 1.5 50 or 60

Actuators Refer to specific actuator documentation



103049-001

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 User’s 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, thread-cutting 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.

25Preparation


26

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 onewater drain for spent cooling water and another to eliminatecondensate from the air conditioner.

2. If the water supply is not cool enough, a drinking fountain watercooler 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 regulatorand the temperature valve of the cooling unit, or the flow control valveof the air conditioning unit, causing improper performance.

Strainers may clog and stop all cooling.

Excessive temperature will cause the sensor to shut off, or blockageof water flow will cause the A/C to shut off. This shut off will requireresetting and correction before restarting.



103049-001

S

Basis Wei

with Std. A

with AGC

BW with C

Smart Bas

IR Moistur

with Std. A

with Heate

Reflection

with Std. A

with Heate

Caliper (S

Air Bearing

Vacuum Pl

Probe Hea

Caliper (D

Lift-Off Tub

Vacuum Pl

Probe Hea

Caliper (N

Top Air Bea

Bottom Air

Caliper GT

OptiPak™

Purge

Vacuum Pl

Air Bearing

Figure 2-1 Air Requirements Calculation Work Sheet for SPs

(continued on next page)

Air Flow Per Sensor Totals

ensor SCFM M3/HR Pressure # In System # Times Flow

ght

ir Wipe 4.0/wipe 6.8/wipe <35 PSIG

5.5/wipe 9.4/wipe 10-20 PSIG

AP 4.0/wipe 6.8/wipe

is Weight 4.0/wipe 6.8/wipe 40 psig

e Transmission

ir Wipe 5.3/wipe 9.0/wipe 10-20 PSIG

d Air Wipe 5.5/wipe 9.4/wipe 10-20 PSIG

Moisture/Coat Weight

ir Wipe 5.3 9.0 10-20 PSIG

d Air Wipe 5.5 9.4 10-20 PSIG

ingle Air Bearing)

4.0 6.8 40 PSIG

ate 2.0 3.4 40 PSIG

ter 2.0 3.4 30-40 PSIG

ual Contacting)

e 1.0 1.7 40 PSIG

ate 2.0 3.4 40 PSIG

ter 2.0 3.4 30-40 PSIG

on-Contacting)

ring 2.0 3.4

Bearing 2.0 3.4

2.0/head 2.0/head

5.0 8.5 40 PSIG

ate 4.2 7.1

Plate 4.2 7.1

Air Requirements Calculation Work Sheetfor Smart Platforms

27Preparation


28

Smart

Roll H

Gloss

Air Wip

Air Pur

Sheet

MP/SP

Smart

Microw

Single-

Dual-s

Smoot

Norma

High T

Tempe

Figure 2-1 (continued)

Air Flow Per Sensor Totals

Sensor SCFM M3/HR Pressure # In System # Times Flow

Ash 4.0/head 6.8/head

ardness 8.5 14.5

es 5.0 8.5

ge/Sensor 3.5 5.9 40 PSIG

Guides (4) 24.0 40.8 20 PSIG

Clutch 0.0 0.0 40-50 PSIG

Color 4.0/head 6.8

ave

sided 0.18 0.3

ided 0.18 0.3

hness

l None None

emperature 0.001 N 0.001 N

rature 1.5 2.6 30 psig

TOTAL =



103049-001

Verifying Electrostatic Discharge Control

Note: All maintenance in the cabinet is only allowed when protective “ESDrestrap”, 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 anti-static 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.

29Preparation


30

Receiving the EquipmentWhen 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.



103049-001

3Hardware Installation & Setup

Section............................................................................................... Page

Electronics Cabinet Installation ..................................................................... 32Platform Installation ...................................................................................... 34Power Distribution Panel Installation ............................................................ 35Tachometer Installation ................................................................................. 36Actuator Installation ...................................................................................... 38Wiring Connections ....................................................................................... 39Hardware Setup ............................................................................................. 44I/O Subrack .................................................................................................... 54Fieldbus Information ..................................................................................... 56MasterBus Information .................................................................................. 56



32

Electronics Cabinet InstallationFollow the general guidelines below for all electronic cabinets. For information on Master electronics cabinets, see the Advant Controller 450 User’s 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 User’s 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.

Hardware Installation & Setup 103049-001


103049-001

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 User’s 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.



34

Platform InstallationSeveral 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 101764-004

Smart Platform 1200 101764-003

HyperScan 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.



103049-001

Power Distribution Panel InstallationFollow 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 customer’s 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.



36

Tachometer InstallationFor 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.



103049-001

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 tachometerand 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.



38

Actuator InstallationSee appropriate Actuator documentation.

Smart Weight Profiler 101794-003

Smart CoatWeight Profiler 103007-003

Smart Calender Profiler 103020-002

Smart Consistency Profiler 103046-002



103049-001

Wiring ConnectionsThe 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.

Figure 3-1 RS232/20ma Converter

Yellow LED = transmitGreen LED = receive

to communications submodule port

24 V DC powerUNUSED

UNUSED

8 screw terminals for 20 mA loop



40

f

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.

Figure 3-3 Power in to DIN Rail

3. Tighten the connector that ties 1,2, and 3 together (3-screw bar near center).

rom Power SupplyGROUND WIRE



103049-001

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.

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.

0V 24V



42

Table 3-1 RS-232 Pin Assignments

Note: The ground connection is actually the screw on the RS-232 9-pinconnector.

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: DON’T forget to set the S1+ to T+ jumper.

Description AbbreviationScrew

Terminal (from left)

9-pin Connector

Supply Voltage 24 V pin 1 --

0 V pin 2 --

Transmit Data TxD pin 4 pin 3

Receive Data RxD pin 5 pin 2

Clear to Send CTS pin 6 pin 8

Request to Send RTS pin 7 pin 7

Functional Ground GND pin 8 pin 5

Data Terminal Ready STR -- pin 4

Data Set Ready DSR -- pin 6

Ground -- See note. Shield



103049-001

Note: The ground connection is actually the screw on the TTY 9-pinconnector.

Figure 3-5 Point-to-Point Wiring (Converter to Client)

Table 3-2 TTY Pin Assignments

Note: The ground connection is actually the screw on the TTY 9-pinconnector.

Description AbbreviationScrew

Terminal (from right)

9-pin Connector

current source 2 neg. polarity S1- pin 3 pin7

current source 2 pos. polarity S1+ pin 4 pin 3

current source 1 neg. polarity S2- pin 1 pin 9

current source 1 pos. polarity S2+ pin 2 pin 5

transmit data neg. polarity T- pin 7 pin 6

transmit data pos. polarity T+ pin 8 pin 2

receive data neg. polarity R- pin 5 pin 8

receive data pos. polarity R+ pin 6 pin 4

Ground -- See note. Shield



44

Hardware SetupThe 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 submodule’s IP address. This address is the same for all logical ports assigned to that submodule.



103049-001

Ite

POR

TYP

SLO

LPR

IP

BAU

CHA

STO

PRT

CFG

CFG

Item Definitions for Class ID = Port

Table 3-3 Port Item Definitions

m Type Description

T I Port logical ID (1 - 255)

E I 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 emulation5 = AccuRay Sockets Interface client via FB+6 = AccuRay Sockets Interface server via FB+

T I Slot no. & subModule no. of physical port (decimal “SM”)

T I Physical port no. on submodule (1 or 2) or local TCP/IP port number

C16 TCP/IP address of remote port in dot notation

D L Baud rate (150 to 38400)

R I Number of data (character) bits (7 or 8)

P 1 Number of stop bits:5 = .5 stop bit1 or 10 = 1 stop bit15 = 1.5 stop bits 2 or 20 = 2 stop bits

Y I Parity:0 = no parity1 = odd parity2 = even parity3 = parity 0 (force low)4 = parity 1 (force high)

1 I 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


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)



46

CFG

CFG

CFG

CFG

STS

Ite


Type 4 host side connection:0 = AccuRay Sockets Interface (TCP/IP)1 = AccuRay Direct Interface (serial)

4 L Configuration parameter 4



I Port status:0 = OK1 = Port type code error2 = Instance limit exceeded for this device handler3 = Device handler signal channel creation failure4 = Device handler task creation failure5 = Instance limit exceeded for transceiver drivers6 = Transceiver driver task creation failure7 = Device could not be initialized (perhaps nonexistent)8 = No response from submodule9 = bad client count10 = No INET class defined11 = No INET object defined12 = 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

m Type Description



103049-001

ERR

Ite

I 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

m Type Description



48

ERR(con

Ite

’t)

I $002B = (undefined)$002C = AccuRay direct packet error$002D = AccuRay Direct packer format error$002E = serial emulation field type differs from group’s 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

m Type Description



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HIST

Ite

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


BAUD baud rate (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 = 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


BAUD baud rate

CHAR number of data bits

STOP number of stop bits

PRTY parity

L11 Activity history array:Total IORB signals receivedTotal output messagesTotal output bytesTotal input messagesTotal input bytesTotal flushed input messagesTotal flushed input bytesTotal retriesTotal timeout errorsTotal physical errors reported by the deviceTotal protocol errors

m Type Description



50

Ite

SL

I

MA

GA

NA

ST

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 application’s 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

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

m Type Description

OT I Slot number & subModule number of physical port (decimal “SM”)

P C16 IP address of local port in dot notation

SK C16 Subnet mask in hexadecimal long format (e.g. FFFF0000) (optional)

TE C16 IP address of default gateway in dot notation (optional)

ME C16 Name of local host (optional)

SI

Network setup status:0 = OK1 = port type conflict

Decimal Binary Hexidecimal

255 11111111 FF

254 11111110 FE

252 11111100 FC

248 11111000 F8

240 11110000 F0

224 11100000 E0

192 11000000 C0

128 10000000 80

0 00000000 00



103049-001

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 D=5 FFS1_Port1

• PC11.1.211:6 D=6 FFS1_Port2

Actuator ports are set at the following locations:

• IR Profiler (CDIR) xPNy.PRT1NM

• Parallel Linear Stepper (CDWT) xPSy.PRT1NM xPSy.PRT2NM

• Water Spray (CDAW) xPWy.PRT1NM

• ScaniValve (CDGN) xPGy.PRT1NM

• Smart Calender (CDTP) xPYy.PRT1NM

• Serial (CDSR) xPZy.PROTID

• Smart Weight (CDWT) xPXy.PRT1NM xPXy.PRT2NM



52

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.



103049-001

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.


PRO

PRIETAR

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ay be made w

ithout written perm

ission.

54H

ardware Installation &

Setup103049-001

I/O Subrack

DO820MTU831

DO820MTU831

20831 T

B80

7

AO810MTU830

AO810MTU830

10830

TB

807

...

For complete information on the S800 I/O refer to S800 I/O User’s Guide, 3BSE 008 878 latest revision. See Figure 3-6 and Figure 3-7.

Figure 3-6 Sample Layout for S800 I/O

AI810MTU835

AI810MTU835

AI810MTU835

DI8MTU

AO810MTU830

AO810MTU830

DI820MTU831

CI810Station 1

TC505 AF100TC501V150

SD81224VDC 5A

CI522

TK515

TC512ModemTC505

TC501 V150 AI810MTU835

AI810MTU835

AI810MTU835

AO8MTU

AI810MTU835

AO810MTU830

AO810MTU830

CI810Station 2

TC505 AF100TC501V150

SD81224VDC 5A

up to J6

AC450 Cabinet

PRO

PRIETAR

Y DATA: This docum




ay be made w

ithout written perm

ission.

55H

ardware Installation &

Setup103049-001

AI810MTU835

AI810MTU835 T

B80

7

...

035

AI810MTU835

AI810MTU835 T

B80

7

...

Figure 3-7 Sample Wiring for S800 I/O

AI810MTU835

CI810Station 1

SD81224VDC 5A

TC505

Located in back of cabinet

Power Distribution Panel

120 VAC

NEUGND

NEUGND

120 VAC

L (120 VAC)

N (Neutral)

PE (Ground)

3C/12 AWG

#12B

LK

#12BLK

#12WH

#12GR

#12G

R

#12W

H

+-SHSH

+-SHSH

+-SHSH

AI81MTU8

CI810Station 2

SD81224VDC 5A

L (120 VAC)

N (Neutral)

PE (Ground)

+24 VDC0 VDCDC OK

#12B

LK

#12G

R

#12W

HL+ L- SA

+-SHSH

+-SHSHL+ L- SB

as necessary

3C/12 AWG

#12GR

#12BLK

#12WH

+24 VDC0 VDCDC OK

L+ L- SA

L+ L- SB

1P/22AWGAF100<2450 ft (750 m)


56

Fieldbus InformationFor Fieldbus information, refer to the Advant Fieldbus 100 User’s Guide, 3BSE 000 506 latest revision.

MasterBus InformationFor Masterbus infomation, refer to the Master Net User’s Guide, 3BSE 003 839 latest revision.



103049-001

4Software 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 ....................................................................................................... 58Toolbox Commands ....................................................................................... 59Licenses ......................................................................................................... 60Configuration & Setup Displays ................................................................... 61

57Software Installation and Setup


58

OverviewFor 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 customer’s 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.

Software Installation and Setup 103049-001


103049-001

Toolbox CommandsThe following commands should be performed in the order shown.

• cfg1190∆jonnnn configure a job order

• cfglvl1∆jonnnn configure level 1 I/O and control for job order

• bld1190∆jonnnn build a job order

• bldlvl1∆jonnnn build level 1 I/O and control for job order

• dim1190∆jonnnn scan all of the node source and produce dimensioning

reports

• cmp1190∆jonnnn compress the node source

• trs1190∆jonnnn build execute command files for database and AMPL PC

programs

where jonnnn = job order identifier (It is used to select correct job order directory.)

Figure 4-1 Command Sequence

cfg1190

cfglvl1

bld1190

bldlvl1

dim1190 comp1190 trs1190



60

LicensesThe 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.



103049-001

Configuration & Setup DisplaysThe 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:



62

3. Press OK.

The start up will continue until the following screen appears.

If you select help, you will get the following window:



103049-001

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.



64

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∆-h∆0 [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).




103049-001

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.



66

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.


2. Select Maintenance (D8).

3. Select Object References (D6).

4. Enter password.

You will see the following window:




103049-001

5. Select List.

You will see the following window:

6. Set Reference Status to Unresolved.




68

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:



103049-001

Advant ProceduresCPIO 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 tells it to output-c writes header in ASCII format-x handles special (device) files-B block input/output at 5120

Station Backup Procedure

To backup the Advant station, perform the following steps:


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:


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.



70

Application Dump/Load ProceduresTo 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: DUAP∆filename

4. To load the software, type: LOAP∆filename



103049-001

5System Startup

Chapter Three discusses System Startup, including the major sections listed below.

Section............................................................................................... Page

Startup Checklist ........................................................................................... 72Smart Platform Data Setup ............................................................................ 73PMM-Based Frame Data Setup ..................................................................... 75

Set Up Scan Speed .................................................................................. 75Set Up Scan Speed .................................................................................. 75Set Up Coldstart Variables ...................................................................... 77Servo Set Up ........................................................................................... 82Set Up Auto Edge-Of-Sheet (AEOS) ..................................................... 84Setting Sheet-Break Override ................................................................. 87

Grade Data Setup ........................................................................................... 89Changing Grade Dependent Data Grouping ........................................... 89Changing System Grade Data ................................................................. 91Changing Measurement Grade Data ....................................................... 92

71System Startup


72

Startup ChecklistComplete 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).

System Startup 103049-001


103049-001

Smart Platform Data SetupFor 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).

73System Startup


74

Figure 5-1 Frame Setup Display



103049-001

PMM-Based Frame Data SetupFor 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, 101766-014, 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).

75System Startup


76

Figure 5-2 PMM Frame Setup Display



103049-001

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.

Figure 5-3 Frame Limits

Table 5-1 Frame Position Definitions

Position Definition

Off-sheetPosition on the frame, next to the process, where maintenance will be performed on the sensor heads

STDZPosition on the frame, just off the process sheet edge, where sensor standardization takes place

Single PointThe default single point position where the sensor heads stop whenever this mode is entered

Current Home EOSThe 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)

Current Far EOSThe 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)

Fixed Home EOS Determines the minimum limits of Current Home EOS

Fixed Far EOS Determines the maximum limits of Current Far EOS

Delta for On-sheet Move

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

Max Trim

Frame 2

Frame 1

LFEOS LHEOS

Center ofSheet

77System Startup


78

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 head’s 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.



103049-001

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 headssometime “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 performingthe 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 edge-of-sheet position.

DHEOS

KHEOS KFEOS

LHEOSSTDZOFF LFEOS

Sheet

Video

79System Startup


80

CAUTION

This position must be less than or equal to the far edge-of-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 edge-of-sheet position.

CAUTION

This position must be greater than the home edge-of-sheet 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 limitsFixed Far EOS and Fixed Home EOS. Moving the current edge-of-sheet positions inside the limits causes the end data boxes to beempty.



103049-001

SOURCE CLOS

A green indicatoON when the rashutter on the scCLOSED.

OFF-SHEET

This push busensor packoff-sheet. Wthe button, sunder compuntil you prSHEET pus

LOCAL

Press to transfeplatform frommanual so youjogging functi

JOG REVE

Press to manscanning he

REVERSE L

Press to set tscanning lim

CALIBRATE SA

Enables special scollection. Use itwith lab tests at tof a reel.

Reserved f

Figure 5-5 Measurement Platform Control Panel

ED

r lamp that is diation source anning head is

SOURCE OPEN

A red indicator lamp that lights when the radiation source shutter on the sensor head is OPEN.

tton causes the age to move hen you press canning is not uter control ess the ON-h button.

ON-SHEET

This push button allows the sensor package to move on-sheet and enables computer control of scanning.

r control of the computer to can use the on.

REMOTE

Press to transfer control to the host system.

RSE

ually drive the ad backward.

IMIT

he reverse it.

MPLE

ensor data in conjunction he completion

SAMPLE CHECK

Press to activate scanning head measurement circuitry when the head is off-sheet. It allows you to make a sample check measurement.

or Future Use

JOG FORWARD

Press to manually drive the scanning head forward.

FORWARD LIMIT

Press to set the forward scanning limit.

Reserved for Future Use

R F

R F

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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.


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.



103049-001

• 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 edge-of-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 toprovide smooth and even scanning. This adjustment results in someovershoot when operating in single point mode.

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Farof S

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.

Figure 5-6 Auto Edge-of-Sheet Parameters

E1E2SensorMeasurementHeadD2

S2

L2

D1 D2

SensorMeasurementHead D1

S1

L1

Measure Window

Scan Width

Trim Width

Home Edgeof Sheet

AEOS DimensionalRelationships toProcess Edges

Edgeheet



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Table 5-2 AEOS Frame Setup Entries

Note: A compromise must be reached in determining the ‘S’ and ‘E’dimension. Bringing the window area edge close to the sheet edgedecreases 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 befrequent scan limit changes resulting in longer waits at EOS in orderto re-compute the scan speed and data box arrangement. Themeasurement window area will also be close to the sheet edge.

If S and E is large, the measurement window area will not be closeto the sheet edge, but there will be few, if any, scan limit changesoccurring. This condition is a problem if sheet wander brings thesheet out from under the measure windows. Therefore, in setting upthe E dimension, make sure the anticipated sheet wander will notexceed S and E.

AEOS Entry Description Required Values

L1 Distance between center of the Home Edge-of-Sheet HEOS detector (D1) and head reference line in customer units

Must be greater than 9.9 inches (in) or 25.2 centimeters (cm)

L2 Distance between center of the Far Edge-of-Sheet (FEOS) detector (D2) and head reference line in customer units

Must be greater than 6.4 in or 16.3 cm

E1 Distance in customer units between center of HEOS detector (D1) and home sheet edge when head is positioned at the desired home edge-of-sheet position at the off-sheet end of the frame

Must be between S1/2 and S1-D1

E2 Distance in customer units between center of FEOS detector (D2) and far edge-of-sheet when head is positioned at the desired far edge of sheet position

Must be between S2/2 and S2-D1

S1 Distance between the center of the HEOS detector (D1) and the HEOS side (M1) of the sensor cluster

Must be less than L1-2.4 in (6.1 cm)

S2 Distance between the center of the FEOS detector (D2) and the FEOS side (M2) of the sensor cluster

Must be less than L2-2.4 in (6.1 cm)

SWO Sheet width computation offset in customer units

Determined by any consistent errors that occur in calculation of sheet width

ENABLE Enables or disables AEOS 0 = Disable 1 = Enable

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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

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.

Variable Nominal Minimum Maximum

E1 12.1” (30.7 cm) S1/2 S1 - D1

E2 8.6” (16.8 cm) S2/2 S2 - D2

L1 16.5” (41.9 cm) 9.9” (25.1 cm) N/A

L2 11.0” (27.9 cm) 6.4” (16.3 cm) N/A

S1 14.1” (35.8 cm) E1 + D8 L1 - 2.4” (6.1 cm)

S2 8.6” (21.8 cm) E2 + DB L2 - 2.4” (6.1 cm)



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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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.


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 SetupGrade 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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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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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



103049-

Index

Numerics20ma

converter, 39

AActuators, 10

installation, 38power, 24

Aircalculations, 27requirements, 26

Altitude, 16

BBackup

software, 69

CCabinet

environment, 19, 23I/O rack, 5installation, 32

cables, 33utilities, 33

layout, 3location, 11power, 5, 24processor & communications rack, 5

Cablesconnecting, 33

Communications rack, 5layout, 6main processor, 7submodules, 8

Compatibility, 2Configuration

port, 49Contamination, 17Converter

RS232/20ma, 39wiring, 39

DDeconamination units, 23Delta for On-Sheet Move, 78Direct Digital Control Setup, 82

EEdge-of-Sheet

auto, 84current far, 78current home, 78current position, 79fixed far, 78fixed home, 78

Electronics Cabinets, 10connecting cables and utilities, 33handling, 32mounting, 32

Electrostatic Discharge (ESD), 29Enclosure

rating, 17requirements, 19

Environment, 14altitude, 16cabinet, 19checking, 22contamination, 17enclosure rating, 17humidity, 14HyperScan, 20operator station, 19rectifying, 23Smart Color, 20Smart Platform, 20summary, 21temperature, 14vibration, 15

FFieldBus, 56Flexible Couplings

installing, 36

93Index001


94

GGrade data

setup, 89Grounding, 25

HHardware

installation, 32printer, 52setup, 44

Humidity, 14HyperScan, 8, 9

environment, 20installation, 34power, 24

II/O, 5

layout, 54wiring, 55

Installationactuator, 38cabinet, 32electronics cabinets, 32hardware, 32HyperScan, 34power distribution panel, 35preparation, 29scanning frames, 34Smart Platform, 34software, 58–60tachometer, 36utilities requirements, 24verifying electrostatic discharge, 29

MMasterBus, 8, 56Mounting

cabinet, 32

OOperator station

backup, 69environment, 19, 23location, 11

PPCMCIA, 7, 9

Portallocations, 44assignment, 51configuration, 49definitions, 45

Powercabinet, 5distribution panel (PDP), 35grounding, 25requirements, 24

Printersetup, 52

ProcessorABB, 9main, 7

Processor rackSee Communications rack, 5

RRS232, 8

converter, 39

SSetup

grade data, 89hardware, 44PMM-based frame, 75printer, 52Smart Platform, 73software, 61

Smart Colorenvironment, 20power, 24

Smart Platformenvironment, 20installation, 34power, 24setup, 73

Smart Platformsair calculation, 27

Softwarebackup, 69dump/load, 70installation, 58–60setup, 61

Startup, 72Submodule, 8

connection, 39System Grade Data, 91

Index 103049-001


103049-

TTachometer, 36Temperature, 14

UUtilities

air, 26power, 24water, 26

VVibration, 15

WWater

requirements, 26Wiring

cabinet, 32I/O, 55

95Index001

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103049-001 IndustrialIT Quality Control Setup and Installation Manual (Release 5.0 &

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