SCANNER INSTALLATION & SERVICE MANUAL
Contents
1. EN e THE LEADER IN MEASUREMENT amp CONTROL PAGE 43 OF 58 9990069 u CHAPTER 5 SCANNER MAINTENANCE THE LEADER IN MEASUREMENT amp CONTROL PAGE 46 OF 58 CHAPTER 5 5 0 MAINTENANCE 5 1 TROUBLE SHOOTING Maintenance of the S TEC Measurement and Control System is straightforward The System can be separated into 3 general categories 1 The Sensor Heads which include the Sensors 2 The Electrical Electronic items 3 The Scanner Drive mechanism Should any problem arise from the system the first thing to do is to identify which of the above categories the problem belongs to Once this is identified the component causing the problem should be very easy to find For problems associated with the Sensor Heads and Sensors the appropriate Manuals should be referred to For problems associated with the Electrical Electronic items and the Scanner Drive mechanism refer to the Drawings and the descriptions included in the previous2. g om e VEU F z 18 THE LEADER MEASUREMENT amp CONTROL PAGE 36 OF 58 E THE LEADER IN MEASUREMENT amp CONTROL PAGE 37 OF 58 fe g ies e CROLEY OO a uO 20 e0 NO oro e THE LEADER IN MEASUREMENT amp CONTROL PAGE 39 OF 58 TS XN OS APN WIS LL
3. vas 092 SCANNER MOUNTING S tec omen a full 38N 19M PROJECTION SITE DETERMINED 15 amp 15 2 539314 r 022 539314 8 910 03148 9144 LNN 530 3d p 9X0ZW MIHIS 5393198 coxa MIHIS wagers o ONLIVINSNI ENIHSNE NILVTASNI 53039 Z 910 sa0ald v 9144 LON 5303ld V 98X9 IA MIHIS a 14805 pa N3NNVOS THE LEADER IN MEASUREMENT amp CONTROL PAGE 11 OF 58 The Paper sheet needs to pass in between the top and bottom Sensor Heads as the Scanner is scanning This defines the height of the Scanner footing required The recommended method is to make the Scanner footing such that it is about 10mm short of the required height The final fine adjustments will be made using shims These shims are added in small increments until the paper sheet passes exactly through the middle of the Sensor Heads Before making these adjustments the Sensor Head Pass Angle must first be adjusted 2 2 ADJUSTMENT OF SENSOR HEAD PASS ANGLE Once the Scanner Frame is placed in location the Sensor Heads must be checked for the correct Pass Angle such that the paper web will pass through the gap between the Sens
4. ug E an THE LEADER IN MEASUREMENT amp CONTROL PAGE 7 OF 58 EXAMPLE SCANNER ESA gt 1 f h VER m m x HA r 7 1 THE LEADER IN MEASUREMENT amp CONTROL PAGE 8 OF 58 CHAPTER 2 SCANNER INSTALLATION THE LEADER IN MEASUREMENT amp CONTROL PAGE 9 OF 58 CHAPTER 2 2 0 INSTALLATION 2 1 MOUNTING THE SCANNER FRAME The S TEC Measurement and Control system is a fully integrated stand alone unit so there is no need for major civil works to mount the scanner or special electrical installations such as air conditioning a room for the computer system All components are housed within the Scanner Frame All field wiring is terminated at terminal blocks located within the Scanner Frame Installation of the S TEC Scanner Frame is a very simple task both mechanically and electrically Basically it consists of lifting the Scanner onto mounts installed in the selected position adjustment of the level adjustment of the Sensor Pass angle connecting the Instrument Air supply and connecting the 220Vac Power Supply and Ground plus communications cable Once these few tasks are completed the system is ready for operation The Scanne
5. THE LEADER IN MEASUREMENT amp CONTROL PAGE 27 OF 58 CHAPTER 4 SCANNER COMPUTER THE LEADER IN MEASUREMENT amp CONTROL PAGE 28 OF 58 CHAPTER 4 COMPUTER COMPUTER ENCLOSURE OVERVIEW The Computer Enclosure is an anodised aluminium enclosure with clear Perspex cover The enclosure houses the computer cooling fan SVDC computer supply 24 process supply Digital I O Isolation and Terminations Analog I O Terminations Tacho Terminations and power ground connections for the enclosure Information on each of the above items is below The enclosure is cooled using a Vortex Cooler mounted under the cabinet with the cold fraction entering the enclosure and hot fraction escaping into the scanner end enclosure It is important to keep the Perspex cover on the enclosure to ensure that no dust dirt or moisture can enter and to keep the cool air from the vortex cooler inside 5V DC POWER SUPPLY The 5VDC regulated power supply is a switch mode It provides all the power for the computer and also powers the Encoder The power supply is adjusted using the potentiometer to 5 0VDC at the computer terminals There is no maintenance to be done on this power supply other than to ensure the voltage is correct with little noise and that it remains clean THE LEADER IN MEASUREMENT amp CONTROL PAGE 29 OF 58 DIGITAL 1 0 TERMINATION BOA
6. mer Oil f mar Oral Tag tt uir err Tana ma E wei Of tar ort O ert ones TEST el seu err 26 Ti fr eect invert or an3eroniirten To organ eto invert 28 er enon aver 26 ont rsen ener rer Ee ene ee ss rer ENT Sy Bearer NS eso al 1 20 cl ete grin mi Ct board config Ft DIO config F2 DIO test Al contig Fa Al test 5 cr amp AO POS a sen rz hoard conng Fi bro rz pro test FS Al config Al wst rs cT amp pos amp s perm Buy carte re cu aw een ica ener rica a Lower Test ace ae Pastor pere rset Jr uere ge q la lanas Cont bx cette ETATE Scamormamtemanco 20 ovorview FI sample calibration F2 actual prortes F3 scanner configuration scanner overview r sampio actual promos scanner configuration Ar por ton ETE rhs etn amp J THE LEADER IN MEASUREMENT amp CONTROL PAGE 35 OF 58 SCANNER COMPUTER ENCLOSURE LAYOUT
7. CHAPTER 3 SCANNER ELECTRICAL CHAPTER 3 ELECTRICAL LAYOUT OF COMPONENTS The S TEC Measurement and Scanner Control components are all housed within the stainless steel covered Scanner Frame Access to all components is possible by removing the stainless steel covers The computer enclosure is housed inside the front end enclosure of the scanner frame Also on the tending side and optionally also on the drive side of the scanner are the control press buttons and indicators for scanner control All cable terminations for the system are done through terminal blocks These terminal blocks are all located inside the Scanner Frame and inside the front enclosure AC Power and Ground are terminated in the front enclosure 24VDC regulated power supply for clutch and head heaters and the control relays for the scanner control are in the tending side end enclosure The drive side end enclosure of contains the mechanical hardware for the scanner drive system This side of the scanner is called the Drive Side as it contains all the Drive components which move the Sensor Heads across the paper sheet It is also typically located on the Drive Side of the paper machine The sensor heads rely for alignment on two proximity switches one on the upper beam and the other on the lower beam in the Off Sheet or home position The home position is normally near to the drive side of the scanner Towards the c
8. GENERAL MAINTENANCE SENSOR HEADS Sensors and Sensor Head maintenance is described in the Sensors and Sensor Head Service Manuals Periodic inspection is recommended to check for dirt build up and condition of the Sensor windows The S TEC Sensor Heads can be separated automatically This is achieved by pressing the Head Separate push button on the tending side of the scanner when the Sensor Heads are in the Off sheet home position This function first moves the upper head away from the lower head so that the lower head sensor windows can be cleaned and inspected Pressing the button one more time will move the upper head back to the home position and move the lower head out so that the windows on the upper head can be clean and inspected Pressing the button repeatedly will alternate between these two states Pressing the Off Sheet will cause the heads to be realigned This takes a few minutes DRIVE MECHANISM COMPONENTS DRIVE SIDE ENCLOSURE Encoder Clutch Upper Head Drive Belt Seal Belt Tensioning Inverter Omron Drive Shaft SEW Motor Gearbox Lower Head Drive Belt SCANNER COMPUTER ENCLOSURE Ensure the enclosure cover is always on to protect against the entry of dirt Periodically clean the blades of the fan and blow any accumulated dust from the computer boards Check proper cooling of the enclosure by the Vortex Cooler and ensure the Vortex Cooler has an adequ
9. well as Exit Saving Changes peripheral devices Exit Discarding Changes eys to change menu lect menu i Use Arrow keys to change menu iten use Enter to se C Copyright 2004 Ampro Computers Inc http wwu anpro con Anpro Setup Utility for Little Board 700 SU0S462 C Boot Sth mone Help for Initiali Boot 6th none Noe Drive and Boot Options If this field is set to Enabled the Floppy Seek Disabled BIOS will initialize the PS 2 mouse Hard disk Seek Disabled Floppy Suap Disabled If this field is set to Disabled the Boot Method Boot Sector BIOS will not initialize the PS 2 Primary IDE Cable Auto mouse which may result in not being Secondary IDE Cable futo recognized by the Operating Systen Primary Master ATA mode Primary Slave ATA node Keyboard and Mouse Mumlock to nodify Esc to exit Use Arrow keys to change item use to pedir C Copuright 2004 mpro Computers Inc n _ Setup Utility Little Board 700 m Date 4 Tine Help for Drive A Date 31 Oct 2009 Tine 91 31 11 Select the type of floppy drive Drive t attached to the cable Select none nd if there is no floppy drive attached rive none HDD CF on Pri Master none none none none Drive Drive C CDROM none none Use Arrow keys to change item use to modify Esc C Copyright 2004 Ampro Computers Inc http www apro Setup Utility
10. V5 0October 2010 CONTEN CHAPTER 1 4 10 MECHANICAL 4 1 1 Scanner Overview 4 12 Sensor Mounting 5 13 Drive Mechanism 5 1 4 Computer Enclosur 6 15 Power Ground Compressed CHAPTER 10 2 0 INSTALLATION 10 2 1 Mounting the Scanner Frame 10 2 2 Adjustment of Sensor Head Pass Angle 12 2 3 Power Requirements 14 24 Grounding 14 2 5 Instrument Air 14 2 6 Cooling of the System 15 CHAPTER 17 3 0 ELECTRICAL 17 3 1 Layout of components 17 3 2 System Power Distributioi 18 3 3 24VDC Regulated Switch Mode Power Supplies 18 3 4 Encoder Connection 18 3 5 Scanner Drive amp Inverter Control 19 3 6 Motor Control Omron Inverter 20 3 7 Proximity Switche 22 CHAPTER 4 29 40 COMPUTER 29 41 Computer Enclosure Overview 29 422 45V DC Power Supply 29 4 3 Digital I O Termination Board 30 4 4 Analog I O Termination Board 30 4 5 Tacho amp Digital 1 0 Termination Boar 31 4 6 AMPRO Little Board Computer 4 7 Diamond DMM32 Board CHAPTER 5 5 0 MAINTENANCE 5 1 Trouble shooting 5 2 Scanner Drive Mechanism Maintenance 53 General Maintenance CHAPTER 5 5 0 KEY COMPONENTS CHAPTER 1 SCANNER MECHANICAL THE LEADER IN MEASUREMENT amp CONTROL PAGE 3 58 CHAPTER1 MECHANICAL SCANNER OVERVIEW The purpose of the scanner is to continuously measure the important properties of the paper web
11. It is necessary that the S TEC Measurement and Control system is provided with a very good ground The whole system is designed with heavy consideration given to grounding The grounding supplied must be not more than using the normal methods of ground measurement It is recommended that the Grounding wire to be connected to the system has a core size of at least 8mm separate instrument ground is desirable for the computer and sensors INSTRUMENT AIR The S TEC Measurement and Control system relies on good clean oil free and dry Instrument Air for system cooling radiation source shutter operation and air curtains for the Sensors It is therefore very important to ensure that a good air supply is given for this purpose Having high quality air will ensure long and trouble free operation of the S TEC Measurement and Control system The Paper Mill is required to supply the necessary filter regulator water separator and oil filter as necessary for this purpose The minimum air pressure required is 60psig but 80psig is preferred A push in connection is provided for this air under the front end enclosure of the scanner frame This is the only air connection necessary for the S TEC Measurement and Control system All cooling shutter operation and air curtains are derived from this air source THE LEADER IN MEASUREMENT amp CONTROL PAGE 14 OF 58 COOLING OF THE SYSTEM The Scanner front end enclosure cont
12. controlled by a computer located in the Computer Enclosure on the Tending Side of the frame Access to the computer is by opening the stainless steel door and then removing the Perspex cover of the Computer Enclosure The Computer Enclosure contains the computer cooling fan power supplies Analog Digital and Encoder terminations circuit breakers and vortex cooler Full information about this assembly can be found in a later chapter of this manual Great care must be taken to protect these computer components by 1 Ensuring the Perspex cover and the scanner door are always kept closed 2 Ensuring that the vortex cooler has an adequate air supply and is working OK 3 Ensuring that the internal cooling fan is working and that there is no excessive dust build up 4 Bysupplying power from a UPS power supply 1 5 POWER GROUND COMPRESSED AIR The scanner requires Power Ground amp Compressed Air utilities as follows UTILITY SPECIFICATION AMOUNT USED FOR UPS POWER 230VAC 1KW Computer Power Supplies NORMAL POWER 230VAC 2KW Drive Heater Clutch COMPRESSED AIR 80PSI 30 CFM For Cooling Shutter amp Purge INSTRUMENT GND Ground For Sensors amp 1 0 ELECTRICAL GND Ground For P S motor amp frame grounding SCANNER CONSTRUCTION ao db pa
13. 0 n34 Motor Protection Time Min 8 5 n35 Fan Rotates while RUN 0 0 n36 52 2 1 n37 53 5 n38 S4 3 6 n39 55 6 ri n40 Multifunction O P Terminal Running 1 1 n41 REF Frequency Gain 100 100 n42 REF Frequency Bias 0 0 n43 Analog Freq ref Filter s 0 1 0 1 n44 Analog O P 0 0 n45 Analog O P Gain 1 1 46 Frequency Select 4 47 Inverter Restarts Power Up 0 2 n48 Auto Retries on fault 0 0 n49 Jump Frequency 1 0 0 n50 Jump Frequency 2 0 0 n51 Jump Width 0 0 n52 DC Control Current 50 50 n53 Interrupt DC Control Time s 0 5 0 5 54 Start up Control Time 0 0 n55 Stall Prevention During Deceleration 0 0 n56 Stall Prevention Level 170 170 n57 Stall Prevention During Operation 160 160 58 Det Level 0 0 n59 Over torque Detection 0 0 n60 Over torque Detection Level 160 160 n61 Over torque Time s 0 1 0 1 n62 Don t UP Down 0 0 n63 Torque Compensation Gain 1 i 64 Motor Rated Slip 2 9 2 9 n65 Motor No Load Current 62 62 n66 Slip Compensation 0 0 n67 Slip Compensation T C 2 2 PROXIMITY SWITCHES Alignment is automatically checked when the scanner is sent off sheet and the alignment procedure is initiated if the heads are not perfectly aligned This automatic alignment depends entirely on two Proximity Switches located near the drive side of the scanner frame at the scanner home position one on the upper beam and the other on the
14. chapters of this Manual 5 2 SCANNER DRIVE MECHANISM MAINTENANCE The only category that has large sized mechanical moving parts that require servicing is the Scanner Drive mechanism This servicing is made very simple because all the parts are readily accessible GREASING It is necessary to do some routine greasing on some of the moving parts of the Scanner Drive system The mechanical moving parts of the Scanner Drive system consists mainly of the 3 motor and gearbox the drive shaft and its bearings the linear bearings that carry the Sensors and move along the round rails The Motor amp gearbox and the Drive shaft bearings are all housed in the Drive side end bell There are 3 greasing points here one on the gearbox one on each of the two bearings that holds the Drive shaft IT IS NECESSARY TO ADD GREASE AT THESE GREASING POINTS EVERY 6 MONTH INTERVAL Adding grease is easy through use of a normal Greasing gun It is recommended that the Grease used is at least of the quality of multi purpose Lithium Grease THE LEADER IN MEASUREMENT amp CONTROL PAGE 47 OF 58 The round rails along which the Linear bearings run also requires greasing These rails are mounted on the upper and lower double on the right side of the Scanner Frame looking from the Tend Operator station side IT 15 RECOMMENDED THAT THIS GREASING BE DONE EVERY 3 MONTHS Firstly both the upper and lower rail stainless steel covers m
15. for display and for control To do this the scanner must move the sensor heads back and forth across the web The sensor heads are equipped with Basis Weight Moisture and Edge Sensors Typically a scan from one side of the paper to the other takes 15 20 seconds but this can be changed by programming the AC drive Inverter The scanner scans until either the edge sensors see the paper edge or until it reaches the turn round proximity sensor whichever is first At this point the scanner heads will decelerate stop accelerate in the opposite direction and then scan at scan speed to the opposite paper edge or proximity sensor Scanning is started by pressing the SCAN press button on the tending side of the scanner To send the scanner off sheet i e back to the home position the OFF button must be pressed During scanning it is very important that the top and bottom heads are kept in exact registration and do not rock move relatively in any direction MD CD or UP DOWN To achieve this the S TEC scanner uses 4 linear rails and bearing bushings The Sensor Head is an enclosed unit that houses the Sensors and provides the necessary controlled environment for the Sensors to operate This ensures accurate measurements from the Sensors over long periods and maintains reliable operation on the Paper Machine Control of the scanner is from the integrated micro computer system located on the tending side enclosure of the scan
16. 15 EXAIR USA Scanner Frame amp Mechanical Parts Various S tec China DC Power Supplies 24VDC 5VDC Switch Mode MW Taiwan THE LEADER IN MEASUREMENT amp CONTROL PAGE 58 OF 58
17. ITCH MODE POWER SUPPLIES There are two regulated 24Vdc Power Supplies used in the S TEC Measurement and Control system 1 24VDC Switch mode regulated Power Supply which is located inside the Computer Enclosure It is used for buttons lamps shutter solenoid flag solenoid relay operation proximity switches etc 2 24VDC Switch mode regulated Power Supply which is located above the computer enclosure It is used to drive the magnetic clutch and for the sensor heads heating 3 4 ENCODER CONNECTION The encoder tachometer is connected directly to the tacho terminations inside the Computer Enclosure It uses the same 5VDC supply that the computer uses The shield of the tacho cable is grounded to the common ground SCANNER DRIVE amp INVERTER CONTROL he function of the Scanner is to carry the Sensor Heads back and forth cross the paper sheet as the paper is being reeled This action enables the ensors to measure the Basis Weight and Moisture of the sheet ontinuously as the paper is being reeled Because Paper manufacturing is a 4 Hour process the mechanism for this function must be able to maintain ignment at all times between the upper and lower Sensor Heads as they move across the sheet The mechanism must also be stable and very reliable The S TEC Measurement and Control system Scanner Drive Mechanism meets all these requirements Q o The Drive mechanism is driven by motor whose speed and di
18. RD This board is the interface between the computer DMM32 and most of the discrete inputs and outputs It provides isolation and indication both for inputs and outputs Each board of 3 can handle up to 8 digital inputs or 8 digital outputs or 4 digital inputs 4 digital outputs depending on the computer configuration and the position of jumpers on the board Isolation for digital outputs is by way of DIL socket mounted Reed Relays These provide excellent isolation An LED indicates when an output is ON Isolation for digital inputs is by way of dual darlington Opto Isolator ICs An LED is lit when there is an input to the circuit ANALOG 1 TERMINATION BOARD This board is the interface between the computer DMM32 and all Analog inputs Each of 2 board can handle either 8 differentially connected analog inputs OR 16 single ended analog inputs The configuration is determined in the software and on the hardware links of the DMM 32 board The board will accept O 10 signals These signals can be conditioned by connecting R C capacitive filtering on the board Low voltage Varistors are installed to help protect the computer from any high voltage connections to the terminations Jumper connections on the board determine which set of analog inputs this board connects to Jumpers also determine if a parallel 5 resistor is connected across the differential inputs to convert 0 2mA sensor signals to 0 10VDC Other j
19. ains the computer box which is cooled by a Vortex type air cooler This type of cooler has no moving parts and is very reliable provided the air is clean The vortex cooler works on a principle of conservation of angular momentum The air is forced to spin at very high angular speed gt 1 000 000 rpm inside the device This high speed air is mechanically guided in such a way that the air finally splits into two streams one hot and the other cold This is then piped out to the cold side outlet and the hot side outlet to be used as necessary The temperature of the cool air coming out from the Vortex cooler depends on the air pressure at the inlet The higher the inlet pressure the cooler the cold side outlet air similarly with the hot side VORTEX COOLER Compressed Air Supply gt E Hot Air From Cabinet Cold Air The Vortex cooler is mounted on the bottom of the computer enclosure The cold air enters the enclosure for cooling and pressurization purposes The hot side is left to blow into the Scanner Frame inside the stainless steel covers This also ensures a slight positive pressure throughout the bottom part of the Scanner which helps keep out the dust The upper and lower sensor heads are also cooled in the same way The hot side air is used here for the air curtains that surround the measurement windows of the Sensors The details of this can be found in the S TEC Sensor Heads Manual Ku 17
20. ate compressed air supply pressure and is optimally adjusted Check that there is no condensation inside the computer enclosure Power Supplies DMM 32 AMPRO AI TERM DIO TERM TACHO TERM Planned Maintenance Schedule 1 Daily Maintenance a Simple check of the system to ensure there are no obvious problems i Scanner Radiation warning lights are lit ii Scanner is scanning normally ii Head is clean if necessary clean Ask the Operators if everything is OK 2 Weekly Maintenance in addition to the daily maintenance above a Clean the sensor heads Separate the sensor heads and clean the sensor windows Check windows for signs of damage Realign and check for proper head alignment Open the upper and lower head covers and check inside i Check to ensure the vortex cooling is working ii Check to ensure the sensors are not too hot less than 40 Deg C is normal iii Check to ensure the IR Moisture sensor lamp is functioning iv Check for anything loose or unusual v Check to make sure all the fans are working Clean dust dirt from end enclosures Visually inspect the motor gearbox inverter encoder clutch for correct operation Check to ensure that the scanner computer enclosure is clean and the vortex cooling is working Check and log the compressed air pressure at the scanner air regulator Log the Standardization values Note any unusual deviations Measur
21. b The Sensor heads can be moved across the 3 strings to check for the correct pass angle and further adjustments made until the sensors make a clean pass across the strings Final adjustments to the Scanner height can then be made Once this is done all the bolts must be securely fastened to maintain this alignment situation There should be no further need to re align the Scanner once this procedure is completed THE LEADER IN MEASUREMENT amp CONTROL PAGE 12 OF 58 THE LEADER IN MEASUREMENT amp CONTROL PAGE 13 OF 58 POWER REQUIREMENTS The S TEC Measurement and Control system requires a single phase 220Vac 50Hz UPS Power Supply for operation All other system power requirements are derived from this single Power source This makes it a very simple system to install and start up Assuming the first option it is recommended that the Paper Mill supplies this Power from a dedicated UPS rated at 3kW with a Circuit Breaker and using 3 core Power cables each core size of 4mm This cable is terminated inside the Scanner front end bell on the left side on the Terminal block TB3 As an alternative two supplies one smaller UPS supply and on unregulated supply can be used In this case the UPS supply will be used to power the computer and sensor electronics while the unregulated supply will power the motor and heater clutch power supply GROUNDING
22. channel this field Assign IRQ 7 Enabled should be set to Disabled Assign IRQ 9 Enabled 4 Assign IRQ 10 Enabled If PnP BIOS is Disabled then this Assign IRQ 11 Enabled DHA channel is not assigned Assign IRQ 12 Disabled IRQ 14 Disabled Disabled to modify Esc to exit http uww anpro con Help for Assign DMA 1 Use Arrow keys to change item use C Copyright 2004 Ampro Computers Inc 4 7 DIAMOND DMM32 BOARD The Diamond DMM 32DX AT Board has a PC 104 format It plugs directly into the AMPRO Little Board Computer The DMM32 has the capability of up to 32 Analog Inputs and 31 digital 1 0 Two ribbon cables are connected to the connectors of this board A 50 way ribbon connects the DMM32 to the Analog Input Termination Board A 32 way ribbon connects the DMM32 to the Digital I O and Tacho Termination boards Links on the board provide addressing interrupt pull up down and 1 0 configurations setup If the board is replaced it is essential that these link configuration be replicated on the new board THE LEADER IN MEASUREMENT amp CONTROL PAGE 34 OF 58 32 SETUP example boari config FI pto conng rz DIO test Al sirio tine __ pa oss met s t pense Dinar pru cari mer a inate Toon oa
23. e the standard Basis Weight samples and log along with the calibration data Check the scanner operating buttons lamps are functional m Clean and polish the scanner stainless steel covers 3 Monthly Maintenance in addition to the weekly maintenance above a Sensor Heads vi vii Check that the inside of the heads are free from dust i Check the internal voltages inside the sensor heads iii Check that the vortex cooling system Check that the fans are working Check to ensure that the shutter mechanism is free and that the warning lights are operating correctly Check to ensure that the magnetic head separation switch is working and correctly prevents the shutter from operating if the heads are not together Check the sensors as suggested in the sensor manuals b Scanner vi vii viii Remove all of the covers from the beams Blow out all dust that may be on the beams Grease the linear bearing rails with high temperature grease e g Lithium based grease Check the Power Track for any sign of damage and that it operates normally Check the drive belt for signs of wear and that the tension is normal Check the seal belt for signs of wear and that the tension is normal Verify the correct operation of the clutch and blow out any dust that might have accumulated on the clutch plate Check the 5V and 24VDC supplies 1 The 5V should be at least 5 2V normally 5 3V no l
24. entre of the scanner is a mid position proximity switch which checks the position of the Sensor Heads as it scans across the sheet and can reset the position in case of drift Tending side and drive side scan limit proximity switches are provided which will turn the scanner around if reached before the edge of the sheet is detected For safety purposes there are a total of four crash switches which cut off power to the system should the Sensor Heads travel too far at each end Two switches are located in the front side while the other two are located at drive side of the scanner LEADER IN MEASUREMENT amp CONTROL PAGE 17 OF 58 Two Emergency cut off switches are also provided in cases it may be necessary to stop the Scanner manually These switches are located externally on each end of the Scanner This switch is a latch type which is activated by pressing the button Once depressed the button will latched until the operator releases it by rotating the switch Once the button is released normal operation of the Scanner can be resumed 3 2 SYSTEM POWER DISTRIBUTION The S TEC Measurement and Control system typically requires two single phase 220Vac 50 60Hz power supplies One rated at 1 kW from the normal electrical power supply and the other 1kW from a UPS supply These are terminated on cables in the front end enclosure Alternatively all can be powered from a single UPS power supply 3 3 24VDC REGULATED SW
25. ess than 5V actually on the computer board else operation will be unreliable 2 Check the small 24VDC regulated power supply inside the computer enclosure for 24V 3 Check the large 24VDC power supply which operates the clutch and heaters The voltage should be at least 24V Note that a lower voltage might miss operate the clutch 4 Quarterly Maintenance in addition to the above monthly maintenance above a Grease the drive belt bearing with a grease gun Back up the flash memory and store in a safe place Back up the SQCSExplorer software Back up the MIS data base Make screen prints of the important calibration and control tuning pages and back up pans CHAPTER 6 KEY SENSOR COMPONENTS CHAPTER 5 5 0 KEY COMPONENTS COMPONENT MODEL MANUFACTURER COUNTRY OF ORIGIN Linear Rail 40mm dia tapped 500mm centres Rextroth Wonshaft BaoLong Germany Korea Taiwan Linear Bearing Bushing R0632 040 00 Rextroth Germany Motor Gearbox SEW SEW Germany Clutch Friction type 24VDC Ogura QianDai Japan Taiwan Encoder 360ppr quadrature encoder Omron Japan Inverter 3G3JV Omron Japan Single Board Computer Littleboard AM LB700 Q 12 AMPRO USA PC 104 DMM 32DX AT Diamond Systems USA 1 Pcbs Digital I O ADC 1 0 Tacho I O S tec China Power Track Cable Varies TKD Germany Power Track Varies IGUS Germany Vortex Coolers 32
26. for Little Board 700 54054624 User Interface Show Hit Del Fi Error Wait Config Box Splash Screen Memory Henory Test Menory Hole Shadow D000 D3FF Shadow D400 D7FF Shadow D800 DBFF Shadow DCO0 DFFF DRAM Clock Frequency DRAM CAS Latency DRAN Bank Interleave lt Help for DRAN Fast Precharge to exit Use Arrow keys to change item use to modify Esc CICopyright 2004 Anpro Computers Inc http ww anpro con THE LEADER IN MEASUREMENT amp CONTROL PAGE 32 OF 58 Anpro Setup Utility for Little Board 7 DRAN Refresh Rate Pouer Managnent ACPI led This field specifies us Disabled for the selected Serin Pert advanced features Post Memory Manager Disabled If the Serial Port is Disabled then CPU Serial Number Enabled IRQ is assigned Watchdog Timeout sec Disabled Serial Console Hot Cable Serial Ports 1 and 2 can not share L Port 3F8h the IRQ USB Boot Support Disabled On Board Serial Ports IRQs used for Serial Ports 1 and 2 Serial 1 can not be used for Serial Port 3 or n 4 4 and vice versa 93 232 Serial 2 2F8h TQ 3 SuoS462A c Aus Help for IRQ i to exit rrow keus to change item use to modifu Esc C Copuright 2004 Ampro Computers Inc http uww anpro com k fmpro Setup Utility for Little Board 700 SU054624 C USB 4 Ports Help INTD IRQ Audio Enabled On Board Video This field i
27. lower scanner beam These Proximity Switches are adjusted such that when the sensor heads are in the home position the alignment pins passes through the upper and lower sensor heads alignment holes The signals from these Proximity Switches ultimately connect to the Digital I O terminations in the computer enclosure This alignment is already factory set But sometimes due to transportation and other causes this setting may need to be readjusted In such cases it is necessary to do some re alignment by adjusting the Proximity Switch position until the Sensor Heads are aligned in the Home position as described above This is a very simple task SCANNER PROMXIMITY SENSORS THE LEADER IN MEASUREMENT amp CONTROL PAGE 23 OF 58 THE LEADER IN MEASUREMENT amp CONTROL PAGE 24 OF 58 THE LEADER IN MEASUREMENT amp CONTROL PAGE 25 OF 58 POWER TRACK SIGNALS E THE LEADER IN MEASUREMENT amp CONTROL PAGE 26 OF 58 SIGNAL DISTRIBUTION PCB
28. ndicates the IRQ used for Franebuffer Size 16 PCI INTD or none at all AGP Aperture Size 12818 Display The following devices use PCI INTD Panel Type 640x 480 18 TFT First On Board USB Controller On Board Audio Legacy Second On Board USB Controller SoundBlaster Disabled PC 104 Plus adapters configured to IRQ 5 use INTD 1 MPU 401 Midi Disabled INTA IRQ INTB IRQ INTC IRQ i to exit Use Arrow keys to change item use to modify Esc C Copyright 2004 Ampro Computers Inc http uuw anpro con Utility for Little Board 700 SU054620 C Ufode RS 232 Help for PS 2 Mouse Serial 3 IRQ 11 If this field is set to Enabled the ES RS 232 On Board PS 2 Mouse Controller is Serial 4 2 used Em 10 le RS 232 If the On Board PS 2 Mouse Controller On Board LPT Port is Disabled then IRQ 12 is available LPT 1 378h for other purposes IRQ Da 3 Standard On Board Controllers Floppy Primary IDE IDE fy Esc to exit Use Arrow keys to change item use to C Copyright 2004 Computers Inc htt Setup Utility for Little Board 700 SWO5462A C Plug and Play PnP BIOS Enabled PnP 05 Enabled If this field is set to Enabled th Assign IRQ 1 Disabled the BIOS can assign this DMA Channel Assign IRQ 3 Enabled to a Plug and Play adapter Assign IRQ 4 Enabled Assign IRQ 5 Enabled If another device in the systen is Assign IRQ 6 Disabled using this DMA
29. ne type is for the Upper and Lower Sensor Heads Drive Belts and the second type is the Seal Belts for the upper and lower beam There are thus a total of 4 belts in the scanner The type of belt used for driving the Sensor Heads across the sheet is steel reinforced polyurethane timing belt 32mm wide with 10mm pitch T10 OR 8mm pitch This belt is of very high quality and very tough with minimum stretch so will not cause misalignment of the sensor heads The tension of this belt is adjusted by four bolts that hold the belt pulleys located at the front end of the Scanner Frame he correct tension is achieved by estimation and is not critical but the upper and lower belts must be similarly tensioned Tension is estimated by pushing the belt at a position well away from the heads and end pulleys so that it is free to deflect If it can easily be deflected only about 10mm then the tension is about right The third type of belt is the Sealing Belt These Belts seals the Scanner beams from external influences along the length of the Scanner The tension adjustment for these belts is located inside the Drive side end bell of the Scanner Frame Tightening the nuts increases the tension of the seal belts The correct tension is achieved by observing the behaviour of the belts as the Sensor Heads scans As long as the belts move smoothly and without causing any unusual noise the tension is considered OK They should not be over tightened
30. ner Signals go from the computer to the Inverter AC Drive The AC drive allows the selection of scan off sheet amp crawl speeds plus acceleration and deceleration Crawl speed is use for automatic alignment of the top and bottom heads This feature ensures that the heads are correctly aligned in the CD direction while allowing such facilities as HEAD SEPARATE Head Separate feature separates the heads for easy cleaning of the sensor windows and then automatic alignment again Head Separate is initiated by pressing the HEAD SEPARATE button 1 2 SENSOR MOUNTING The Sensors are all housed within a single enclosure called the Sensor Head This Sensor Head is made up of a Upper Head and a Lower Head The Lower Head houses the Basis Weight Radioactive source and the Moisture Sensor IR Lamp IR Sensor or Passive Microwave Cavity Microwave Sensor The Upper Head houses the Basis Weight and Moisture Sensor receivers The Sensor Heads are securely bolted onto the carriage of the Scanner Drive system 1 3 DRIVE MECHANISM The Sensor Heads are mounted on the Scanner carriage The carriage sits on Linear Bearings which wrap around especially hardened 4 diameter steel rails Movement of the carriage is by means of these Linear Bearings and along the rails During Scanning the carriage moves forward and backward across the paper all the while measuring the paper and sending Measurement signals back to the C
31. olled by the Invertor Drive which provides variable frequency 3 220Vac Power output from a single 1D 220Vac 50Hz Power supply This type of speed control is very accurate as the speed adjustment is frequency based GROUP SET UP DATA UNITS FACTORY S TEC DEFAULT STANDARD n01 Allow Parameter Setting 0 1 n02 Multifunction 0 1 n03 Frequency Reference n21 0 1 n04 Frequency Deceleration 0 0 05 Reverse Rotation Possible 0 0 n06 Stop Reset Key Enable 0 0 1 07 0 0 n08 Enter Key Enabled 0 0 Maximum Frequency Hz 60 80 10 Max Voltage VMAX V 200 200 n11 Maximum Voltage Frequency FA Hz 60 60 12 Middle Output Frequency FB kHz 15 1 5 13 Middle O P Frequency Voltage VC V 12 12 14 Minimum Frequency kHz 15 1 5 nis Minimum O P Frequency Voltage Vmin 12 12 n16 Acceleration Time 1 s 10 1 ni7 Deceleration Time 1 s 10 1 18 Acceleration Time 1 s 10 1 19 Deceleration Time 1 5 10 1 n20 S shape Accel Dec Characteristic 0 0 n21 Frequency Ref 1 Stop Hz 6 0 n22 Frequency Ref 2 Crawl Hz 0 8 n23 Frequency Ref 3 Scan Hz 0 50 n24 Frequency Ref 4 Off Sheet Hz 0 55 n25 Frequency Ref 5 not used Hz 0 0 n26 Frequency Ref 6 not used Hz 0 0 n27 Frequency Ref 7 not used Hz 0 0 n28 Frequency Ref 8 not used Hz 0 0 n29 Inching Frequency Hz 6 0 n30 Frequency Reference UL 100 100 n31 Frequency Ref LL 0 0 n32 Rated Motor Current A 0 1 18 n33 Protection Mode 0
32. omputer for Processing This forward and backward motion is achieved using a special Drive mechanism that is designed to give the best stability and reliability The Drive mechanism consists of two steel reinforced polyurethane Drive Belts one for the top carriage and the other for the bottom These belts are securely fastened to the respective carriages in a manner that allows the carriage to be pulled forward and backward across the paper sheet Both top and bottom belts are driven by toothed Pulleys which are connected to a single shaft the top via a Clutch As this Drive shaft rotates the belts will move and hence pulls the carriage in the desired movement direction This Drive shaft is rotated by a Motor Gearbox arrangement The direction of rotation and the rotation speed of the motor determine the Scanning direction and the Scanning speed respectively of the Sensor carriage An electronic Inverter device is used to control the rotation speed and direction of the motor This device ensures very stable rotational speed for the motor and is very reliable The Power Supply input to the Inverter is single phase 220Vac 50Hz Its output to the Drive Motor is three phase 220Vac with adjustable variable frequency It is this frequency that determines the speed of rotation of the motor and therefore the linear velocity of the sensors 1 4 COMPUTER ENCLOSURE The S TEC Scanner system is a fully integrated and stand alone unit It is
33. or Heads This adjustment is also made easy with the S TEC Measurement and Control system Two spacer bars are included with the system These spacer bars are placed within the Sensor Heads gap such that the four alignment bolts can pass through the top head spacer bar and the lower head smoothly These four alignment bolts ensure that the top and bottom Sensor Heads are aligned to each other and then the bolts are tightened to hold them exactly together The spacer bars ensure that the correct Sensor measurement gap between the Sensor Heads is maintained during the adjustment With the measurement gap fixed the Sensor Heads can now be rotated The four alignment bolts will ensure proper alignment of the top and bottom heads as the Heads are rotated to achieve the desired Pass angle To rotate the Heads the four bolts which hold each Sensor Head on to the mounting brackets of the Scanner carriage must be loosened Care must be taken here because the Heads are very heavy about 30kg for each Sensor Head It is recommended that this alignment job is done with at least 3 people two for supporting and rotating the Sensor Heads and the third loosening and tightening the bolts The Paper Pass Angle can be simulated by pulling strings along the Paper run direction It is recommended to pull 3 strings one at each sheet edge at a location which would represent the real sheet edges while the third string to be somewhere in the centre of the paper we
34. r Frame can be lifted as a single unit using the lifting eye bolts provided These eye bolts screw in the top beam of the Scanner and can be removed later and the hole covers replaced The Scanner must be mounted on Scanner Footings which allows some height adjustment The Customer should prepare the footings before the Scanner arrives on site Two such footings are required one for each leg of the Scanner and fabrication of these are the responsibility of the Paper Mill Once the Footings are put in place and leveled the Scanner can be lifted and placed onto these Footings Final height and leveling is done by adding or removing shims The Scanner must be electrically isolated from the Footing and the rest of the Paper Machine A rubber Insulation pad with nylon insulating bushings is provided to give this required insulation The Scanner sits on this Insulation pad and is held in place by four bolts 2 for each leg of the Scanner which bolt onto the Scanner Footings The nylon bushings insulate the bolts from the scanner frame This method of Installation ensures that the Scanner ground has no direct contact with nearby parts of the Paper Machine The Scanner ground is terminated by a thick and dedicated ground wire to a proper and suitable Electrical ground provided by the customer This ground should not have more than resistance THE LEADER IN MEASUREMENT amp CONTROL PAGE 10 OF 58 TYPICAL MOUNTING ARRANGEMENT
35. rection of rotation is controlled by the Inverter Drive The set up of the inverter is isted in the pages below The program for the Inverter is fixed during manufacturing and is not normally changed by the customer To change the set up requires an AB programming module which can be inserted into the front of the Inverter Contact Output signals from the Digital O Boards in the Computer Enclosure drive interfacing 24VDC relays The relays signal to the Inverter the direction of travel forward reverse and the speed Scan Off sheet Crawl Stop The Inverter takes care of the acceleration and deceleration A B 0 0 STOP 0 1 CRAWL 1 0 5 1 1 OFF SHEET The Scan speed is used during normal Scanner operation when the Sensors are moved forward and backwards across the sheet The Off Sheet speed is used during sheet breaks when it is necessary for the Sensors to go off sheet quickly The Crawl speed is used when the Sensor Heads are being aligned after being separated for cleaning or whatever purpose 3 6 MOTOR CONTROL OMRON INVERTER The S TEC Measurement and Control system uses a 220Vac 50Hz 550W motor to drive the Scanner carriage This motor is direct coupled to a Harmonic gear type gearbox which drives the Drive shaft using toothed pulleys and a timing belt The speed of the motor determines the scanning speed of the Scanner as it traverses the sheet This speed is contr
36. umpers can be used to pull inputs to ground if unused to divide the input voltage if gt 10VDC eg 24VDC signal from the magnetic switch TACHO amp DIGITAL 1 0 TERMINATION BOARD This board makes the connections to the encoder and decodes the quadrature tacho signal to determine the direction of travel The direction signal and the pulses from the tacho are sent to the computer DMM so that the computer can know the position of the scanner heads Two additional Contact Inputs and three additional Contact Output are available on this board AMPRO LITTLE BOARD COMPUTER The AMPRO Little Board computer has a Pentium processor The computer has only one power supply need 5VDC and has many input and output capabilities While not used for the scanner application the computer has keyboard VGA Video LCD Screen Hard Disk Floppy Disk ON Off Switch etc For the scanner application the computer 1 0 capability is utilised for Compact Flash Memory typically 128mb Ethernet 100BaseT PC104 connectivity When installing a new board ensure that JP4 is inserted since this allows booting from the CF Flash disk CMOS setup of the Ampro boards is as follows Help for BIOS and Hardware Settings gt BIOS and Hardware Settings This selection enters the screen with setup paraneters Reload Initial Settings Load ctory Default Settings These parameters configure the 8105 and the hardware
37. ust be removed to reveal the round rails that the Linear Bearings run along as the Scanner is scanning across the sheet These rails should be wiped clean from the previous old grease There are 2 linear bearings on the round rail on one side and one on the other side of both the upper and lower beams The space between the two bearings must be cleaned as well Once the rails are wiped clean a new thin layer of multi purpose Lithium grease is applied throughout the whole length of the rail A thicker layer of grease should be applied on the space between the two bearings Once this thicker layer of grease has been applied the Sensor Heads can be scnnerd Every year remove the linear baring housings one at a time clean and repack with Lithium grease SCANNER RAILS Cross Section View LINEAR RAILS It is also recommended that the Scanner Drive mechanism is checked periodically for normal operation Checks should be made for any unusual noises motor temperature belt tension belt condition smooth traverse of the linear bearings The drive mechanism components should all be wiped clean periodically BELT TENSION ADJUSTMENT There are 2 types of belts used in the Scanner Drive mechanism O
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