3BUS209559 K en NP 700 Installation and Maintenance Manual

Network Platform 700
Installation and Maintenance Manual

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.
PROPRIETARY DATA
This document contains proprietary data of ABB Inc / Ltd.
No disclosure, distribution (electronic or otherwise), reproduction,
or other means or dissemination may be made without written permission.
Produced by QCS Product Development.

Writers: Jerry Blessing, Håkan Hjalmers and Gerard Kenny
Artists: Melinda Hoyle, Kathleen Poirier
Contributors: Don Barger, Keith Carson, Jack Dukes, Ake Hellström, Mort Jensen, Al
Luckman, Donald Stephens, Alan Maguire, Finian Moore, Gabriel Farrelly
© 2008, 2009, 2010, 2011, 2013, 2014 by ABB Inc/Ltd. All rights reserved.
™ Smart Platform, Network Platform, 800xA, 1190 Paper Machine Measurement and Control System,
FirstSight Measurement Technology, 1180 MicroPlus, 1180 MICRO, OptiPak, and ACE are trademarks of
ABB Inc/Ltd.
® Teflon is a trademark of DuPont.
® AccuRay and ABB MasterAid are registered trademarks and service marks of ABB Inc/Ltd.
ii 3BUS209559 rev K
Document Version History

Network Platform NP 700
Installation and Maintenance Manual
Version Effective By Changes
Level Date
R&D Initial release based on 3BUS208001
A Oct 2008
R&D 4-1 Air purge
B Feb 2009 5 VLT settings
R&D 5 AEOS setup.
C June 2009 5 Advanced STDZ details.
6 Heater parameters for Ash and BW.
11 AI self test chapter added
R&D 1, 6 Added HPIR-T sensor
D April 2010 6 Positioning units
6 Sheet Temperature
4 Flushing of Water lines
9, 10 Motor obsolescence
10 Ribbon cable routing check
R&D 3 Update ‘Attaching the platform to the pedestals’
E June 2011 5 Update references correct text.
10 Replacement parts update
11 NP Bulk DC details added
R&D Table 10-4 corrected ID for item S
F Aug 2011
Pedestal measurements in Figure 3-5 corrected.
Fixed formatting, links and broken characters.
11 ASPC LEDs updated about 5VSB
Added a Commuication subsection in Electrical Hook-up
GK Several updates, clarifications and corrections to chapter Air and Water Supply on page 4-3.
G April 2013 et. al.
Page 5-25 Corrected homeScanLimit equation and duplicate equation removed.
Clarification of Accelerated Standardize on page 5-29.
Renamed several headings in Section 9 Maintenance Procedures to better describe their content.
Updated Carriage Drive Belt Tension Inspection and Measurement on page 9-6
Updated Drive End Motor Belt Inspection on page 9-8
Updated Carriage Wheel Inspectionon page 9-13
Corrected part numbers in Air Purge Filter Inspectionon page 9-16.
Updates and additional figures in Inspecting the Compressed Air Filter Regulators & Filterson
page 9-18
Renamed several headings in Section 10 Replacement Procedures to better describe their

content.
Drive Motor Belt Replacement and Inspection on page 10-2 Improved text and added figure
showing alternative method to check belt deflection tension.
Added text to Flex Cable Suspension Replacement on page 10-17

Added important updates to chapter Position Encoder Replacement on page 10-34 to avoid
early life encoder failures from bearing side loading. Added encoder pictures and introduce new
belt tensioning assembly.
Chapter Scanner Replacement Parts List on page 10-36 Added pictures, corrected part numbers
and added parts added.
Updated chapter ASPC LEDs on page 11-3
Page 11-22. Add new section Basic Troubleshooting and Supportline Data Collection Steps
Page 11-25. Add section Troubleshooting Data Collection Requirements for ABB Supportline.
Page 11-26 Updated VLT motor controller troubleshooting details
3BUS209559 rev K iii

Version Effective By Changes

Level Date
Page 11-27 Table 11-4 Addressing Issues add AL7 data
GK Change 3bus214905-001NP7 PosEncoderBeltTensionCheck Tool deflection from 10mm to

H Sep 2013 7mm
Add several updates, clarifications and corrections to chapter Air and Water Supply page 4-3
adding location and air pipe length advice for the frame air filter regulator.
Add Drive Shaft Inspection section to Page 9-8
Added ® for all Teflon® references.
GK Improve Table 10-5 Replacement Parts List text for 3BUS212258-002 motor replacement on
I Dec 2013
page 10-36 item F.
Correct Figure 10-4 text designation in Drive Motor Belt Replacement and Inspection on page
10-2
Remove references to old Radiation Safety Manual (for customers), 3BUS 208 089 RXX01and
Field Radiological Procedures Manual (For ABB personnel only 016263-001) from page vi.
Add HAW setup data to Heated Air Wipe Installation 6-47
Introduced new type of NP Bulk DC Power Supply Kit (3BUS215432-001) containing new
power supply 3BUS215138-001 in Table 10-5 on page 10-36 and in DC Power Supply
Replacement section on page 10-19. Replaces obsolete modular power supply 3BUS208859-
XXX.
AM Update Table 10-6 ASPC Replacement Parts for obsoleted FO-NIC unit 3BUS209375-001
J July 2014 GK/ Edit text improvements and add figure pictures in new type NP Bulk DC Power Supply Kit
AM (3BUS215432-001) in DC Power Supply Replacement section on page 10-19.
Add the word ‘kit’ and picture to 3BUS209894-001 Air Pressure Guage Kit 0-60Psi 2” Spare
Parts Page 10-48
Update Table 10-6 ASPC Replacement Parts for obsoleted FO-NIC unit 3BUS209375-001 to
say use -022.
Correction to text re tuning paramin Motor Controller Adjustment of U/f Characteristic – f on
page 5-10
Add quantities and note about part numbers for the extended wheel assembly option to Table
10-5 Replacement Parts List.
Add additional ideler end pulley data to Table 10-5 Replacement Parts List.
Add note 9 to Carriage Wheel Inspection on Page 9-13
Change Table 5-2 Group 5 VLT paramater 5-40 from 9 to 53 adding Note 1.
Rename Figure 10-27 & Figure 10-29 pre July 2014 VLT wiring & programming information
on page10-29 and page10-30.
Add Figure 10-28 post July 2014 VLT wiring & programming information to page 10-29.
Add Figure 10-30 post July 2014 VLT wiring and programming information on page 10-30.
Add word ‘remote’ to the text for Figure 10-29 & Figure 10-30. Update same information on
preceeding pages.
Add AC100 Re-Use Advice to Motor Drive Setup (ABB ACS-100) section page 5-11.
Scanner Replacement Parts List improvements. Add a note starting on page 10-36 saying ABB
may not supply the VLT unit at the 3BUS209323-100 part level. Add seal belt parts 100434-
006 & -105. Update belt photocell text. Update timing belt text. Correct Rotary Motor Safety
Lockout Switch part number from -001 to -030 and add picture.
Add Figure 11-16 Alarm Documentation and improve text in the preceeding note.
Make NP7 Troubleshooting data section text same as NP12 manual on page 11-22.
K Aug 2014 AM Update details for VLT controller, removed parameter tables from manual.
Add steps 2&8 to Air Profile Collection section on page 6-43.
22Aug2014 GK
Add drive belt tensioning methods A&B to Drive Motor Belt Replacement and Inspection
19Jan2015 section on pages 10-2 and 10-3
New reference for Microwave Manual on page 6-5
iv 3BUS209559 rev K
Preface
The audience for the Network Platform NP 700 Installation and Maintenance Manual, 3BUS 208 000 146, is
the person(s) who initially sets up and maintains the Network Platform. The purpose of this manual is to
provide for installation, setup, and maintenance of the Network Platform.
While limited information is included, the user is expected to be somewhat familiar with operations related to
the Service Workstation and Health Reports. Additional background is available in the documents listed
below.
The following documents are recommended for maintenance of the Network Platform:
• Liquid Cooling Unit Reference Manual, 3BUS 208 146 RXX01
• Network Platform Software Reference Manual 3BUS209544
• Specific sensor manuals
3BUS209559 rev K v
Caution and Warning Symbols

General Safety Forms and Colors
Geometric Form and Meaning
Geometric Form Meaning
Prohibition or
mandatory action
Warning
Information (including
instructions)
General Meaning of Safety Colors

Safety
color Meaning or Objective Example of Use
Red Stop Stop signs

Prohibition Emergency stops
Prohibition signs
This color is also used for fire-prevention and fire-fighting equipment

and its location
Blue1 Mandatory action Obligation to wear personal

protective equipment
Yellow Caution, risk of danger Indications of dangers,

(fire, explosion, radiation, toxic
hazards, etc.)
Warning for steps, low
passages, obstacles2
Green Safe condition Escape routes

Emergency Exits
Emergency showers
First-aid and rescue stations
1. Blue is considered a safety color only if used in a circular shape.

2. Fluorescent orange-red may be used in place of safety yellow except on safety signs. This color
is very conspicuous, especially in conditions of poor natural lighting.
vi 3BUS209559 rev K
Definition of Cautions and Warning Symbols

The following symbols represent warnings and cautions which you may find on the product or in
product documentation.
This symbol warns of dangerous voltage. This symbol

is used if there is a danger of a harmful or fatal shock.
This is a radiation warning and is used when ionizing

rays are present. Where a lamp is used to indicate the
presence of ionizing radiation it is red.
This is a general warning symbol and is to be used if

there is no other more specific symbol available.
This symbol warns of potential electrostatic

sensitive devices. It is used as a reminder to
observe all electrostatic discharge control
procedures.
This symbol warns of a potential crushing hazard.

For example, if the motor controller is not properly
adjusted to stall, it may be possible for someone to be
crushed between the head package and the end
column.
This symbol warns of a potential hand or

finger entrapment hazard.
3BUS209559 rev K vii

This symbol warns that equipment may

automatically start-up.
This symbol is a reminder that the motor must be

locked off before performing any action where
unexpected movement of the head package or any of
the associated drive elements would pose a hazard.
Note that the motor lock-out switch removes power
from only the motor controller and motor. It does
NOT remove all power from the SP.
MOTOR ONLY .
This symbol is a reminder that it is mandatory to

read and understand the supporting manual before
proceeding. Additional necessary information is in
the manual.
WARNING
See WARNING text.
Exposed moving parts can

cause severe injury.
Do not operate machine
without guards in place.
Follow lock out procedure
before servicing machine.
This symbol indicates the maximum

weight of an SP and refers to this manual for
more information. See Chapter 3,
“Hardware Installation”.
4.5 TONS
viii 3BUS209559 rev K

Table of Contents
1 PRODUCT OVERVIEW ............................................................................ 1-1

NP 700 Options .............................................................................................1-3
ABB Smart Processing Center (ASCP) .......................................................1-4
Mechanical Structure....................................................................................1-7
Way System ..................................................................................................1-8
Drive System .................................................................................................1-9
Electrical and Cable Systems ....................................................................1-10
Service Workstation ...................................................................................1-12
Service Tools ..............................................................................................1-13
2 RADIOLOGICAL SAFETY ........................................................................ 2-1

Safety Features .............................................................................................2-2
Handling the Source .....................................................................................2-4
Installation of the Source .............................................................................2-5
Individual Responsibility..............................................................................2-6
3 HARDWARE INSTALLATION .................................................................. 3-1

Unpacking Instructions ................................................................................3-2
Handling Instructions ...................................................................................3-3
Safety.............................................................................................................3-6
Installation Requirements ............................................................................3-8
Liquid Cooling Unit Setup ..........................................................................3-11
Pedestal Installation and Alignment ..........................................................3-12
Attaching the Platform to the Pedestals ...................................................3-15
Platform Alignment .....................................................................................3-20
Carriage Alignment .....................................................................................3-22
Pass Angle Alignment ................................................................................3-23
Process Direction Alignment .....................................................................3-28
Air Gap Alignment ......................................................................................3-30
Scan Direction Alignment ..........................................................................3-32
4 UTILITY SERVICE INSTALLATION ......................................................... 4-1

Air Purge .......................................................................................................4-2
3BUS209559 rev K ix
Air and Water Supply ................................................................................... 4-3

Electrical Hook-Up ....................................................................................... 4-6
NP Power up Procedure ............................................................................... 4-9
Starting Up the Software ............................................................................ 4-12
5 PLATFORM TUNING ............................................................................... 5-1

Platform Software Setup Checklist ............................................................. 5-2
Motor Drive Setup (VLT Micro Drive) .......................................................... 5-3
Motor Drive Setup (ABB ACS-100) ............................................................ 5-11
Frame Tune ................................................................................................. 5-12
Head Position Setup................................................................................... 5-16
Head Package Dimensions Setup ............................................................. 5-20
Automatic Edge-of-Sheet ........................................................................... 5-23
Standardize Off-Sheet Delay Setup ........................................................... 5-27
Accelerated Standardize ............................................................................ 5-29
Other Host Setup Procedures ................................................................... 5-30
6 MEASUREMENT SETUP ......................................................................... 6-1

Setup Checklists .......................................................................................... 6-2
Operation of Service Workstation Health Reports ..................................... 6-7
Temperature Controller Setup for Basis Weight and Ash Sensors ........ 6-10
Setup of Customer Units ........................................................................... 6-14
Enter Calibration Head Constants............................................................. 6-16
Standardize Limits ..................................................................................... 6-28
Verification.................................................................................................. 6-41
Air Profile Compensation for Ash, Basis Weight, Caliper & OptiPak ..... 6-43
Default Compensations for IR Moisture, Microwave & Ash Sensors...... 6-45
Calibrate Sample - Minimum Time Data Accumulation ........................... 6-46
Heated Air Wipe Installation ...................................................................... 6-47
7 CONTROL PANEL OPERATION ............................................................. 7-1

Control Panel Description............................................................................ 7-2
Network Platform Modes of Operation........................................................ 7-3
Control Panel Functions .............................................................................. 7-4
Head Separation ........................................................................................... 7-7
Limit Switches .............................................................................................. 7-8
8 STARTUP OPTIONS ................................................................................ 8-1
x 3BUS209559 rev K
9 MAINTENANCE PROCEDURES .............................................................. 9-1

Network Platform Maintenance Log ............................................................9-2
Inspecting the Incoming Power ...................................................................9-4
Inspecting the Drive System ........................................................................9-5
Carriage Wheel Inspection .........................................................................9-13
Platform Alignment Inspection ..................................................................9-14
Scan Direction Alignment Inspection ........................................................9-15
Air Purge Filter Inspection .........................................................................9-16
Inspecting the Compressed Air Filter Regulators & Filters .....................9-18
Inspecting the Water Filter .........................................................................9-21
Power and Temperature Checks ...............................................................9-22
10 REPLACEMENT PROCEDURES ........................................................... 10-1

Drive Motor Belt Replacement and Inspection .........................................10-2
Carriage Drive Belt Replacement...............................................................10-6
Idler Pulley Replacement ...........................................................................10-9
Carriage Wheel Assembly Replacement ................................................. 10-11
Seal Belt Replacement ............................................................................. 10-14
Seal Belt Roller Assembly Replacement ................................................. 10-16
Flex Cable Suspension Replacement ...................................................... 10-17
DC Power Supply Replacement ............................................................... 10-19
Motor Drive Controller Replacement – ACS to VLT................................ 10-27
Motor Drive Controller Replacement – Fincor or Lovejoy to VLT ......... 10-33
Position Encoder Replacement ............................................................... 10-34
Scanner Replacement Parts List ............................................................. 10-36
Replacement Parts for the ASPC ............................................................. 10-51
Replacement Parts List ............................................................................ 10-56
11 TROUBLESHOOTING ............................................................................ 11-1

Alarm Messages .........................................................................................11-2
ASPC LEDs .................................................................................................11-3
Power Down and DC Power Analysis ........................................................11-6
AI Self Test feature .....................................................................................11-7
Diagnostic Card Operation....................................................................... 11-11
Basic Troubleshooting and Supportline Data Collection Steps ............ 11-22
Troubleshooting Data Collection Requirements for ABB Supportline . 11-25
VLT Motor controller troubleshooting ..................................................... 11-26
3BUS209559 rev K xi
Table of Figures
Figure 1-1 System Overview 1-2
Figure 1-2 Network Platform ASPC Block Diagram 1-5
Figure 1-3 Power and Signal Interconnect Board 1-6
Figure 1-4 Platform Cross Section 1-7
Figure 1-5 Carriage System 1-8
Figure 1-6 Drive System 1-9
Figure 1-7 Electrical Component Locations 1-10
Figure 2-1 Shutter Status Lights on Lower Carriage and End Column 2-3
Figure 2-2 Types of Safety Labels Used on Shipping Containers 2-4
Figure 2-3 Safety Labels 2-6
Figure 2-4 Safety Label for the X–ray Sensor 2-7
Figure 2-5 Measurement Beam 2-8
Figure 3-1 Network Platform on Shipping Dollies 3-2
Figure 3-2 Rigging Recommendations 3-4
Figure 3-3 Liquid Cooling Unit Setup 3-11
Figure 3-4 Alignment of the Mounting Pedestals 3-13
Figure 3-5 Attaching Drive Side of Network Platform to Pedestals 3-15
Figure 3-6 Platform to Pedestal Installation – Idler Side 3-16
Figure 3-7 Preliminary Alignment Setup 3-17
Figure 3-8 Jackscrew Orientation 3-18
Figure 3-9 Verifying Platform Alignment 3-20
Figure 3-10 Head Alignment Conditions 3-22
Figure 3-11 Pass Angle Adjustment 3-23
Figure 3-12 Manual Clutch Operation 3-24
Figure 3-13 Lower Electrical Enclosure 3-25
Figure 3-14 Simulating the Process Pass Line 3-25
Figure 3-15 Pass Angle Adjustment Tool 3-27
Figure 3-16 Process Direction Alignment Points 3-28
Figure 3-17 Air Gap Alignment Points 3-31
Figure 3-18 Scan Direction Optimum Alignment Point 3-32
Figure 3-19 Scan Direction Adjustment 3-33
Figure 3-20 Manual Alignment Setup 3-34
Figure 4-1 Purge Air Duct Attachment 4-2
Figure 4-2 Network ports on SBC 3BUS213621-001 4-7
Figure 4-3 Network port on SBC 3BUS209587-000 4-8
Figure 4-4 Network ports on Fiber Optic Network Card 4-8
Figure 4-5 Circuit Breakers 4-9
Figure 5-1 LCP 11 Control Panel 5-4
Figure 5-2 S200 Switches 1 - 4 5-9
Figure 5-3 Velocity Profile graph 5-10
Figure 5-4 Frame Health Report – Frame tune options 5-12
Figure 5-5 Head Position Calibration Measurement 5-13
Figure 5-6 Frame Health Report – Scanner Setup 5-14
Figure 5-7 Frame Health Report – Servo Setup 5-15
Figure 5-8 Network Platform Positions at the Host Computer 5-17
Figure 5-9 Frame Health Report – Scanner Setup –Head Position Setup 5-17
Figure 5-10 Limits for Multiple Platform Installations 5-18
Figure 5-11 SWS Frame Health Report - Scanner Setup 5-19
Figure 5-12 Location of Head Package Measurements 5-21
xii 3BUS209559 rev K

Figure 5-13 Automatic Edge-of-Sheet Position Measurements 5-24

Figure 5-14 SWS Frame Health Report - AEOS Setup 5-26
Figure 5-15 SW Frame Health Report -Stdz Setup 5-28
Figure 6-1 Health Report Icon 6-7
Figure 6-2 Frame Health Report – Selecting a NP 6-7
Figure 6-3 NP Workstation Frame Health Report - Overview 6-9
Figure 6-4 Service Workstation Basis Weight Health Report - Heater 6-11
Figure 6-5 Positioning Customer units 6-14
Figure 6-6 SWS Basis Weight Ream Size Entry 6-15
Figure 6-7 SWS Caliper Health Report 6-15
Figure 6-8 SWS Basis Weight Health Report – Calibration 6-17
Figure 6-9 SWS Air Column Health Report – Setup 6-17
Figure 6-10 SWS IR Moisture Health Report – Calibration 6-18
Figure 6-11 SWS Ash Health Report - Calibration 6-20
Figure 6-12 SWS Temperature Health Report – Calibration 6-21
Figure 6-13 NP Configuration Tool - Temperature 6-21
Figure 6-14 SWS Gloss Health Report – Calibration 6-22
Figure 6-15 NP Workstation Caliper Health Report - Calibration 6-23
Figure 6-16 SWS Microwave Health Report – Head Constants DS30 6-24
Figure 6-17 SWS Microwave Health Report – Compensation 6-24
Figure 6-18 NP Workstation Optipak Health Report – Calibration 6-25
Figure 6-19 NP Workstation Optipak Health Report – Recalibration I 6-26
Figure 6-20 NP Workstation Optipak Health Report – Recalibration II 6-26
Figure 6-21 NP Workstation Optipak Health Report – Recalibration III 6-26
Figure 6-22 NP Workstation Optipak Health Report – Recalibration IV 6-27
Figure 6-23 NP Configuration tool - StdzWaitTime 6-28
Figure 6-24 Standardize Mode Selection 6-31
Figure 6-25 Frame Health Report - FCP Standardize Type 6-32
Figure 6-26 NP Workstation BW Health Report - Standardize Limits 6-33
Figure 6-27 NP Workstation Caliper Health Report - Standardize Limits 6-35
Figure 6-28 Ash Sensor Health Report - Standardize Limits 6-39
Figure 7-1 Network Platform Control Panel 7-2
Figure 7-2 Limit Switch Locations 7-8
Figure 7-3 Idler End Proximity Switch A 7-8
Figure 7-4 Drive End Proximity Switch 7-9
Figure 7-5 Detail of Proximity Switch 7-9
Figure 7-6 Attachment of Metal Target 7-10
Figure 7-7 Safety Mechanical Stop Position 7-10
Figure 9-1 Network Platform Lockout Switch Location 9-5
Figure 9-2 Drive Belt Measurement and Adjustment 9-7
Figure 9-3 Drive Motor Belt Check and Adjustment 9-8
Figure 9-4 Drive Motor Belt Check and Adjustment 9-9
Figure 9-5 Seal Belt Tension Checks 9-9
Figure 9-6 Manual Clutch Head Separation 9-11
Figure 9-7 Head Separation Switches 9-12
Figure 9-8 Air Filter Regulator and Status Indicators 9-19
Figure 9-9 Filter Element Replacement 9-20
Figure 9-10 NP Workstation Frame Health Report 9-22
Figure 10-1 Drive Motor Belt 10-2
Figure 10-2 Air Clutch Drive Assembly 10-4
3BUS209559 rev K xiii

Figure 10-3 Alternative Method of Checking Drive Belt Tension 10-4

Figure 10-4 Manual Clutch Drive Assembly 10-5
Figure 10-5 Carriage Drive Belt 10-7
Figure 10-6 Idler Pulley 10-10
Figure 10-7 Carriage Wheel Assembly Removal Pictures 10-12
Figure 10-8 Carriage Wheel 10-13
Figure 10-9 Seal Belt Clamp and Adjustment Bolts 10-14
Figure 10-10 Seal Belt 10-15
Figure 10-11 Seal Belt Tension Checks 10-15
Figure 10-12 Roller Assembly 10-16
Figure 10-13 Carriage Assembly (Top View) 10-18
Figure 10-14 3BUS215138-001 NP Bulk DC 12.5V 15V 24V 42V Power Supply
3BUS208968-101 NP DC Power Supply link-up cable attached. 10-19
Figure 10-15 3BUS215138 NP Bulk DC 12.5V 15V 24V 42V Pwr S. Terminals 10-20
Figure 10-16 NP Bulk DC Power Supply shield is not re used 10-21
Figure 10-17 NP7 Assembly example with full cable compliment connected. 10-22
Figure 10-18 NP12 Assembly example showing white cable connector locations. 10-22
Figure 10-19 NP7 Assembly tie wrap example. 10-23
Figure 10-20 3BUS208997-001 NP DC Power to CSS cable Optipak/Gloss/Ref IR 10-24
Figure 10-21 3BUS208973-001 DC 42V power link for Reflection IR cable. 10-24
Figure 10-22 3BUS208997-002 DC power 24V to CSS and 42V to Ref IR cable. 10-24
Figure 10-23 3BUS208968-101 NP DC Power Supply Link-Up cable connection. 10-24
Figure 10-24 NP Bulk DC power supply type 3BUS208859-xxx (obs Dec 2013) 10-25
Figure 10-25 End view for Bulk DC supply with module positions 10-26
Figure 10-26 VLT Adapter plate 10-27
Figure 10-27 Connection of VLT on Pre July 2014 NP1200 and NP700 Scanners 10-29
Figure 10-28 Connection of VLT on Post July 2014 NP1200 and NP700 Scanners 10-29
Figure 10-29 Connection of VLT on Pre July 2014 Remote J-Box Based Scanners 10-30
Figure 10-30 Connection of VLT on Post July 2014 Remote J-Box Based Scanners 10-30
Figure 10-31 Encoder Drive End Pictures 10-35
Figure 10-32 Belt Tension & Belt Pulley Distance Setting Kit 3BUS214905-100 10-35
Figure 10-33 Drive End Column Parts 10-50
Figure 10-34 Network Platform ASPC 3BUS208692-001 10-51
Figure 10-35 Network Platform ASPC 3BUS208692-002 (HPIR-T & ATXC) 10-52
Figure 10-36 Bulk DC Elements 10-53
Figure 10-37 Idler End replacement Parts 10-56
Figure 10-38 Air Filter Regulator Replacement Service Parts 10-57
Figure 11-1 PCI backplane LEDs 11-3
Figure 11-2 Self test functional example 11-7
Figure 11-3 Self test SWS controls 11-8
Figure 11-4 Example self test result with 2.5V Self test voltage 11-9
Figure 11-5 Test Board Hookup 11-11
Figure 11-6 Basis Weight Source Module 11-12
Figure 11-7 Basis Weight Detector Module 11-13
Figure 11-8 Sample Diagnostic Card: Top Power 11-14
Figure 11-9 Sample Diagnostic Card: Bottom Power 11-15
Figure 11-10 Sample Diagnostic Card: Top Signal 11-16
Figure 11-11 Sample Diagnostic Card: Bottom Signal Sensor 11-17
Figure 11-12 Power Cable Connectors 11-18
Figure 11-13 Sample Diagnostics Card: Bottom Auxiliary Power 11-19
xiv 3BUS209559 rev K

Figure 11-14 Sample Diagnostics Card: Detector Module 11-20

Figure 11-15 Sample Diagnostics Card: Source Module 11-21
Figure 11-16 ABB Alarms and Software Documentation is available in the SWS 11-24
3BUS209559 rev K xv
Tables
Table 1-1 ASPC Fuses ...................................................................................................... 1-4
Table 1-2 Electrical Components .................................................................................... 1-11
Table 3-1 Dimensions and Weight..................................................................................... 3-5
Table 3-2 Environmental Data for the Network Platform ................................................ 3-8
Table 5-1 VLT Controller Usage ...................................................................................... 5-7
Table 5-2 Motor Drive Parameter Settings (Scanner Defaults) ......................................... 5-8
Table 5-3 NP Service Workstation Frame Servo/Temp Entries ...................................... 5-15
Table 5-4 Head Package Dimensions .............................................................................. 5-20
Table 5-5 Sensor Window Diameters .............................................................................. 5-22
Table 5-6 Edge of sheet parameters ................................................................................. 5-23
Table 6-1 Basis Weight Sensor Setup ................................................................................ 6-2
Table 6-2 IR Moisture Sensor Setup .................................................................................. 6-2
Table 6-3 HPIR-T Moisture Sensor Setup ......................................................................... 6-3
Table 6-4 OptiPak Sensor Setup ........................................................................................ 6-3
Table 6-5 Ash Sensor Setup .............................................................................................. 6-3
Table 6-6 Gloss Sensor Setup ............................................................................................ 6-4
Table 6-7 Apparent Density Setup ..................................................................................... 6-4
Table 6-8 Caliper Sensor Setup ......................................................................................... 6-4
Table 6-9 Sheet Temperature Sensor Setup ....................................................................... 6-5
Table 6-10 Microwave Sensor Setup ................................................................................. 6-5
Table 6-11 Smart Color Sensor Setup................................................................................ 6-5
Table 6-12 IR CoatWeight Sensor Setup ........................................................................... 6-6
Table 6-13 Temperature Controller Tuning Parameters .................................................. 6-12
Table 6-14 Flow Versus Current with the Heater Fully On ............................................. 6-12
Table 6-15 Basis Weight Calibration Constants .............................................................. 6-16
Table 6-16 Air Column Measurement Constants ............................................................ 6-18
Table 6-17 Head Constants .............................................................................................. 6-19
Table 6-18 Ash Sensor Head Constants ........................................................................... 6-20
Table 6-19 Head Constants for the Gloss Sensor ........................................................... 6-22
Table 6-20 Microwave Moisture Calibration Constants .................................................. 6-23
Table 6-21 Constants for the Optipak Sensor ................................................................. 6-25
Table 6-22 Range for Basis Weight Sensor Standardize Limits ...................................... 6-34
Table 6-23 Range for Caliper Sensor Standardize Limits ............................................... 6-36
Table 6-24 Range for IR Sensor Standardize Limits ....................................................... 6-37
Table 6-25 Range for OptiPak Standardize Limits .......................................................... 6-38
Table 6-26 Range for Ash Sensor Standardize Limits ..................................................... 6-39
Table 6-27 Standardize Limits for the Gloss Sensor ...................................................... 6-40
Table 6-28 Compensation Requirements ......................................................................... 6-45
Table 9-1 Purge Blower Part Numbers ............................................................................ 9-16
Table 10-1 Belt tension for various scanner lengths. ....................................................... 10-8
Table 10-2 3BUS215432-001 Bulk DC supply kit contents.......................................... 10-20
Table 10-3 3BUS208859-xxx Bulk DC supply variants ............................................... 10-25
Table 10-4 Motor Controller parameters ACS vs VLT ................................................. 10-32
Table 10-5 Replacement Parts List ................................................................................ 10-36
Table 10-6 ASPC Replacement Parts ............................................................................ 10-54
Table 10-7 Idler End Replacement Parts ....................................................................... 10-56
xvi 3BUS209559 rev K

Table 10-8 Air Filter Regulator Replacement Service Parts ..........................................10-57

Table 10-9 Liquid Cooling Unit Water Supply Pre Filter Replacement Service Part ....10-58
Table 11-1 ATXC LED details .........................................................................................11-4
Table 11-2 RS485 Serial Card LEDs ...............................................................................11-4
Table 11-3 SSCB LEDs ....................................................................................................11-5
Table 11-4 Addressing Issues ........................................................................................11-27
Table 11-5 VLT Warning & Alarm List ........................................................................11-29
3BUS209559 rev K xvii

PROPRIETARY DATA: This document contains proprietary data of ABB Inc. No disclosure, distribution (electronic or otherwise), or other
means of dissemination may be made without written permission.
1 Product Overview
The NP 700 is a full size (maximum of 7 meters long), high-performance platform for small-to-
medium size paper machines with up to 5.3 meters (208 inches) of trim. The platform can carry up
to seven sensors at a ± 25º pass angle (optionally at a ± 45º pass angle). It has on-board electronics
for local sensor and platform signal processing. This chapter discusses the Network Platform
hardware. Figure 1-1 shows a typical NP 700 based measurement system. This chapter contains the
following major sections:
Section .......................................................................................................Page
NP 700 Options .............................................................................................1-3
ABB Smart Processing Center (ASCP) .......................................................1-4
Mechanical Structure....................................................................................1-7
Way System ..................................................................................................1-8
Drive System .................................................................................................1-9
Electrical and Cable Systems ....................................................................1-10
Service Workstation ...................................................................................1-12
Service Tools ..............................................................................................1-13
3BUS209559 rev K 1-1

Scanning Platform
Purge Blower
Process Water
Compressed
Liquid
Air
Cooling Unit
Sensor(s)
Power
Transformer
(240 4-wire)
Service
Workstation
Host Computer System
Figure 1-1 System Overview
1-2 3BUS209559 rev K

NP 700 Options
The NP 700 can be configured with the following options listed below.
Sensor Options
The following sensors can be mounted on the NP 700.
• Basis Weigh
• Infrared Moisture
• High Performance Infrared Tranmission Moisture (HPIR-T)
• Caliper
• Ash
•
OptiPakTM
• Gloss
• Temperature
• Microwave Moisture
• Edge-of-Sheet
• Color
• Smart ReflectionPlus CoatWeight
• Fiber Orientation
Scanner Options
The following options are also available for the NP 700.
• High temperature scanner insulation kit
• Remote electronics
• Remote control panel
3BUS209559 rev K 1-3

ABB Smart Processing Center (ASCP)

The Network Platform ABB Smart Processing Center consists of:
A Passive PCI Backplane with:
Single board PC running with Flash memory running Windows Embedded XP® operating
system
RS-485 Serial card for control panel and sensor communication.
One or two DAQ (Data Acquisition) cards (2nd card used on systems with a large sensor load)
Fiber Optical/Electrical Ethernet card.
Power supply for PCI backplane and its cards.
Optional HDLC card for Fiber Orientation sensor
A Standard Signal Interconnect Board with:
One or two Standard Signal Conditioning Boards (matching number of DAQ cards)
One or two Standard Signal Jumper Board (matching number of DAQ cards)
A Power Signal Interconnect Board with
Power Signal Conditioning Board
Jumper plugs P1 and P2 for power configuration
Air accelerator for air circulation and supply of instrument air for ASPC cooling
See Figure 1-2 for block diagram and Figure 10-34 for physical layout of ASPC.
The Power Signal Interconnect Board in the ASPC distributes power from the power supplies to
other ASPC components and to the power cables to upper and lower frame carriages. The
interconnect board has 6 fuses. (120VAC AC has no fusing except for trip switches at power entry.
Other DC voltages are not fused but current limited from supplies).
Fuse 1 + 12 Volts DC Fused (Used for Digital Inputs to the NP)
Fuse 2 - 12 Volts DC Fused (Used for Digital Inputs to the NP)
Fuse 3 + 12 Volts DC
Fuse 4 - 12 Volts DC
Fuse 5 + 15 Volts DC
Fuse 6 - 15 Volts DC
Table 1-1 ASPC Fuses
A modular Power Supply supplies ±12 Volts DC, ±15 Volts, 42 Volts, and 24 volts. A separate
power supply supplies power for lamp in the Gloss and Optipak Sensors.
1-4 3BUS209559 rev K

Figure 1-2 Network Platform ASPC Block Diagram
3BUS209559 rev K 1-5

Figure 1-3 Power and Signal Interconnect Board
1-6 3BUS209559 rev K

Mechanical Structure
The platform beams are constructed of custom extruded, aluminum box beams.
Torsion
box
Payload
Area
Figure 1-4 Platform Cross Section

The end columns are also made of aluminum box sections. The Scanning Platform is welded
together in a rigid ‘‘O”. The end columns house on-platform electronics and a drive system.
For longitudinal expansion, there is a Teflon® glide pad mounted under one end column. The other
end column is fixed.
3BUS209559 rev K 1-7

Way System
The upper and lower sensors are carried across the web by means of a three-way system with eight
wheels on each carriage. The principle of operation is shown in Figure 1-5 below.
NOTE: Encoder and Drive Shaft have been removed for clarity.
.
Carriage Wheels Carriage
Wheel
Mounting
Screw
Way Bar
Removable
Carriage
Wheel
Assembly
Figure 1-5 Carriage System

The weight of the carriage is carried on the side way bars which provide precision of motion. The
horizontal guidance is provided by the top way bar. The top carriage wheels are used in pairs with
one fixed and one spring-loaded to provide precise horizontal tracking with no backlash.
The carriage wheels are made from a hard, carbon fiber reinforced conductive polymer. The
bearings are permanently lubricated ball bearings.
The way bars are permanently laser aligned at the factory and locked by high strength fasteners. The
side way mounting bolts are covered by an extruded strip.
Note: The way bar alignment is never to be adjusted in the field.
1-8 3BUS209559 rev K

Drive System
The upper and lower carriages are traversed across the web by the drive system. The principle of
operation is shown in Figure 1-6.
Idler
Encoder End
Bearing
Upper Drive Belt
Drive
Pulley
Idler
Drive Pulley
Shaf t
Motor
Controller
Drive
Shaf t Drive
Motor
Tension
Motor Adjust
Belt
Bearing Lower Drive Belt
Drive
Pulley
Head Idler
Separation Pulley
Clutch
Drive
End
Figure 1-6 Drive System

The drive motor is a three-phase, variable frequency AC gear motor. The motor controller supplies
the drive wave forms. The drive belts are 1 inch (25 mm) wide and made of steel-reinforced
polyurethane.
A pneumatic, self-aligning head separation clutch at the bottom of the drive shaft allows for head
separation. Frames manufactured prior to August 1999 had a manual clutch.
3BUS209559 rev K 1-9

Electrical and Cable Systems

The major electrical components and their locations are shown in Figure 1-7. The electrical
component descriptions are given in Table 1-2.
Drive Idler
End End
IR Lamp Upper Limit Switch
Encoder Limit Switch
Transformer Flex Proximate
Proximeter
Cable
Motor ABB
Controller Smart
Processing
Center
(ASPC)
Control
Panel Control
Carriage Panel
Carriage
Power PCB Signal PCB
Head
Separation
Switch
Sensor AC Power
IR Sola Entrance
Cables
Transformer Module
Head
Sep aration
Switch and
Pressure
Switch Source
Motor Motor Lower Bulk
Light
Lockout Controller Flex DC
Switch Transformer Assembly Cable Supplies
Figure 1-7 Electrical Component Locations
1-10 3BUS209559 rev K

Table 1-2 Electrical Components

Item Description
AC Power Entrance Module Contains circuit breakers, filters, and the

outlet and termination for incoming AC
power
Bulk DC Supplies Delivers bulk DC voltages for the ABB Smart
Processing Center, sensors, and accessories
ABB Smart Processing Center Contains all of the electronic modules
(ASPC) for platform and sensor processing,
connector systems for most of the cables,
and an environmental control system
Control Panels Allows for operation of the platform and
display status via LEDs
Limit Switch Used to stop head travel and to reset the
encoder counter
Encoder Located on the drive shaft; gives head
position feedback to the system
Motor Controller Delivers three-phase power to the drive
motor; incoming AC power is isolated
via the motor controller transformer
Head Separation Pressure Switch Located at the drive clutch assembly; it
senses the head separation to take safety
action during head split
Head Separation Switch Located on both end columns to activate
head separation clutch
Motor Lockout Switch Allows for positive lockout of power to
the drive motor for safety during
maintenance operations
IR Sola Transformer Delivers stabilized AC power to the IR
source head and lamp transformer
IR Lamp Transformer Provides for lamp power at the carriage
Carriage Connector Boards Distribute the power and signal functions
from the flex cables to the sensors
Flex Cables With signal ribbon cable, power ribbon
cable and flex hoses connect moving
carriages to end column
Sensor Cables Connect sensors to carriage connector
boards
3BUS209559 rev K 1-11

Service Workstation
The Service Workstation PC is used for local interaction with the PC ABB Smart Processing Center
(ASPC). The Service workstation can be either a dedicated PC supporting one or multiple Frames or
a Laptop temporarily connected to the platform.
For the detailed hardware requirements and the instructions for loading and using the NP Client Suit
see 3BUS209544 - Network Platform Software Reference Manual.
The Service Workstation provides the capability to interface with various utilities that are used for
monitoring, tuning and diagnostics of the electronics and the sensors on the platform
1-12 3BUS209559 rev K

Service Tools
Service tools include:
A belt tension gauge is used to set the tension in the drive belts.
A gap setting tool is used to verify the alignment of the upper and lower heads.
A test panel is used to access platform and sensor signals at diagnostic outlets.
3BUS209559 rev K 1-13

2 Radiological Safety
This chapter is about radiological safety and the Network Platform. The information in this chapter
is meant to be an overview and not a substitute for training and authorization.
This chapter contains the following major sections:
Section .......................................................................................................Page
Safety Features .............................................................................................2-2
Handling the Source .....................................................................................2-4
Installation of the Source .............................................................................2-5
Individual Responsibility..............................................................................2-6
3BUS209559 rev K 2-1

Safety Features
The radioactive material used in the nucleonic sensors is hermetically sealed in a high integrity
metal capsule to form a sealed source. Each sealed source is manufactured to exacting
specifications and is subjected to rigorous quality control procedures.
The sealed source in the nucleonic sensor and the X–ray tube in the X–ray sensor are shielded
because they are encased in metallic source holders and are equipped with spring–loaded, fail–safe
shutter mechanisms. The shutters are designed to remain closed except during operation. During
operation, the system applies power to overcome the spring of the shutter mechanisms. The shutters
close automatically if power to the Network Platform is turned off or interrupted.
When power is applied, the status of the shutters (open or closed) is indicated by the red and green
shutter lights on the Network Platform. A red light means one or more shutters are open and there
may be a radiation beam in the measuring gap. A green light, at the control panel on the end
column, means all the shutters are fully closed. Refer to Figure 2-1 for a representation of the
combined shutter and status lights on the end column. The shutter status lights for each individual
shutter mechanism are located on the lower head carriage. Refer to Figure 2-1 for the locations of
the shutter status lights. The Ash High–Voltage status light (yellow) indicates that the X–ray tube is
energized when the light is illuminated.
2-2 3BUS209559 rev K

Shutter Closed Shutter Open

(Green) (Red)
Off-Sheet On-Sheet
(Amber) (Green)
Local Remote
(Amber) (Green)
Jog Reverse Jog Forward

R F
(Amber) (Amber)
Calibrate Sample Sample Check

(Amber) (Amber)
Clean Standardize Maintenance
R F Set Forward
Set Reverse
Limit Limit
Basis Weight Ash

Shutter Open Shutter Open
(Red) (Red)
Basis Weight Ash

Shutter Closed Shutter Closed
(Green) (Green)
Ash High Voltage

(Yellow)
BW ASH
Figure 2-1 Shutter Status Lights on Lower Carriage and End Column
3BUS209559 rev K 2-3

Handling the Source

Only persons specifically trained in radiological safety and specifically authorized by their
controlling, regulatory agency may handle, install, or service the radiation source, the radiation
source containment, or the radiation source shielding.
Nuclear sources for the sensors are shipped to the site in a separate container which is clearly
marked with the International Radioactive Hazardous Materials shipping label and marking
statement. Refer to Figure 2-2 for a description of the labeling and markings.
Upon receipt, the shipping container is to be placed in secure storage by an authorized person, who
is on–site and responsible for radiological safety.
The nuclear source is to remain unopened and in secure storage until a trained and authorized person
removes it for installation into the sensor.
RADIOACTIVE
CONTENTS:
ACTIVITY:
TRANSPORT INDEX
RADIOACTIVE
CONTENTS . . . . . . . . . . . . . . . . . .
7 ACTIVITY . . . . . . . . . . . . . . .
RADIOACTIVE MATERIAL, N.O.S.

UN 2982, USA DOT 7A TYPE A
RADIOACTIVE MATERIAL
SPECIAL FORM, N.O.S.,
UN 2974, USA DOT 7A TYPE A
Figure 2-2 Types of Safety Labels Used on Shipping Containers
2-4 3BUS209559 rev K

Installation of the Source

Installation of the radiation source may take place only after power has been turned on to the
Network Platform and operation of all the radiological safety features has been verified.
Only persons specifically trained in radiological safety and specifically authorized by their
controlling regulatory agency may handle, install, or service the radiation source, the radiation
source containment, or the radiation source shielding.
3BUS209559 rev K 2-5

Individual Responsibility
All personnel are responsible for adhering to the radiological safety cautions and procedures
indicated on the labels and in the manuals that are part of the AccuRay® 1190 TM Paper Machine
Measurement and Control System. Refer to Figure 2-3 and Figure 2-4 for examples of the safety
labels.
REGULATORY CONDITIONS
THE RECEIPT, POSSESSION, USE, AND TRANSFER OF
THIS DEVICE ARE SUBJECT TO A GENERAL LICENSE OR THE
EQUIVALENT AND THE REGULATIONS OF THE U.S. NRC OR A
STATE WITH WHICH THE NRC HAS ENTERED INTO AN
AGREEMENT FOR THE EXERCISE OF REGULATORY
AUTHORITY..
ABANDONMENT OR DISPOSAL PROHIBITED UNLESS
TRANSFERRED TO PERSONS SPECIFICALLY LICENSED BY
NRC OR AN AGREEMENT STATE.
OPERATION PROHIBITED IF THERE IS INDICATION OF
FAILURE OF, OR DAMAGE TO, CONTAINMENT OF RADIOACTIVE
MATERIAL.
INSTALLATION, DISMANTLING, RELOCATION, REPAIR
OR TESTING SHALL BE PERFORMED BY PERSONS
SPECIFICALLY LICENSED BY NRC OR AN AGREEMENT STATE.
DEVICE SHALL BE TESTED FOR LEAKAGE OF
RADIOACTIVE MATERIAL AND PROPER FUNCTIONING OF THE
ON–OFF MECHANISM AND INDICATOR, IF ANY, AT INTERVALS
SPECIFIED ON THE ATTACHED YELLOW LABEL.
35715REMOVAL OF THIS LABEL IS PROHIBITED
CAUTION
RADIOACTIVE MA
TERIAL
MODEL____________________
___________________________
DATE MEAS.________________
TEST INTERVAL
REMOVAL OF THIS STICKER IS PROHIBITED

DO NOT CONTINUOUSL Y OCCUPY THE
AREA WITHIN OF THIS DEVICE
Figure 2-3 Safety Labels
2-6 3BUS209559 rev K

Figure 2-4 Safety Label for the X–ray Sensor

Individual responsibility also includes the following precautions:
• Pre–planning work activities to keep radiation exposure to a minimum.
• Determining that the sensor shutters are closed by looking at the status lights before
beginning work near the sensor carriage.
Never put any part of the human body in the sensor measuring gap when the
shutter is open. Refer to
Figure 2-5
3BUS209559 rev K 2-7

Sensor Measurement Beam

Figure 2-5 Measurement Beam
• Maintaining the safety labels and safety features.
• Not using a sensor until the safety features are functioning properly.
.
2-8 3BUS209559 rev K

3 Hardware Installation
Hardware Installation guides you from the arrival of the Network Platform on-site to alignment of
the head package assembly.
Section .......................................................................................................Page
Unpacking Instructions ................................................................................3-2
Handling Instructions ...................................................................................3-3
Safety.............................................................................................................3-6
Installation Requirements ............................................................................3-8
Liquid Cooling Unit Setup ..........................................................................3-11
Pedestal Installation and Alignment ..........................................................3-12
Attaching the Platform to the Pedestals ...................................................3-15
Platform Alignment .....................................................................................3-20
Carriage Alignment .....................................................................................3-22
Pass Angle Alignment ................................................................................3-23
Process Direction Alignment .....................................................................3-28
Air Gap Alignment ......................................................................................3-30
Scan Direction Alignment ..........................................................................3-32
3BUS209559 rev K 3-1

Unpacking Instructions
The Network Platform is carefully packed for shipment. The platform arrives on dollies so that you are
able to move it directly into position in the mill. See Figure 3-1. Depending on the location of the mill,
some Smart Platforms will arrive with the dollies bolted to a skid. For those shipments, unpacking
instructions are posted inside the crate.
Figure 3-1 Network Platform on Shipping Dollies

Various components and cables are removed and packed separately for shipment. The Network Platform
comes with a bill of lading. Use the checklist below during the unpacking process.
Checklist
 Inspect the platform and components for dents, scratches, and damaged parts.
 Verify that the delivered components match the bill of lading.
 If there is minor damage, make a note of the damage on the bill of lading. Photograph the
damage, when possible.
 If there is major damage, immediately notify the ABB shipping department in Columbus, Ohio
or Dundalk, Ireland.
3-2 3BUS209559 rev K

Handling Instructions
The Network Platform arrives on dollies so that it can be maneuvered into place at the mill. Use
caution when rolling the platform on an uneven floor to keep from getting the wheels stuck in a
hole. If you need to lift the platform, see Figure 3-2 and make certain that you observe the
following guidelines:
• Attach any rigging used to the two lifting eyes on top of the platform.
• Lifting forces must be spread over 75% of the platform.
• Do not lift from one point.
• Use a crane or hoist to move the platform (a dual pulley house crane is preferred to
prevent weight distribution problems).
• Make certain that the platform is not subjected to bending and twisting forces.
• Do not bump or drop the platform.
• Secure the platform from movement while it is being stored.
3BUS209559 rev K 3-3

Best
Dual Pulley House Crane
Good
Spreader Bar
Possible
If lift angle is 30° or more
Minimum 30°
Unacceptable
Figure 3-2 Rigging Recommendations
3-4 3BUS209559 rev K

Dimensions and Weight

The Network Platform is supplied in standard lengths between the pedestal center lines as indicated
in Table 3-1. Weights include sensors and dollies.
Standard Maximum Approx.

Length for Trim Weight
Hole Centers
mm in. mm in. kg lb.
4000 157.5 2295 90.4 702 1549
5000 196.9 3295 129.7 762 1680
6000 236.2 4295 169.1 821 1811
7000 275.6 5295 208.5 881 1942
Table 3-1 Dimensions and Weight
Space Requirements
Installation requirements are dependent upon the facilities and space available at the site location.
Refer to the general installation plans made prior to installation of the Network Platform.
The customer-supplied platform supports must be flat and unobstructed. Allow sufficient access
space around the support for cables to be connected and disconnected.
It is advisable to drill necessary cable holes through the concrete floor before the pedestals are
mounted. A single hole of approximately 3 in. (75 mm) in diameter and located near the idler end is
sufficient. A similar hole can be used for the liquid cooling unit. See Figure 3-3.
3BUS209559 rev K 3-5

Safety
The Network Platform has been designed to comply with ABB and worldwide standards including
the following:
• ABB PA Electrical Safety Directive, 3BDU000002
• ABB PA Machinery Requirements and Policy, 3BUS000159
• ABB PA Field Installation Considerations for Design of Electronics, 3BSE000161
• ABB PA EMC Requirements and Policy, 3BSE000200
The following personnel and machine safety rules should be followed when installing and operating
the Network Platform.
Personnel
Symbols appearing on the equipment warn personnel

of potential hazards. Symbols for dangerous voltage
warning, radiation warning, crushing hazard warning,
hand entrapment hazard warning, moving machinery
warning, and a warning that equipment may
automatically start up are shown on the left. Refer to
the explanations in the Caution and Warning Symbols
section at the beginning of this manual.
All people working on the Scanning Platform system

Must know the location of the main power supply
switch to the system and how to operate it.
Service on the SP system is to be performed

only by qualified, trained personnel. Hazardous
voltages exist inside the ABB Smart
Processing Center (ASPC) and in the SP beam.
Work with care when supply voltage is applied in

the SP system. The voltage in the ASPC and the
SP beam can cause injury and can even be fatal.
3-6 3BUS209559 rev K

Machine
Avoid discharges of static electricity by grounding both
yourself and tools before handling circuit boards and
other parts of the equipment.
Use the grounded wristband installed in the cubicle

when handling parts of the system.
Always store circuit boards in approved anti-static bags

when not installed in the system rack.
Always switch off the voltage before extracting or

inserting a board.
Switch off voltage to the system and withdraw all boards

at least 2 cm before electrical welding is performed near
the Scanning Platform.
3BUS209559 rev K 3-7

Installation Requirements
Environmental Data
Table 3-2 lists some of the standard parts of the Network Platform system and the maximum
ambient temperatures in which they were designed to be used.
Part ºF ºC Rel. Hum.
NP 175 80 95% non-condensing
Remote ASPC Junction Box 120 50 90% non-condensing

(Optional)
SPDC 140 60 95% non-condensing
Purge Blower 140 60 80% non-condensing
Liquid Cooling Unit (LCU) 110 43 95% non-condensing

Table 3-2 Environmental Data for the Network Platform
If the temperature around the idler end column is above 50ºC, then the ASPC severe environment
option which moves the ASPC into a Remote Junction Box enclosure is required.
Electrical Supply and Grounding Requirements

Supply
The signal-processing electronics in the Scanning Platform is chassis-grounded and all suppression
of external signal noise uses the chassis as a reference ground. If this requirement is not satisfied,
the Scanning Platform system may be sensitive to high frequency interference from unsuppressed
relays, contactors, and the discharge of static electricity.
The main power supply to the Scanning Platform must be from the same power supply as the host
system. If there must be a deviation, then the two supplies must be bonded to the same ground
(single point earth reference).
Grounding
• The electrical connections of the reference ground are to be effective and permanent.
• The cable shields are to be connected to the chassis with a short lead of less than 10 cm
(0.5 inch).
• The introduction of an extra grounding system such as an instrument ground is
absolutely forbidden. The system is to be grounded with a copper lead to the
distribution box (single point earth reference).
Scanning Platform Power Distribution Center (SPDC)

The main power supply to the Scanning Platform must be from the same power supply as the host
system. If there must be a deviation, then the two supplies must be bonded to the same ground
(single point earth reference).
A neutral to ground bond must exist on the secondary side of the Scanning Platform Distribution
Center (SPDC). This bond must be only in the SPDC.
3-8 3BUS209559 rev K

The SPDC is 10KVA and can handle the largest Scanning Platform system including the purge
blower and Liquid Cooling Unit. Even if your installation does not consume that much power, the
input wiring, fusing, and disconnect should still be sized for the full 10 KVA
• Rated Input Voltage: 240, 230, 220, 208, or 200 volts ± 10%
• Rated Frequency: 50 or 60 Hertz (Hz) ± 1%
• Rated Current: 41.7 amps @ 240 VAC
The secondary is always wired as 120/240 volts alternating current (VAC).
Cabling
The National Fire Protection Association (NFPA), Publication No. 70 “The National Electric Code
(NEC)”, Article 725 states that Class 1, Class 2, and Class 3 Remote-control, signaling, and power-
limited circuits acknowledges alternative requirements for circuits characterized by usage and
electrical power limitation. It specifies less stringent requirements than those for general wiring
elsewhere in the code.
The Network Platform utilizes ± 12 volts with adequate isolation to be safe without further
protective measures, even in wet environments. However, due to the amperage available, it does not
qualify as power-limited. Any of the circuits with direct ties to the ± 12 volt power supplies qualify
as “Class 1 Remote-Control and Signaling Circuits” as defined by NEC Article 725-11b and as
such, require insulation suitable for 600 volts.
NEC Article 725-52a(2) prohibits conductors of Class 2 or Class 3 circuits from being “placed in
any cable, cable tray, compartment, enclosure, outlet box, raceway, or similar fitting with
conductors of electric light, power, Class 1, and non power-limited fire protective signaling
circuits”, except where conductors of the different circuits are separated by a barrier.
Cable requirements are as follows:
Cable Use Cable Type Max. Run
Ethernet Cable CAT-5E 100 Meters
Operator Panel to ASPC connectorized 75 ft.

(standard
length)
Equipment Location
The location of the ASPC, the SPDC, the operator panel, and the blower will be site specific. Refer to
the System Specifications prepared prior to your installation for details on where each component will be
installed.
ASPC Remote Location

The ASPC is designed to be securely mounted to the wall in the paper mill facility. Refer to Drawing
DC-D-130181-001 for details on the weight and hole pattern required for mounting the ASPC. For
information on termination, refer to the appropriate wire list.
A connection terminal block for the supply voltages is located behind the cover over the main circuit
breakers. The phase conductors of the main 120/240 VAC terminate directly to the main breaker;
neutral and ground to the adjacent terminals.
3BUS209559 rev K 3-9

The European service power and the system 120/240 must be

bonded to the same ground.
Scanning Platform Power Distribution Center (SPDC)

The Network Platform Power Distribution Center (SPDC) is designed to be securely mounted to the wall
in the paper mill facility.
Operator Control Panel Location

Refer to Drawing DC-D-121599-001 for information on the location and mounting requirements for the
operator panel.
Blower Location
Refer to your blower specific drawings for information on its location and mounting requirements.
3-10 3BUS209559 rev K

Liquid Cooling Unit Setup

Setup procedures for the liquid cooling unit are available in the Liquid Cooling Unit Reference
Manual, 3BUS 208 146 RXX01.
WEB
Cable/Plumbing
Hole
PLATFORM
Idler End Drive End

Pedestal Pedestal
COOLING
UNIT Cable\Plumbing
Hole
Figure 3-3 Liquid Cooling Unit Setup
3BUS209559 rev K 3-11

Pedestal Installation and Alignment

The ultimate objective of the pedestal installation and alignment procedure is to ensure a precise
dimensional relationship between the source heads, the detector heads, and the process. This
objective can be achieved by following the guidelines and procedures in this section.
Installation Guidelines
Observe the following guidelines when installing the Network Platform.
• The pedestals must be stable in the machine direction and cross-machine direction.
• The pedestals must be level in the machine and cross-machine direction.
• The pedestal center lines must be perpendicular to the machine direction and to the
sole plate.
• The top surfaces of the pedestals must be in the same horizontal plane.
• The top surfaces of the pedestals must be at the prescribed distance from the sheet pass
line through the center of the Network Platform.
• The height of the Network Platform and the angle of the sensor heads may have to be
adjusted to compensate for the process angle.
3-12 3BUS209559 rev K

Alignment of the Customer Pedestals

Refer to Figure 3-4 while aligning the pedestals.
Weight
Check specified
Piano Wire or
off sheet
Machinists String
location Any Paper Roll
Check
back
distanc
e
Paper Web
Check distance
between
mounting bolts
Machine
Direction
Check
front
distance
Set pedestals
90º against
Piano wire
Weight
Figure 3-4 Alignment of the Mounting Pedestals
3BUS209559 rev K 3-13

1. Scribe a center line on each pedestal exactly halfway between the mounting bolt pattern and
perpendicular to the machine direction.
2. Stretch a length of piano wire (or thin, strong, machinist’s string) 0.012 in
(0.3 mm) in diameter between the two mounting pedestals.
3. Attach a weight to each end of the wire (approximately 10 lb/5 kg). The wire should pass over
the scribe lines on the pedestal’s top surface.
4. Adjust both mounting pedestals by gently tapping their sides with a hammer until the piano
wire passes directly over the scribe lines for both pedestals.
5. Visually determine that the wire and the scribe lines coincide within 0.04 in. along an 8 in.
length (1 mm along a 200 mm length) on each pedestal.
6. Make certain the distance between the pedestals and off sheet location (center line to center
line) corresponds to the dimensions on the site specific engineering drawings.
7. Determine that the top surfaces of the two pedestals are at the same elevation.
If the pedestals must be leveled, then recheck the alignment of the scribe lines after
completing the leveling.
8. Determine that the piano wire is parallel to the adjacent process rolls within 0.08 in. (2 mm) by
measuring the back and front distances of the roll to the piano wire with vertical plumb lines.
The mounting pedestals are now aligned.
3-14 3BUS209559 rev K

Attaching the Platform to the Pedestals

This section describes the attachment of the Network Platform to the pedestals.
1. Transport the Network Platform on its shipping dollies or skids to the installation site.
2. Remove the end column doors to avoid damaging them during placement.
3. Coat the entire top surface of both pedestals with a corrosion preventive compound.
4. Install shims. Refer to Figure 3-5 below and Figure 3-6 on page 3-16.
Install the 0.5 in. (13 mm) plate at the idler end. Install the 0.375 in. (10 mm) plate and
the 0.125 in. (3 mm) Teflon® pad at the drive end.
Drive Side Tighten this screw to 1/2 compression of lock washer..

Use 0.75” or M20 bolt with a lock washer and large flat
washer (customer supplied). Use a thread-locking
compound to avoid vibration loosening. Screw cannot
be tightened hard, it is an expansion mount.
Jackscrews
Thermal
Expansion Slot
The top of customer

pedestals to pass line
is normally 28.75”
Base 0.75” (19 mm) thick (730.2 mm). This includes
manufactured plates and
0.5”(12.7 mm)
extended set screw,
(both end columns).
Steel mounting plate

0.375” (10 mm), seating
for set screws
Teflon® plate Tapped holes or

0.125” (3 mm) thick nut on backside
Figure 3-5 Attaching Drive Side of Network Platform to Pedestals
3BUS209559 rev K 3-15

Idler Side
Front Jackscrew
Base 0.75” (19 mm) thick
Steel mounting plate

0.50” (13 mm) thick; Seating for
screws
Figure 3-6 Platform to Pedestal Installation – Idler Side

5. Make certain that the mounting surfaces on the bottom of the platform are clean and smooth.
6. Coat the entire surface on the bottom of the platform with a corrosion preventive compound.
7. Thread two parallel lengths of wire over the rolls onto which the process is to be guided. See
Figure 3-7.
These wires should be placed in the positions that are representative of the outside edges of
the process sheet.
8. Suspend a weight of approximately 5 lb. (3 kg) from each end of the wire.
3-16 3BUS209559 rev K

Figure 3-7 Preliminary Alignment Setup

9. Check the dimension from the customer pedestals to the process being simulated by the wires.
Make sure that this dimension corresponds to the dimension on the Network Platform
specification drawings. These drawings are customized for each installation site.
10. Temporarily remove the two parallel lengths of wire to allow placement of the Network
Platform.
3BUS209559 rev K 3-17

11. Install eight jackscrews in the platform mounting bases.

12. See Figure 3-8. The four front (inner most) jackscrews should protrude 0.125 - 0.250 in. (3 - 6
mm) below the mounting surface, and the remaining jackscrews should be flush with the
mounting surface.
Inner Hold
Jackscrews Down Bolt
Outer
Jackscrews
Drive End Idler End
Figure 3-8 Jackscrew Orientation

13. Connect a heavy duty cable or chain through the two large lifting lugs located on the top beam
of the Network Platform.
3-18 3BUS209559 rev K

14. Using the lifting device, secure it to the cable or chains connected to the lifting lugs.
15. Carefully lift the Network Platform from the transporting skid or dolly and position it on the
customer pedestals so that the platform and the support structure mounting holes are aligned.
The mounting holes center–to–center dimension should be within 0.125 in. (3 mm) of the
dimension noted on the dimensional outline drawing. The dimensional drawing is site specific.
16. Install four customer-provided hold-down mounting bolts, leaving them loose enough for
Network Platform alignment later.
The platform is now in position.

17. Rethread the two parallel lengths of wire over the rolls onto which the process is guided. See
Figure 3-7 on page 3-17.
18. Verify that the wire locations represent the outside edges of the process sheet.
19. Separate the head assembly.
20. Manually move the lower carriage assembly close to the wire at one end of the platform.
21. Adjust the jackscrews in the base of the applicable column to position the wire at the center of
the source detector air gap. See Figure 3-6 on page 3-16 and Figure 3-8 Jackscrew
Orientation on page 3-18.
22. Move the carriage assembly to the other end of the Network Platform.
23. Adjust the front jackscrews to position the wire in the center of the source detector air gap.
24. At the drive end of the platform, compress the lock washer approximately half–way.
25. At the idler end of the platform, tighten the screws securely.
26. Verify that there is approximately equal travel remaining in each direction in the slotted holes in
the drive end pedestal.
This completes the preliminary installation of the Network Platform.
3BUS209559 rev K 3-19

Platform Alignment
To accomplish alignment of the Network Platform, proceed as follows:
1. Place a machinist’s level on the leveling blocks located on the inner side of each end column.
See Figure 3-9 below.
Do not make any adjustments to the alignment block. The

adjustment block is factory adjusted. Any adjustment will render
the block unusable.
Alignment
Block
Machinist’ s
Level
Figure 3-9 Verifying Platform Alignment

2. Loosen the hold-down mounting bolts.
3. Adjust the inner jackscrews on the end column to zero the level at one column, and repeat for
the column at the other end of the platform.
4. Maintain the same orientation of the machinist’s level at both ends of the platform.
5. Check the position of the wire in the air gap to assure that the pass line angle is unchanged.
Should the angle appear to have changed, repeat Step 3.
6. Adjust the outside jackscrews down against the mounting support.
3-20 3BUS209559 rev K

7. The adjusted jackscrews should be snug, but they should not lift the platform off the front (inner
most) jackscrews which are already precisely set.
8. Place the machinist level on the leveling blocks to monitor the final settings and to make certain
no changes in leveling occur.
9. When all four jackscrews at one of the columns are adjusted satisfactorily, tighten the hold-
down mounting bolts to secure the Network Platform to the support structure.
Do not over stress the mounting bolts.

10. Repeat Steps 1 through 7 for the other column.
11. Remove the wires.
This completes the Network Platform alignment.
3BUS209559 rev K 3-21

Carriage Alignment
The mechanical alignment (relative positioning) of the sensor’s upper and lower heads is critical in
maintaining proper measurement characteristics. Both the static (off-sheet) and the dynamic
(scanning) alignments must be correct. Static and dynamic alignment conditions (see Figure 3-10)
which should be considered for the sensor heads include the following alignments and adjustments:
 Pass Angle Adjustment (on page 3-23)
 Process Direction (lateral alignment) (on page 3-28)
 Air Gap Dimension (vertical spacing) (on page 3-30)
 Scan Direction (horizontal alignment) (on page 3-32)
These alignment and adjustment procedures are in the following sections.
Upper
Head
Process
Direction
Scan
Air Gap Direction
Process
Lower Head
Figure 3-10 Head Alignment Conditions
3-22 3BUS209559 rev K

Pass Angle Alignment

This procedure describes how to make adjustments to the pass angle. To ensure proper alignment of
the sensor carriage assembly, you will perform a process direction alignment and an air gap
alignment at the same time. See Figure 3-11.
Adapter Plate
Extension Upper Radial Plate
Mounting Bolts
Upper Adapter Plate
Adapter Plate Mounting
Pass Angle Bolts with Eccentrics
Adjustment Tool
Adapter Plate
Mounting Bolts with
Large Parallel Face
Washers
Lower Adapter Plate

Adapter Plate Mounting Bolts
Lower Radial Plate
Figure 3-11 Pass Angle Adjustment
Note: Whenever a pass angle change is made, no matter how slight, be sure to
follow the procedure below.
1. Move the sensor head package to the off–sheet position.

2. Place the platform in local by pressing the LOCAL push button on the control panel.
3. Turn off the power to the platform.
4. For a frame with a manual clutch, loosen the clutch nut by turning it three times see Figure
3-12
3BUS209559 rev K 3-23

Figure 3-12 Manual Clutch Operation

5. For frames with an air clutch, activate the head separation switch located at either end of the
Network Platform
Deactivating the clutch also trips a switch which also causes the platform to enter local mode
6. Manually move the bottom head package away from the top head package.
Note: Prior to removing the electrical covers on the lower carriage assembly,
wipe them of any accumulated dirt or moisture to avoid damaging exposed
components.
7. Remove the lower carriage electrical enclosures on both sides of the carriage see Figure 3-13.
3-24 3BUS209559 rev K

Lower
Electrical
Enclosure
Figure 3-13 Lower Electrical Enclosure

8. Using a 13 mm socket or wrench, loosen the four locking M8 bolts (lower adapter plate
mounting bolts) in the curved slots on each side of the bottom carriage. See Figure 3-11.
9. Thread two parallel lengths of wire over the rolls onto which the process is being guided. See
Figure 3-14.
These wires should be placed in the positions that are representative of the outside edges of the
process sheet.
10. Suspend a weight of approximately 5 lb. (3 kg) from each end of the wire.
Stretched wire
representing sheet
edge
Weight
Customers Roll
Figure 3-14 Simulating the Process Pass Line

11. Rotate the lower head to the desired pass angle.
3BUS209559 rev K 3-25

12. Tighten the four locking M8 bolts (lower adapter plate mounting bolts) on each side of the
bottom carriage. See Figure 3-11.
Note: Prior to removing the electrical covers on the upper carriage assembly,
wipe them of any accumulated dirt or moisture to avoid damaging exposed
components.
13. Remove the top cover and electrical enclosures from each side of the upper head. See Figure
3-15.
Note: Lift the carriage seal sled manually to allow free removal or insertion of the
electrical enclosure.
14. Loosen upper adapter plate mounting bolts and remove the mounting bolts with eccentrics. See
Figure 3-11.
15. Loosen the adapter plate extension mounting bolts. See Figure 3-11.
16. Adjust the four vertical adjustment screws so that the weight of the upper carriage rests on the
bolts of the upper adapter plate.
This is done so that when you adjust the air gap between the upper and lower sensor heads you
have enough slack to move the upper head vertically.
17. Rotate the upper head package to approximate pass angle and move the upper head package
directly over the lower head package.
18. Rotate the upper head package to match the lower head package angle closely by visual
inspection.
19. Tighten the upper adapter plate extension mounting bolts. See Figure 3-11.
Note: When aligning the head packages, all reference points will be located on
the Basis Weight sensor plate. If a Basis Weight sensor is not present, use
the Ash sensor for the alignment reference. If neither Basis Weight or Ash
sensors are present, use the Basis Weight/Ash sensor blank base plate.
20. Align the upper and lower base plates of the Basis Weight sensor using the procedure for
Process Direction Alignment beginning on page 3-28.
21. Continue with the Air Gap Alignment on page 3-30.
22. Perform the Scan Direction Alignment on page 3-32.
3-26 3BUS209559 rev K

Carriage Extension Plate
Vertical Adjustment Bolt
Horizontal
Alignment Rod
Vertical Adjustment Bolt

Upper Adapter Plate
Extension Mounting Bolts
Upper Adapter Plate

Extension
Mounting Bolts
Horizontal
Adjustment Bolt
Eccentric
Upper Adapter Plate

Mounting Bolts
Adapter Plate
Figure 3-15 Pass Angle Adjustment Tool
3BUS209559 rev K 3-27

Process Direction Alignment

Note: When aligning the head packages, reference points will be located on the
Basis Weight sensor plate. If a Basis Weight sensor is not present, use the
Ash sensor for the alignment reference. If neither the Basis Weight or Ash
sensors are present, use the Basis Weight/Ash sensor’s blank base plate.
If a Smart Caliper GT is present, one reference point will be located on the
caliper sensor.
1. Use a machinist straight edge [or the back side of the air gap tool (Part Number 128624-
001)] to make certain that the upper and lower heads are parallel. They should be flush
within ± 0.01 in. (0.254 mm). See Figure 3-16 below.
Upper
Head
Machinist’s
Straight
Edge
Use Feeler
Gauge Here
Lower
Head
Figure 3-16 Process Direction Alignment Points

2. Place the straight edge against the machined surface on the upper and lower base plates of
the Basis Weight sensor. If the plates are perpendicular to the straight edge, they are
parallel to each other.
3. Align the upper head to the lower head using the horizontal adjustment bolts on the adapter
plate extension. See Figure 3-15 above.
4. Turn the horizontal adjustment bolts clockwise to move the upper head towards you;
counterclockwise to move the upper head away from you.
3-28 3BUS209559 rev K

Do not force the horizontal adjustment bolts if binding is felt.

Instead, loosen both bolts before resuming alignment.
The horizontal adjustment bolts have to be adjusted with respect to each other to avoid
binding the upper head carriage. For example, every half-turn of one horizontal
adjustment bolt necessitates a half-turn to the other.
3BUS209559 rev K 3-29

Air Gap Alignment

Refer to Figure 3-15 Pass Angle Adjustment Tool and Figure 3-17 Air Gap Alignment
Points while performing the air gap alignment procedure.
1. Use the vertical adjustment bolt to achieve a 7.5 ± 0.5 mm (0.295 ± 0.020 in.) cold air gap
between the base plates along the on-sheet end of the sensors and at the points designated in
Figure 3-17 Air Gap Alignment Points. For every half turn of a vertical adjustment bolt,
perform a half turn to its opposite adjustment bolt. Across the sensor window, check the
distance using the air gap tool provided with the platform. If bolts seem to bind at any time,
adjust the opposite side air gap before proceeding.
Note: You need to protect the carriage assembly from damage from mechanical
forces by not positioning the vertical adjustment bolts such that the weight
of the carriage is supported on three bolts instead of four as this may twist
the carriage. Also, never rest the upper head package weight on the lower
head package by leaving the air gap tool between the sensors.
2. Adjust the off–sheet side air gap to 7.5 ± 0.5 mm (0.295 ± 0.020 in.) cold.
3. Continue to adjust the vertical adjustment bolts until the specified air gap is achieved.
4. After acceptable air gap is set, make certain the sensor is still aligned in the process direction.
See the Process Direction Alignment on page 3-28
5. Tighten the bolts which have large parallel face washers onto the upper adapter plate.
6. Replace bolts with eccentrics.
7. Rotate the eccentrics on the adapter plate extension so that they bear the weight of the upper
head assembly.
8. Tighten the bolts that hold the eccentrics in place.
9. To ensure that the top electrical covers will fit, the alignment mechanism should be centered
over the adapter plates.
a. Loosen adapter plate extension mounting bolts.
b. Use the horizontal alignment bolt to center the alignment mechanism over the adapter
plates.
c. Center the horizontal alignment rod in its slot.
d. Tighten the extension mounting bolts.
10. Tighten the bolts on the adapter plate, both sides.
11. Replace the electrical covers.
This completes the Air Gap Alignment Procedure.
3-30 3BUS209559 rev K

WITH SMART CALIPER GT

T
Alignment Points
At each alignment point, set gap to
WITHOUT SMART CALIPER GT
Alignment Points
Figure 3-17 Air Gap Alignment Points
3BUS209559 rev K 3-31

Scan Direction Alignment

The scan direction alignment is checked both close to the drive end column and close to the idler
end column on the scanner.
Alignment at the drive end is set by drive pulley phase adjustment. Alignment at the idler end is
controlled by belt tension.
The scan direction alignment procedure is as follows:
1. Jog the sensor heads near the drive end column.
2. Apply a straight edge and feeler gauge to the machined surface on the upper and lower sensor
heads. See Figure 3-18 below.
Upper
Head
Use Feeler
Gauge Here
Machinist’ s
Straight Edge
Lower
Head
Figure 3-18 Scan Direction Optimum Alignment Point
3-32 3BUS209559 rev K

The machined ears should be flush within +/-0.005 in. If they are not:
a. Loosen the upper drive belt pulley locking screws.
b. Adjust set screws for phasing of the pulley until the heads are parallel.
c. Tighten the screws when finished.
3. Jog the heads near the idler end column.
4. Apply a straight edge and feeler gauge to the machined surface on the upper and lower heads.
5. If they are not aligned in the scan direction within +/- , adjust the belt tension in the
upper or lower belts by means of the idler bracket adjustment screws. See Figure 3-19 below.
Figure 3-19 Scan Direction Adjustment

6. Use belt tensiometer (Part Number 122146-003) to check the belt tensionusing the procedure
outlined in Carriage Drive Belt Tensioning on page 10-8 .
Note: The belt may be installed in such a way that the upper and lower heads are
off by more than one tooth on the belts. This can be corrected by inserting
a short strip of thin sheet metal or hard plastic between the belt and drive
pulley and allows for manual alignment to the next tooth. See Figure 3-20
on page 3-34.
3BUS209559 rev K 3-33

Rotate by hand to Thin Metal or

Plastic Strip
get strip between
tooth of pulley
and belt
Drive Pulley Belt
Figure 3-20 Manual Alignment Setup
3-34 3BUS209559 rev K

PROPRIETARY DATA: This document contains proprietary data of ABB Inc. No disclosure, distribution (electronic or otherwise), or other means of
dissemination may be made without written permission.
4 Utility Service Installation

Section .......................................................................................................Page
Air Purge ....................................................................................................... 4-2
Air and Water Supply ................................................................................... 4-3
Electrical Hook-Up ....................................................................................... 4-6
NP Power up Procedure ............................................................................... 4-9
Starting Up the Software ............................................................................ 4-12
3BUS209559 rev K 4-1

Air Purge
The Network Platform is air purged to assure reliable operation in a paper mill environment. The purge air
duct is attached to the idler end column either directly or with a flexible air hose. If a flexible air hose is used,
the flexible portion of the hose should be less that 10 ft. (3 m) to avoid a drop in pressure. See Figure 4-1
below.
NOTE: Designed to accommodate

6” I.D. Duct
Typical
Installation
Idler End Column
Figure 4-1 Purge Air Duct Attachment
Note: Do not allow the weight of a heavy metal air duct to rest on the plastic top cap. Off
load the duct by means of bracing to the machine foundation or use a flex ducting.
Note: Addition of and Air purge flow switch is supported by NP software and electronics
but is not fitted as standard.
The source of air for air purge can be supplied by either the DC motor cooling air or the ABB purge blower.
Clean DC motor cooling air has the advantage of no special air filter maintenance and is generally preferred
when available. If the DC motor cooling air is used, an adjustable damper is needed to reduce the air flow and
avoid excessive system pressure loss (especially when the doors are opened).
For installation of the ABB purge blower, refer to the instructions which are supplied on the illustration
drawings.
Normal applications should operate with the platform fully sealed. For high temperature applications, a
continuous air flow must be supplied through the scanner beams to the drive end.
4-2 3BUS209559 rev K

Air and Water Supply

Air
Sensors require clean air with maximum 1 ppm by weight of oil and water. Maximum 5 micron ppm of solid
particulate. Air temperature within 20 degrees Celsius of the ambient air.
The customer sensor air supply to the scanner air filter regulators should use a continuous 25 to 50mm
diameter (1 to 2") metal air pipe. Customer supply air pressure requirements are minimum 65psi (4.4bar,
448Kpa) and maximum 80psi (5.4bar, 552Kpa). This at a flow rate of 0.37 m3/min (13 scfm) to 1.7 m3/min
(60 scfm). The flow rate is dependent on the number and type of sensors configured, the scanner inlet filter
regulator settings and the head package manifold valve openings. Refer to the appropriate sensor manuals,
scanner product policy document or consult ABB if further information is required.
The scanner inlet air filter regulators, shown on Figure 9-9 on page 9-20 ,are adjusted to control air pressure to
the scanner’s sensor’s via the air hosing and head package manifold valves. A maximum of 60Psi (4.14bar,
414Kpa) is typically sufficient pressure to the hose pipe. It is preferred to keep this pressure as low as practical
, for example 50Psi (3.45bar, 345Kpa) . This is to minimize undesirable diameter expansion and longitudinal
shrinkage of the scanner air hosing. The scanner inlet air filter regulator is typically mounted to the pedestal
beneath the scanner or to a nearby pillar at the electronics end of the scanner. It should be located as close as
practically possible to the scanner. This to ensure a minimum pressure drop regulator to frame. This is
important on larger head package scanners which consume a lot of air. It is then easy to locate the regulator,
adjust it, check it and lock it. The distance is typically less than 5M..In some exceptional cases such as RSP
the distance may be longer.
The scanner air filter regulators are adjusted to obtain 40 (2.76bar, 276Kpa) to 41 psi air pressure inside the
sensor head package top and bottom manifold. This with all sensor air supply turned on and tuned to
application specific requirements. Measure and set this pressure using a pressure guage as illustrated below.
Some sensors such as HPIR take their sensor heater and purge air direct from an additional dedicated air filter
regulator located at the scanner air entry manifold. This regulator is typically adjusted to 50PSI (3.45bar,
345Kpa), Consult the HPIR installation manual for additional details.
Using a pressure guage and some 0-100Psi air guage Connect the pressure guage to an
rigid piping to measure and set unused head package air
the head package air manifold manifold port.
internal pressure. Use a ‘T’ air fitting when all
ports are in use.
Figure 4-2 Head Package Manifold Air Pressure Checks
3BUS209559 rev K 4-3

Water
Network Platform frames only require a liquid cooling unit if equipped with one or more of the following
sensors:
 Moisture HemiPlus
 Moisture ReflectionPlus
 IR Coatweight
The liquid cooling unit is a heat exchanger type. It provides a closed loop water circulation system to the IR
sensors. Warm coolant returning from the sensor is cooled by customer-provided water. The liquid cooling unit
requires a clean supply drinking water of purity pH 6.0 to 8.0, with hardness less than 85ppm, water supply of
less than 27ºC (80ºF), at a minimum pressure of 45 psi and flow rate of at least 37.9 LpH litres per Hour
(10gph). The liquid cooling unit is installed in an environment of maximum ambient temperature 43°C (110°F)
and humidity: 5% to 90%. Water pipe lines from liquid cooling unit to the NP frame must not exceed 30.48M
[100FT) in length for liquid cooled units and 15.24M (50FT) in length for air cooled units. Additionally and
included in the overall ipie length, the pipe must not exceed 7.62M (25FT) of vertical head height.
After the installation is complete, the liquid cooling unit’s tank is filled with a coolant mixture. The mixture is
25 percent ethylene glycol and 75 percent potable water.2.6 liters of ethylene glycol to 7.8 liters of water or
0.69 gallons of ethylene glycol to 2.06 gallons of water. Fill the tank to approximately two inches over the
coils. This should take 7.6 liters (2 gallons, U.S.) of the coolant mixture. In operation the liquid cooling unit’s
coolant temperature should be 33°C ± 2°C (90°F ± 2°F).
See also liquid cooling unit reference manual 101333-003.
In some applications ABB may supply an alternative air cooled liquid cooling heat exchange unit.
This requires a clean air location and maximum ambient 40C (104F)
Figure 4- on page 4-5 illustrates a typical hook-up.
Water lines are dried with compressed air before shipment. However if extended periods have elapsed between
shipment and commissioning it’s advisable to flush water lines with potable water before connecting liquid
cooling unit.
During installation make sure that the liquid cooling unit is filled with coolant and that the air supply is on
before proceeding with the electrical power up.
4-4 3BUS209559 rev K

Idler
End Liquid Cooling Unit
Filter
Water xxxx-x
Supply
Shut–off
valve
Drain
Type 3/8” (10 mm) tubing

2 Water lines (1 to frame, 1 returns)
Air Filter
Air Regulators
1” Shut–off
Top Sensor Air
Valve Type 1” (25 mm)
tubing
Bottom Sensor Air
Air Supply
Type 1/2” (13 mm) tubing
Air Filter
Figure 4-3 Air and Water Hookup
3BUS209559 rev K 4-5

Electrical Hook-Up
Cabling to a Network Platform is minimal. All that is normally required for hook-up are the AC power,
Ethernet connection to the host system and Service Workstation, sheet break detector, Liquid Cooling Unit
(LCU) flow switch, and reel turn-up detector. Other auxiliary equipment (for example, microwave or optical
caliper sensors processors), depending upon the configuration, may also require cables to the ABB Smart
Processing Center (ASPC).
For details of connecting Reel turn up, Flow switch and other auxiliary equipment if present, please refer to
functional drawings e.g. 3BUS209281 – Network Platform NP1200 and RNP 1200 Print book
Power
Purge Blower Distribution
Center
SP
AC Power
Idler End Column
Back Plane Connectors
AC
Liquid
Cooling
Unit
Flow
Switch Cable
AC Power/Ground Cable
LAN Customer AC
Cable Power
Converter 208 VAC
(optional) 210 VAC
220 VAC
230 VAC
240 VAC
50 / 60 Hz
Reel
Turn up
(Process Signals)
Sheet
Break
Local LAN Cable

(Electrical) Local SWS
(e.g. Laptop)
To Server Room
Figure 4-4 Standard Cable Configuration
Power
The platform is connected to customer power via the Scanning Platform Power Distribution Center (SPDC).
The SPDC also provides the power for the purge blower, Liquid Cooling Unit (LCU), and various auxiliary
equipment. The SPDC is an integral part of the NP electrical design and is required to meet electromagnetic
compliance (EMC) specifications and standards. See Figure 4-4 Standard Cable Configuration.
The main supply to the NP is to be from the same supply as the host system. If there must be a deviation, then
the two supplies must be banded to the same ground (single point earth reference). The introduction of an
extra grounding system such as an instrument ground is absolutely forbidden.
A neutral to ground bond must exist on the secondary side of the NPDC. This bond must be in the NPDC and
only in the NPDC.
4-6 3BUS209559 rev K

The NPDC is 10 KVA to handle the largest NP system. Your particular installation will probably not actually
consume that much power. The input wiring, fusing, and disconnect should, however, still be sized for the full
10 KVA.
Allowable input voltages to the NPDC are:
Rated Input Voltage: 240, 230, 220, 208, or 200 volts ± 10%
Rated Frequency: 50 or 60 Hz ± 1%
The secondary is always wired as 120/240.
Communication
TCP-IP Ethernet connection from the ASCP to the host system can be made:
1. Electrically into
a) The RJ45 connector on the Single Board Computer (SBC), “NP LAN Connection”, autodetect
10Mbps, 100Mbps or 1Gbps.
b) The RJ45 connector on the Fiber Optic Network card, “NP LAN Connection 2”, autodetect
10Mbps or 100Mbps.
However a Fiberoptic Transceiver (e.g. ABB 102204-001) is required to meet CE Mark Radio
Frequency emissions and susceptibility requirements for either connection.
2. Optically into:
a) The optical port on the Fiber optic network card, “NP LAN Connection 2”, fixed 100Mbps.
This is the preferred method.
The suggested fiberoptic cable is ABB 102205-001 with 102206-001 “ST” connectors. These “ST”
connectors require special tooling such as the ABB 102206-100 tool kit.
In addition a local SWS can be connected to the ASPC to either of above ports.
For information on IP addresses and subnet mask configuration see 3BUS209544 - Network Platform Software
Reference Manual
Network platform exists with two types of SBCs 3BUS213621-001 (post Jul 2011) and 3BUS209587-000 (pre
Jul 2011). 3BUS213621-001 has an extra Ethernet port that can normally not be used for host communication,
See Figure 4-2 and Figure 4-3.
Note the electrical and optical port on the Fiber Optic Network card can’t be used simultaneously. See figure
Figure 4-4.
NP LAN Connection NP LAN Connection 3
Figure 4-2 Network ports on SBC 3BUS213621-001
3BUS209559 rev K 4-7

NP LAN Connection
Figure 4-3 Network port on SBC 3BUS209587-000
NP LAN Connection 2 NP LAN Connection 2 NP LAN Connection 2

Optical Transmit Optical Receive Electrical RJ45
Figure 4-4 Network ports on Fiber Optic Network Card
4-8 3BUS209559 rev K

NP Power up Procedure
The following power up sequence is required to ensure no wiring errors or malfunctioning equipment cause a
failure that could jeopardize a successful installation.
1. Verify power is tagged off and locked out at the Motor Control Center (MCC).
2. Verify all circuit breakers in the NP and the SPDC are turned off (see Figure 4-5 below).
Head Split Switch
Figure 4-5 Circuit Breakers

3. Install all required wiring. The connection terminals for the main supply to the NP are located behind the
cover over the main circuit breaker. The phase conductors terminate directly to the main circuit breaker;
neutral and ground to the adjacent terminals.
4. Remove all debris from the installation work and vacuum the enclosure. Verify no tools or assembly materials
were left in the equipment.
3BUS209559 rev K 4-9

The neutral to ground bond is extremely important. If it is not correct, the

electronic filter in the ASPC may be destroyed when power is applied.
5. Verify there is a neutral to ground bond at the SPDC, and ONLY at the SPDC. Ensure that the primary and
secondary are correctly terminated.
6. Remove the lock-out on the MCC and turn on the power to the SPDC. Measure the primary voltages (phase to
phase, phases to neutral, and phases to ground) to verify proper power, grounding, and tap selection.
7. Turn on the SPDC main circuit breaker and measure the secondary voltages (phase to phase, phases to neutral,
and phases to ground). The output must be 240 VAC ± 10% phase to phase; and 120 VAC ± 10% each phase
to neutral and each phase to ground.
8. Turn on the NPDC circuit breaker for the purge blower. Verify that the blower starts. Check that the voltage
at the blower is 240 VAC +10%, -14%. Verify there is air flow inside the idler end column of the NP.
9. Turn on the NPDC circuit breaker for the Liquid Cooling Unit (LCU). Verify that the coolant starts
circulating. Check that the voltage at the LCU is 240 VAC +10%, -14%. Check for leaks.
10. Measure the input voltages on the line side of the Network Platform main circuit breaker. The NP input must
be 240 VAC +10%, -14% phase to phase; and 120 VAC +10%, -14% each phase to neutral and each phase to
ground.
11. Turn on the SPDC circuit breakers for any auxiliary equipment and verify the voltage is within tolerance at
each load.
12. Securely fasten all of the SPDC covers.
13. Switch on the NP main circuit breaker and the Service circuit breaker. Check for 120 VAC at the service
outlet.
14. Turn on the Motor and Bottom AC circuit breakers. Check for 120 VAC at the top and bottom carriage
diagnostic connectors using the test card kits supplied with the system. Measure the 120 VAC with respect to
the chassis.
15. Turn on the DC and IR circuit breakers.
16. Turn on the Top AC breaker.
17. With the power now fully on, re-verify the input voltages at the NP main circuit breaker. The NP input must
still be 240 VAC +10%, -14% phase-to-phase; 120 VAC +10%, -14% each phase-to-neutral and each phase-
to-ground.
18. Turn off the NP main circuit breaker.
4-10 3BUS209559 rev K

19. Securely fasten the power entrance cover.
Note 1: After the initial power up sequence, it is not necessary to turn off each individual
circuit breaker. Just using the main circuit breaker is sufficient.
Note 2: Do not turn on the TOP AC circuit breaker before turning on the DC circuit breaker
and BOTTOM AC circuit breakers. The NP software use timers to turn on the
various sensor heaters in a delayed sequence. These timers start as soon as the
NP software finishes it’s start up. If the TOP AC breaker is turned on too long before
the DC circuit and BOTTOM AC circuit breakers, the resulting current surge to all
the cold heaters may cause the main circuit breaker to trip.
20. Turn the main circuit breaker back on and check the following:
a) Control panel lights should illuminate in a start-up sequence ending with the green source symbol
and Local lights on.
b) The Standard Signal Conditioning board in the ASPC should immediately light up with 5 bottom
LED’s as green indicating that +5V, +/-12V and +/-15V are present and correct. The top LED
“Watchdog” should initially light up red and eventually go out indicating that software has
started fully.
c) The motor controller, located on the drive end column, should have the on light illuminated.
d) The fans at the motor controller should operate.
21. Push the MAINTENANCE push button on the control panel. The lights on the panel should illuminate in a
sequential pattern.
22. Push the JOG FORWARD and JOG REVERSE push buttons to verify that the head moves as instructed.
23. Select the REMOTE push button and verify that the remote and off sheet lights are illuminated, and that the
heads travel to the home limit switch and continue to the off sheet position.
24. Execute a local standardize from the control panel. Verify that the light is illuminated and a standardize cycle
is executed. The shutters should open and the Caliper sensor should close during this cycle. A successful
standardize for all sensors is indicated by the standardize light not blinking after the cycle is completed.
25. Select on sheet at the platform. The on sheet light should illuminate if the communication to the Host is proper
and if the sheet break signal is indicating no break (closed contact).
Note: Until this time, the system has been operating without any regard to the set up and
tuning of the software load. There are several procedures required to ensure that
the configuration, platform tuning, and sensor tuning are appropriate for the
installation. Please refer to 6 Measurement Setup; the STLP-3 and STLK-11 Basis
Weight Sensor Manual (3BUS209545); and the Network Platform Software
Reference Manual, 3BUS209544
For further information of LED’s in ASPC see 11 Troubleshooting
3BUS209559 rev K 4-11

Starting Up the Software

The Service Workstation allows for direct interaction with the Network Platform to allow for tuning of the
scanner and sensors, diagnostics, and monitoring. In order to proceed with platform or sensor setup, the
Service Workstation and the Network Platform software must be activated. Start-up of the Network Platform
can be initiated by a power on. Reset can be performed with a power cycle off then on or with SWS tools.
For the initial configuration and software loading of the Service Workstation and the Scanning Platform,
please refer to 3BUS209544 - Network Platform Software Reference Manual.
Note: It is possible to run the Network Platform software independent of the Host. All
procedures, except where specifically noted, can be executed by local commands
using the control panel and Service Workstation.
4-12 3BUS209559 rev K

5 Platform Tuning
This chapter describes the activities required to set up and tune the scanning control for the Network
Platform.
Section ...............................................................................................................Page
Platform Software Setup Checklist..............................................................5-2
Motor Drive Setup (VLT Micro Drive) ...........................................................5-3
Motor Drive Setup (ABB ACS-100) ............................................................5-11
Frame Tune .................................................................................................5-12
Head Position Setup ...................................................................................5-16
Head Package Dimensions Setup..............................................................5-20
Automatic Edge-of-Sheet ...........................................................................5-23
Standardize Off-Sheet Delay Setup ...........................................................5-27
Accelerated Standardize ............................................................................5-29
Other Host Setup Procedures ....................................................................5-30
3BUS209559 rev K 5-1

Platform Software Setup Checklist

Network Platform software setup ensures efficient movement of the Network Platform head package
and the correct positioning of the head package on the process sheet.
This checklist is a recommended sequence of steps to correctly set up the Network Platform.
 Use the Frame Health Reports Alarm Safety tab to make certain there are no safety
interrupts which might impede the setup process.
 Check for alarms while tuning the frame. Electronics and Frame alarms are explained in
“Troubleshooting”.
 Set up the motor controller (on page 5-3).
 Perform Frame Tune; mostly automatic process to ensure accurate head movement. (on
page 5-12).
 Set up the Network Platform position values (on page 5-16). If required, set up select
positions in the host computer.
 Head Package Dimension Setup (on page 5-20).
 Set up the Auto Edge-of-Sheet (AEOS) detectors, if configured on the Network Platform
(on page 5-23).
5-2 3BUS209559 rev K

Motor Drive Setup (VLT Micro Drive)

General Description
The direction and speed of the AC motor which moves the sensor head package is managed by a
motor drive. The speed and direction information for the motor controller is supplied from the frame
electronics. The controller determines the torque to apply as the head package traverses the frame.
The VLT Micro Drive is a replacement for the ACS-101 drive and is therefore also a replacement
for both the Fincor and Lovejoy motor controllers. Information regarding motor drive replacement is
outlined in the sections Motor Drive Controller Replacement – ACS to VLT and Motor Drive
Controller Replacement – Fincor or Lovejoy to VLT.
In the situation where the motor controller is part of a frame, the controller will be tuned to optimize
performance during pre-shipment commissioning. If the controller has been shipped as a
replacement part it will be programmed with the vendor’s default values. In this situation the
parameters should be checked against the appropriate ABB default values outlined in ‘Table 5-2
Motor Drive Parameter Settings (Scanner Defaults)’ and adjusted accordingly.
Where a controller is shipped as a replacement part, it will be shipped with a retrofit kit which
includes the hardware to allow it replace the existing controller. The retrofit fit is designed to allow
integration of the new controller without the requirement for electrical or mechanical modifications
to the scanner.
Control Panel Functions

The VLT motor controller is delivered with a removable Local Control Panel (LCP 11) used to set
parameters and monitor controller performance and status. The panel can also be used to copy
settings to or from a motor controller.
The panel is hot swappable and does not require that the VLT is powered off before fitting or
removal. Scanner movement is possible with the control panel removed.
3BUS209559 rev K 5-3

Figure 5-1 LCP 11 Control Panel
The menu and navigation keys are used to access and display various tuning parameters. Parameters
are organized into a number of groups (0 - 18). Each group has a number of parameters.
The majority of parameters in these groups retain the motor controller vendor default values. A list
of the modified parameters is outlined in Table 5-2 Motor Drive Parameter Settings (Scanner
Defaults) with values for operation on all frame types.
The Navigation, Operation and Menu keys on the LCP unit are used to choose and set the various
parameters. The LEDs indicate the controller status and the LCD displays menu selections,
parameter values and fault conditions.
LCP (Local Control Panel) Operations

The default display information on the panel is the output frequency, which is part of the unit’s
Status menu. Subsequent pressing of the [] or [] keys will alternate the display between, output
frequency, output current, output power and signal percentage which are also part of this menu.
Moving Around the Main Menu & Setting a Parameter

Following power up the Status menu will be active, access to all parameters is made via the Main
Menu. To enter the Main Menu:
1. Use [MENU] key to place Selected Menu indicator in display above Main Menu
text.
2. Use [] and [] to browse through the parameter groups.
3. Press [OK] to select a parameter group
4. Use [] and [] to browse through the parameters in a specific group
5-4 3BUS209559 rev K

5. Press [OK] to select a specific parameter. This parameter will then blink to indicate
it is selected.
6. Use [] and [] to modify the value of the parameter.
In the situation where the chosen parameter cannot be changed when the controller
is in Auto mode, a message will appear on the display [ nw run ]. It is then
necessary to stop scanner movement if active and to push the [Off Reset] key
before modifying this parameter.
7. Press [OK] to accept the value
8. To exit, press either [Back] twice or [Menu] to return to the Status Menu. If [Off
Reset] had been selected push the [Auto On] key to allow movement again.
Auto On & Off Reset modes

The motor controller has been set up so that on power up the [Auto On] key is activated as indicated
by the illuminated yellow LED above this key. In this situation the motor may be controlled by the
scanner electronics.
- To select the motor drive stop mode or to reset an alarm situation push the [Off
Reset] key. When this mode is selected the yellow LED above the key will be
illuminated.
- To allow movement of the motor push the [Auto On] key. The yellow LED above
the key illuminates to indicate the mode is active and control of the motor is
possible.
The motor controller must be in Auto On mode for

movement of the scanner head package to be possible.
Downloading Parameters (to Motor Controller)

The LCP unit used with the VLT motor controller allows the possibility to download a parameter
setup stored in the panel to a motor controller.
The procedure for downloading the VLT parameters from the control panel to the controller is as
follows:
1. Place the motor controller in stop mode using the [Off Reset] key.
2. Mount the panel containing the parameters to be downloaded onto the unit if
required.
3. Select Group 0 and Parameter 50. This will show [0] on the display.
4. Choose option [2] and press [OK] to select it.
3BUS209559 rev K 5-5

5. The display will show moving segments in the character normally used to indicate
group information while downloading.
6. When the download is complete, the message [ donE ] is displayed, indicating the
download has been successful.
7. Replace the original LCP unit onto the controller if required.
8. Verify the parameter values in the controller are now as expected.
9. Place the motor controller in auto mode using the [Auto On] key.
Uploading Parameters (from Motor Controller)

The LCP unit includes the functionality allowing storage of parameter settings for the VLT motor
controller. This functionality is useful if the parameter settings for a frame need to be replicated on
another motor controller.
The procedure for recording the VLT parameters from the controller to the LCP unit is as follows:
2. Select Group 0 and Parameter 50. This will show [0] on the display.
3. Choose [1] and press [OK] to select it.
4. The display will show moving segments in the character normally used to indicate
group information while uploading.
5. When the upload is complete, the message [ donE ] is displayed, indicating the
upload has been successful. This LCP unit may now be used to download these
parameters to other motor controllers using the procedure outlined in the
‘Downloading Parameters (to Motor Controller)’ section.
6. Place the motor controller in auto mode using the [Auto On] key.
Note - parameters are not automatically stored in the LCP when modified. Therefore if
parameters are modified in the system, an upload action is required to load/store
these changes onto the LCP unit.
Motor Drive Parameters

The motor controller shipped with a scanner is programmed with optimized tuning parameters.
Motor controllers shipped as part of a sub-assembly are programmed with ABB default values.
Depending on the application these parameters may be fine tuned later; however they will allow the
system to function as required without adjustment. Motor controllers shipped as replacement parts
will be programmed with vendor default values. A number of these values must be modified to the
appropriate ABB default values shown in Table 5-2. These are default values for the relevant
scanner type, they may require ‘fine’ adjustment to the optimized values associated with the scanner
on which the controller is being mounted. The fine tune values can be found on the controller for
replacement if available; otherwise it may be necessary to tune the motor controller as outlined in
the issues of the section Notes on Motor Controller Tuning. In any case the scanner default
parameters will function for the scanner type in question.
In all situations the actual optimized parameters for a system should be recorded for later reference.
The parameters which need to be recorded are those listed in Table 5-2.
Possible scenarios regarding the VLT motor controller usage are outlined in the following table:
5-6 3BUS209559 rev K

Controller usage Parameter information

VLT controller All parameters will be already optimized for this scanner.
delivered as part of a For future reference create a hard copy of actual controller
new scanner settings for parameters outlined in Table 5-2 Motor Drive
Parameter Settings (Scanner Defaults).
Ensure actual parameters are also uploaded to the LCP unit
as outlined in the section Uploading Parameters (from Motor
Controller).
VLT controller Controller will have vendor default settings as outlined in

delivered as Table 5-2 Motor Drive Parameter Settings (Scanner Defaults).
replacement for failed Before scanner operation, these will need to be modified to
VLT unit. match the parameters on the old controller. To do this:
1. Download the parameter settings using the LCP 11 from
the old controller as outlined in the section Downloading
Parameters (to Motor Controller).
or
2. Use the hard copy of the parameter settings from the old
controller and manually set the parameters from Table 5-2
Motor Drive Parameter Settings (Scanner Defaults) differing
from those on the new controller.
or
3. If none of above available use default settings in Table 5-2.
Note in this situation later parameter tuning may be
required for optimal movement.
VLT controller Follow the procedure outlined in the section Motor Drive
delivered as Controller Replacement – ACS to VLT to install the controller.
replacement for failed The correlation between the parameters on the ACS
ACS unit. controller with the VLT controller is shown in Table 10-4
Motor Controller parameters ACS vs VLT. Set the VLT
parameters, highlighted in this table, to match the values
from the ACS controller.
If these values are not available use the values from Table
5-2, for the relevant frame type (SP).
Note in this situation later parameter tuning may be required
for optimal movement.
VLT controller Follow the procedure outlined in the section Motor Drive
delivered as Controller Replacement – Fincor or Lovejoy to VLT to install
replacement for failed the controller.
Fincor or Lovejoy unit. Set the VLT parameters, according to Table 5-2, to match the
frame type.
Note parameter tuning may be required for optimal
movement.
Table 5-1 VLT Controller Usage
3BUS209559 rev K 5-7

Failure to use the correct parameter values may result in

improper frame operation, burn the motor windings or
produce excessive torque.
Vendor NP
Parameter Name Default Default
Settings Settings
Group 1
1-01 Motor Control Principle 1 0
1-20 Motor Power 0.37 kW 0.18 kW
1-23 Motor Frequency 50 Hz 135 Hz
1-24 Motor Current 2.09 A 1.14 A
0 0V 0 16 V
1 230 V 1 230 V
U/f Char. – U
2 230 V 2 230 V
1-55 (array of points defining
3 230 V 3 230 V
the U/f profile)
4 230 V 4 230 V
5 230 V 5 230 V
0 0 Hz 0 0 Hz
1 50 Hz 1 135 Hz
U/f Char. – F
2 50 Hz 2 135 Hz
1-56 (array of points defining
3 50 Hz 3 135 Hz
the U/f profile)
4 50 Hz 4 135 Hz
5 50 Hz 5 135 Hz
Group 3
3-03 Maximum Reference 50.00 120
3-41 Ramp up Time 3.00 s 1.00 s
3-42 Ramp Down Time 3.00 s 0.75 s
Group 4
Motor Speed High
4-14 65.0 Hz 120 Hz
Limit
4-51 Warning Current High 2.5A 2.5A
Group 5
9 or 53
5-40 Function Relay 0
see Note 1
Group 6
6-15 High Ref. Value 50.00 120.00
Table 5-2 Motor Drive Parameter Settings (Scanner Defaults)
Note1:
Post July 2014 scanner and spare parts system’s VLT parameter 5-40 setting will be 53. When the
parameter is set to 53 one must simultaneously have a wire connected to pin 2 TRIP Normally Open
(N.O.). This wire originates at J19-9 (JSIG-9). See the appropriate Functional wiring drawing. This
5-8 3BUS209559 rev K

to get frame movement operation. This is documented in ABB customer Field Alert 3BUS209323-
850.
Pre July 2014 scanner and spare parts system’s VLT parameter 5-40 setting may be 9. When the
parameter is set to 9 the above mentioned wire will be connected to pin 3.
Motor Controller Switches (VLT Drive)

To function correctly in the scanner application it is necessary to ensure that the 4-way DIL switch
S200 is correctly set. This switch is located above terminals 52 – 55. The required settings are
illustrated below:
ON
OFF
1 2 3 4
Figure 5-2 S200 Switches 1 - 4
Motor Controller Adjustment of U/f Characteristic – U

A ‘pre-load’ voltage is applied to the motor to ensure smooth progress at the beginning of
movement. This compensation factor is used to help overcome motor losses and initial inertia. If this
value is too low, there will be a delay before movement begins. In extreme cases this may result in
an alarm situation since the scanner is not following the expected profile. Alternatively if the value
is set too high the motion will start with a sudden jerk.
The procedure for choosing the ideal U/f profile and thereby smooth direction change action by the
scanner is outlined below:
1. Select parameter 1-55 U/f and choose array position [0]. Set this value to 20.
2. Perform a Frame Tune as described in Automatic Servo Tuning.
3. Use SWS to scan frame and observe head package motion as scan direction
changes.
4. If there is a noticeable delay between head package coming to a full stop and the
next scan starting increase the value in array position [0] by 2.
5. If there is a noticeable jerky start when head package changes direction reduce
value in array position [0] by 2.
6. Repeat 3, 4 and 5 until neither symptom 4 or 5 is noticeable.
7. The remainder of the array positions [1-5] should be set to 230.
8. Use the upload procedure outlined in the section Uploading Parameters (from Motor
Controller) to save this value into the LCP unit.
9. Repeat Frame Tune.
Note for Smart Platform users: Network Platform, as opposed to Smart Platform, disables the motor
controller when stationary position is requested. This means the procedure described in Smart
Platform manual for tuning U/f characteristics can not be performed in NP, however it also means
that the U/f variable setting is not as sensitive in NP.
3BUS209559 rev K 5-9

Motor Controller Adjustment of U/f Characteristic – f

Acceleration of the head package to reach cruise speed is controlled by the adjustment of the array
values associated with parameter 1-56. The graph below indicates for different values of 1-56 the
consequence on acceleration.
The settings for the array associated with 1-56 should not require adjustment from the default setting
given in Table 5-2 Motor Drive Parameter Settings (Scanner Defaults).
Acceleration pattern for different parameter 1-56 settings
600
500
400
Velocity (mm./sec.)
135
155
300
200
100
0
0 1 2 3 4 5 6
Secs.
Figure 5-3 Velocity Profile graph
Note that changing the parameter value for 1-23 automatically changes the values associated with
array elements 1-56-1 to 1-56-5. Lowering the values in 1-56, improves the acceleration
characteristic of the system as outlined in Figure 5-3.
Note - increasing the acceleration available for the scanner will however also increase the torque
which can be delivered by the system and can have consequences for the system from a safety
perspective when an obstruction is encountered during motion.
If this parameter is set too high, acceleration appears sluggish; conversely if the parameter is set too
low acceleration appears aggressive.
5-10 3BUS209559 rev K

Motor Drive Setup (ABB ACS-100)

Network Platform is not sold with this controller; however when upgrading a Smart Platform to
Network Platform the controller may be kept.
It’s recommended that the same motor controller settings are kept that were used for the Smart
Platform configuration.
Please refer to “3BUS208000 - SP 1200 Installation and Maintenance Manual” or
“3BUS208001 - SP 700 Installation and Maintenance Manual” for further details concerning
default parameters and trouble shooting of these controllers.
AC100 Re-Use Advice

Two common mistakes are made when re-using the ACS100 in SP to NP upgrades. The scanner
may seem to work ok while on site but later give scanning performance problems. These issues are:
1) ACS100 parameter 306 should be set to a starting value of 20. Then tuned upwards or
downwards to a largest possible value so that the head package does not creep forward
when left idle. On some re-used ACS100 this value has been set to excessively low values
such as 5v. An incorrect value results in non smooth scanning head package movement.
Ensure that the head can be safely stopped by hand.
2) Minimum output (Vmin) may be set to and excessively large value. Start by changing this
value to a low number. For example start with 0.25V. The symptoms for having this value
too large is non head movement or movement and obstruction errors during scanning
operation. One can change the value on the SWS frame health page or in the Configuration
Tool Frame Position Control section’s Minimum Output (ID 4530).
After making the above modifications one should re run frame tuning, confirm frame
operation and make a software backup. Make sure that the head can be safely stopped by
hand.
Collect debug files to assist troubleshooting scanning issues.
3BUS209559 rev K 5-11

Frame Tune
Automatic Frame Tune options
The Automatic Frame Tune has two basic options that can be set in SWS see Figure 5-4:
WITHIN LIMITS (default option)

Frame tune will run a sequence that determines the value or tune the following parameters:
1. MC slope and MC offset
2. PID parameters – Kp Ki, Kd
3. Minimum output.
4. Max speed.
5. Acceleration
This option only moves the head package between home limit switch and far measure limit.
This option should be used any time the frame needs to be retuned e.g. after replacing drive
components or adjusting belt tension.
FULL TUNE
Same as WITHIN LIMITS except that:
1. Head package travels all the way between home and far limit switch.
2. All limits described in Automatic Servo Tuning are set to default values calculated from limit
switch positions.
This option should only be used when starting with a default configuration e.g. after upgrade from
Smart Platform to Network Platform.
Figure 5-4 Frame Health Report – Frame tune options
Automatic Servo Tuning
Before proceeding with this phase, make certain the Far Limit
Switch has been mechanically adjusted to prevent the head
package from hitting an obstruction, such as the machine ropes.
5-12 3BUS209559 rev K

Note: If the head crossing the sheet edge will create a problem, do not proceed.
Wait until there is a sheet break before tuning.
1. Ensure that the Frame is synchronized before starting the procedure, for example by pressing
the Remote button on the Frame Control Panel.
2. Take the Network Platform into Local by pressing the Local button on the Frame Control Panel.
3. Measure the distance from the inner Home end column wrap around on the head carriage. Any
head position can be used, it is not necessary to move the head carriage to the end column. See
Figure 5-5.
4. Enter the distance, in Customer Units, in the Frame Health Report Scanner Setup tab variable
“EC to Head Wrap Dist.”. See Figure 5-6.
5. Take the Network Platform into Remote Locked Off Sheet by pressing the Remote button on
the Frame Control Panel.
6. Simultaneously press the “Set Reverse Limit” and “Set Forward Limit” buttons on the Frame
Control Panel. Continue to press the buttons until the “Jog Forward” and “Jog Reverse” start
Flashing (10s).
7. The head carriage will move back and forward along the frame as several sequences to tune
parameters are performed.
8. Use SWS to save the parameters see 3BUS209544 - Network Platform Software
Reference Manual.
The Network Platform is now tuned and should scan smoothly and stop at the end of scanning
without overshoot or hunting.
If a very short Frame is tuned it’s unlikely that Head carriage will be able to achieve a stable
maximum speed. If this is the case Frame Tune will fail indicated by flashing Maintenance button
and alarm in SWS Health Pages. To tune a short Frame the “Max Velocity (vmax)” must be
lowered.
Home End Column
Measure this distance
Figure 5-5 Head Position Calibration Measurement
3BUS209559 rev K 5-13

Enter Wrap Around distance here
Figure 5-6 Frame Health Report – Scanner Setup
Servo Setup
PLEASE OBSERVE: The controls in SWS Health Pages that displays parameters that are changed
by Frame Tune will not update automatically at end of Frame Tune. To view results of Frame Tune
in the Health pages you need to close and re-open the Health pages.
Frame will tune the scanner to perform quick and well controlled scans whatever desired scan speed
or scan distance. However if only slow scanning will be used the wear on hardware can be reduced
by:
1. Setting “Acceleration” to a lower value see Figure 5-7. This will lower the acceleration used
for all head movement.
2. Setting “Max Speed” to a lower value see Figure 5-6. This will lower the speed used for e.g.
going off sheet or going to single point position.
The following entries are shown on the Frame Health Report under the Servo/Temp Setup tab. See
Figure 5-7 on page 5-15.
Entry Description/Usage
Acceleration Determined during Frame Tune. Value can be
lowered to decrease wear on hardware.
Position Deadband CU Determines desired accuracy of positioning. If

motion results in final position outside dead band
warnings will be produced in debug.
Min output V Determined during Frame Tune as the lowest

voltage necessary to move head package
consistently. Value can be increased if there are
sticky spots on frame.
Max Velocity (VMAX) V Decides maximum allowed output to Motor

controller, effectively limiting maximum speed. If
value is changed Frame Tune needs to be
performed again.
MC Jog Command V Motor Controller Output for Jogging in volts.

Determined during Frame Tune.
PID Proportional Gain Determined during Frame Tune.
5-14 3BUS209559 rev K

PID Integral Gain Determined during Frame Tune.
PID Excessive Position Error In customer units.

This value determines whether a head obstructions
have been detected. If head carriage deviates from
trajectory with more than this value motion will
stop.
PID Feed Forward Gain For future use. Should always be 1.0.
PID Derivative Gain Determined during Frame Tune.

Table 5-3 NP Service Workstation Frame Servo/Temp Entries
Figure 5-7 Frame Health Report – Servo Setup
Changing the Motion Restriction Sensitivity

The maximum torque generated to drive the Head Package is restricted by the motor controller
settings. However the decision to turn off the motor controller when an obstruction occurs is done
by software based on the parameter “PID Excessive Position Error” see Figure 5-7. A smaller
value means that Head Package stops quicker when movement is obstructed, however if value is too
small Head obstruction will be erroneously detected during normal scanning.
3BUS209559 rev K 5-15

Head Position Setup

This section defines specific head position locations. See Figure 5-8 Network Platform
Positions at the Host Computer. The position variables are listed below.
Garage Position (OFF)

The Garage Position is the position on the Network Platform, next to the process, where
maintenance is performed. The entered distance should be the smallest of the Host positions, as
measured from the home end column.
If personal safety and service access needs dictate, it is possible to place the off–sheet position
adjacent to the far column end of the platform. In this case, leave the standardize position at the
home end if possible and note that when going on-sheet, the heads will traverse the entire platform
length from the far end to the home end in order to start its scan.
Standardize Position (STDZ)

The Standardize Position is the position where sensor standardization occurs. This position typically
is the same as the off sheet position and should never be close enough to the sheet edge so that the
far edge detector sees the sheet edge. The entered distance should be less than the value for the
Minimum Home EOS Position.
Normally the off-sheet and standardize positions are identical because this allows the automatic
check sample sequence to be extended after standardize without moving the head to a new position
and enhances accuracy.
Home Measure Limit (LHEOS)

This position defines the home position of the maximum scan width, and the minimum limit for the
Current Home Scan Limit. The Network Platform will never scan outside of the minimum measure
position. This value should be greater than those for the Garage Position and the Standardize
Position. This position is called the Home Measure Limit.
Manual Scan Limit (KHEOS)

This position is the current home side scan limit for the present sheet width. This value will never
be less than the Minimum Home Measure Position. This position is called the Home Scan Limit.
Far Manual Scan Limit (KFEOS)

This position is the current far side scan limit for the present sheet width. This value will never be
greater than Maximum Far Measure Position. This position is called the Far Scan Limit.
Far Measure Limit (LFEOS)

This position defines the far position of maximum scan width, and the maximum limit for Current
Far Scan Limit. The Network Platform never scans outside of the Maximum Measure Position.
This position is called the Far Measure Limit.
5-16 3BUS209559 rev K

Home End Far End

Column Process Sheet Column
1
2
3
4
5
6
7
Figure 5-8 Network Platform Positions at the Host Computer

1. Garage Position (OFF)
2. Standardize Position (STDZ)
3. Home Measure Limit (LHEOS)
4. Home Manual Scan Limit (KHEOS)
5. Default Single Point Position (SPPOS)
6. Far Manual Scan Limit (KFEOS)
7. Far Measure Limit (LFEOS)
Figure 5-9 Frame Health Report – Scanner Setup –Head Position Setup
3BUS209559 rev K 5-17

Notes about Home Measure Limit (LHEOS) and Far Measure

Limit (LFEOS) (Scanning Measurement Limits)
The variables Home Measure Limit and Far Measure Limit define the sheet’s measure limits at the
maximum possible trim positions of the process. This then defines the farthest positions which the
measurement heads can achieve during scanning operations. As a result these variables define the
width and location of all system data boxes.
On multi-frame applications, all frames must be identically aligned with respect to the physical
process. Since sheet shrinkage is a very nonlinear function, it is not recommended that any attempt
be made to compensate for shrinkage by misaligning the frames. Proper compensation for sheet
shrinkage can only be accomplished via algorithmic means. See Figure 5-10 below.
Max Trim
LFEOS LHEOS
Frame 2
Measure Limits
Frame 1
Measure Limits
Center of
Sheet
Figure 5-10 Limits for Multiple Platform Installations
Procedure for Home Measure Limit and Far Measure Limit

1. Determine the physical center line of the process relative to the Headbox at each frame
location. Note that the center line of the rolls in any area of the machine may not be the center
line of the process.
2. The maximum trim locations should be determined by measuring equal distances from the
center line determined above to each edge of the possible sheet run.
3. JOG or otherwise move the head package until the center line of the sensing windows is
directly aligned with each of the maximum trim locations determined above. Permanently mark
the frames to identify the maximum trim locations. These marks will make it easier to check or
set up these locations during maintenance operations.
4. Record the head position while the head package is at each of the marked locations. Enter the
recorded position into Far Measure Limit and Home Measure Limit, as specified for your
system.
5-18 3BUS209559 rev K

Procedure for Determining Position Values

Mark the locations of the machine center line, the Home Measure Limit, and the Far Measure Limit
on the Network Platform for future reference.
1. Select the Frame Health Report..
2. Use the JOG push buttons on the Network Platform end column to move the head package to
the desired position.
3. Record the current head position as displayed on the Health Report.
4. Repeat Steps 2 and 3 for each of the fixed frame positions.
5. Enter values in customer units in the appropriate data fields of the Health Report. See Figure
5-11.
Figure 5-11 SWS Frame Health Report - Scanner Setup
3BUS209559 rev K 5-19

Head Package Dimensions Setup

The sensor head package dimensions are used to control the orientation of the window over the
sheet as the head moves through its various sequences. The variables used for this purposes can be
manipulated to accomplish a variety of head behavior patterns as the head moves from off–sheet to a
scanning condition. This section contains information about the locations of these variables and a
procedure for determining their values. The head package dimensional variables are defined below.
Enter the head dimensions in the Network Platform Frame Health Report page under the Scanner
Setup tab. (See Figure 5-11 ) Two basic equations deal with bringing the head on–sheet, depending
whether auto edge of sheet is turned on or not:
Auto Edge of Sheet Turned Off:
Prepare to measure position = homeScanLimit + curlDist
Auto Edge of Sheet Turned On:
Prepare to measure position = homeEOS + homeWindowClearance + curlDist + homeEdgeTrack
Definition of Head Package Dimensions

Table 5-4 Head Package Dimensions
Home Window Clearance This variable represents the distance, on the
home–side of the head package, from the
measurement center line to the edge of the largest
sensor window in the head package. The window
radii will range from approximately 0.5 in. for a
Smart Ash sensor to 2.5 in. for a HemiPlus sensor
(see Figure 5-12 on page 5-21).
Far Window Clearance This variable represents the distance, on the far–
side of the head package, from the measurement
center line to the edge of the largest sensor
window in the head. The window radii will range
from approximately 0.5 in. for a Smart Ash sensor
to 2.5 in. for a HemiPlus sensor (see Figure 5-12
on page 5-21).
Curl Distance This variable represents the additional distance

that the heads will travel when first coming on–
sheet to the prepare–to–measure position to assure
that sheet contacting sensors, such as caliper, are
fully on–sheet before making contact. The heads
will then back up to the Home Scan Limit to start
scanning.
The locations of these positions on a Network Platform sensor head package are shown in Figure
5-12 on page 5-21.
5-20 3BUS209559 rev K

farWindowClearance
homeWindowClearance
Measurement
Window
Center Line
homeHeadClearance
farHeadClearance
Figure 5-12 Location of Head Package Measurements
Determining and Entering the Head Dimensions

Refer to Table 5-5 on page 5-22 and Figure 5-9 on page 5-17.
1. Split the sensor heads, using one of the head split switches. Head split switches
are located in the drive end and idler end columns.
2. Determine the values for Home Window Clearance and Far Window Clearance
see Figure 5-12 above,Table 5-5 gives typical measurement area diameters for
each sensor.
3. Divide the value for the largest sensor beam diameter by 2 to get the Home Window
Clearance and Far Window Clearance.
4. Enter the resultant number into the Scanner Setup section of the Frame Health
Report. Refer to Figure 5-9 on page 5-17.
5. Enter the Curl Distance.
6. Use the “Save Scanner Configuration” under the “Tools” menu to save the
changes made on the Frame Health Report.
Note: The diameters given in Table 5-5 on page 5-22, define the nominal
dimensions of the various sensor measurement beams. Each sensor has
its own unique tolerance characteristics as the beam encroaches over a
sheet edge. These characteristics will govern, in part, how close the
measurement centerline may be brought to the sheet edge. For example,
a GT Caliper probe may not go beyond the edge. On the other hand, a
HemiPlus IR beam can be as much as halfway over the edge. Check each
sensor’s technical manual for that sensor’s tolerance.
3BUS209559 rev K 5-21

Measurement Beam
Diameter
Sensor Type Sensor Model in. cm
Basis Weight TLS-1 2.5 6.35
STLK* 0.59 .5
STLP* 0.59 1.5
STLXR 0.47 1.2
IR Moisture HPIR-T 0.59 1.5
ReflectionPlus 2.125 5.40
HemiPlus 2.5 6.35
Microwave any -- --
Moisture
Ash STLXR 0.59 1.5
Caliper any 2.0 5.08
Gloss any -- --
OptiPak any -- --
Table 5-5 Sensor Window Diameters
*Cross Machine Direction Only
5-22 3BUS209559 rev K

Automatic Edge-of-Sheet
The Automatic Edge-of-Sheet (AEOS) option available on the Network Platform allows the sensor
head package to closely track the edge of the process sheet, and to respond to changes in the width
of the process sheet. AEOS is made possible by mounting an infrared detector on the home and far
edges of the head package.
This section contains guidelines for the setup of AEOS and a procedure for entering the values in
the Network Platform.
The variables necessary for set up of AEOS are described below.
Max Edge Change This variable represents the maximum amount the sheet edge position is
allowed to change before interpreting the edge change as a sheet break,
this is ignored whenever scanner goes on sheet. All edge changes which
are within this value, but greater than EOS Deadband are considered valid
and sent to the Host computer.
EOS Deadband This variable represents the distance the sheet edge is allowed to wander
before changing the scan trajectory to a new Scan Limit
Home Edge Track This variable represents the target distance from the home edge of the
window in the head package to the home edge of the sheet This value
should be calculated as EosDeadband+SafetyMargin where safety margin
depends on how well tuned the Frame is. Typically 1 to 2mm is enough.
Far Edge Track This variable is the target distance from the far edge of the window in the
head package to the far edge of the sheet. This value should be calculated
as EosDeadband+SafetyMargin where safety margin depends on how well
tuned the Frame is. Typically 1 to 2mm is enough
Home Detector Offset This variable is the distance from the measurement window center line to
the center of the home edge sheet detector.
Far Detector Offset This variable is the distance from the measurement window center line to
the center of the far edge sheet detector.
Home Manual Scan Limit Must be configured to be greater than the minimum process dimension for
the home edge.
Far Manual Scan Limit Must be configured to be less than the maximum process dimension for
the far edge.
Table 5-6 Edge of sheet parameters
These measurement relationships are shown in Figure 5-13 on page 5-24.
Note: If Auto Edge Of Sheet detection is used and the manual scan limits are not
configured correctly to fall within the smallest process dimensions, an
Inherent Sheet Break may be generated when detecting the Sheet Edge
too early.
3BUS209559 rev K 5-23

Figure 5-13 Automatic Edge-of-Sheet Position Measurements
5-24 3BUS209559 rev K

Setup Guidelines
When the Network Platform scans near an edge, the scan limits will change only if the projected new scan
limit is outside the EOS Deadband value of the current scan limit.
It is important that all of the setup parameters be entered in the same customer units.
Do not make either homeEdgeTrackingDistance or farEdgeTrackingDistance smaller than the value for
EosDeadband located on the Frame Health Report. If either of these tracking variables is made too small,
the Network Platform may position part of the window off the sheet edge, resulting in an increase in the
dwell time at the edges. As the EOS Deadband is made smaller, the Network Platform will report a larger
number of scan limit changes.
The relationship between the calculated scan limits and the detected edges is as follows:
homeScanLimit = homeEOS + homeWindowClearance + homeEdgeTrackingDistance
farScanLimit = farEOS - farWindowClearance - farEdgeTrackingDistance
The tracking distance variables should be set such that the scan limit positions allow the edge detectors to
see the sheet edge. If the tracking distance is larger than the detector offset value, the head will not move
smoothly at the sheet edge. In general, the tracking distances should meet the following inequalities:
Tracking Distance + Window Clearance + EOSDeadband < Detector Offset
Tracking Distance > EOSDeadband + Position Deadband
where Position Deadband is from Figure 5-7 on page 5-15.
Entering AEOS Setup Parameters

The values for Home Detector Offset and Far Detector Offset can be measured on the head package. The
other values must be based on the desired performance of the AEOS feature.
1. At the Service Workstation, access the Frame Health Report. See Figure 5-14 on page 5-26.
2. Put the Network Platform off sheet
3. Enter values, in customer units, for the following variables:
Home Detector Offset
Far Detector Offset
EOS Deadband
Max Edge Change
Home Edge Track
Far Edge Track
4. Put the platform in the on-sheet mode to resume normal operation.
5. Use the “Save Scanner Configuration” under the “Tools” menu to save the changes made on the
Frame Health Report.
3BUS209559 rev K 5-25

Figure 5-14 SWS Frame Health Report - AEOS Setup
5-26 3BUS209559 rev K

Standardize Off-Sheet Delay Setup

At times there are large temperature differences between the off-sheet position and where the head
package is over the process. These temperature differences can cause measurement problems if the head
has been off-sheet long enough to cool. Under this situation, it is not appropriate to initiate a standardize
before going back on-sheet, as this will introduce errors to the measurement due to standardizing with a
cooled sensor package. To overcome this potential error, the Standardize Delay feature will delay the
standardize if the head has been off-sheet for more than a specified amount of time. In this case, the
head will forego any scheduled standardize until such time as a prescribed time on-sheet has been
accomplished. During this time delay, the measurements will be valid provided there was an initial good
standardize.
To activate the feature the config entry for “AdvancedSTDZFeature” must be set to a one or use the
“Advanced STDZ Type” dropdown option in the Service Workstation. There are two variables
associated with this feature: Off Sheet Time and On Sheet Time. The values used will necessarily be site
and installation specific, depending on the temperature environment surrounding each frame.
Experiment to determine the correct off- and on-sheet delay times.
This feature is primarily beneficial for the Caliper and OptiPak sensors and on Off-Machine Coaters
where standardize should be delayed after machine startup. Other sensors may also benefit where on and
off-sheet temperature differences are considered large. Unless large temperature differences are present,
turn off the feature if a Caliper or OptiPak sensor is not present in the configuration. However, if it is
on, it will control the standardize of all sensors in the Network Platform.
1. Open the Frame Health Report then, select the Stdz Setup tab. See Figure 5-15 on page 5-28
2. Enter the desired off-sheet time in seconds.
3. Enter the desired on-sheet time in seconds.
4. Select Advanced Stdz Type to be “Delayed” from the Frame Health Report under the Stdz
Setup tab. Figure 5-15 on page 5-28
5. Use the “Save Scanner Configuration” under the “Tools” menu to save the changes made on
the Frame Health Report.
3BUS209559 rev K 5-27

Operation Overview
When the head is moved off-sheet, a timer is started. When the time accumulation equals that of the
Off Sheet Time value, the system will set the Stdz Delay Required flag. If a DIRT standardize
request then comes from the host, the standardize request will be so noted in the Stdz Requested
flag, but the actual standardize procedure will be delayed until on-sheet has been requested and the
head has been over the sheet for at least On Sheet Time seconds. Note that a single point request
will start the on-sheet timer, but the standardize will not occur until the mode changes back to scan
or off-sheet.
The recommended starting value for the off-sheet timer is 10 minutes (600 seconds), and for the on-
sheet timer, 6 minutes (360 seconds). Experiment to determine the most appropriate off and on
sheet delay times for each site. This feature is bypassed when a local standardize is requested from
the FCP or if a CLEAN standardize has been requested from the host or Health Reports.
Figure 5-15 SW Frame Health Report -Stdz Setup
5-28 3BUS209559 rev K

Accelerated Standardize
An "Accelerated Standardize" feature was added to allow the system to recover from the sensors
cooling off too much while off sheet. This feature allows the system to be setup to perform
Standardizes at increasing time intervals until a time limit is reached.
Under this feature, if the head is off sheet for longer than the Off Sheet Time, a Standardize will be
requested:
1. Before going on sheet.
2. Again after On Sheet Time.
3. Then repeatedly after Adv Stdz Interval Factor multiplied by last standardize interval until
Adv Stdz Interval Limit (s) is reached. When this occurs, the system will revert to its normal
operation.
Example:
With values as in Figure 5-15, if head package is off sheet for more than 120s, when commanded
to go on sheet (at time “t”), standardizes will happen at
t0 1st Standardize
t0 + 300s 2nd Standardize (300s after 1st Standardize)
t0 + 300 +300 * 1.5 = t0 +750s 3rd Standardize (450s after 2nd Standardize)
at t0 + 900s the system reverts to normal operation.
NOTE that this feature cannot be run at the same time as the delayed Standardize feature.
To setup this feature:
4. Use Frame Health Report under the Stdz Setup tab to provide values for the Off Sheet Time,
and On Sheet Time in the Scanner object just as with the Delayed Standardize feature. See
Figure 5-15 on page 5-28
5. Add values for Adv Stdz Interval Factor and Adv Stdz Interval Limit.
6. Select Advanced Stdz Type to be “Accelerated” from the Frame Health Report under the Stdz
Setup tab.
7. Use the “Save Scanner Configuration” under the “Tools” menu to save the changes made on
the Frame Health Report.
3BUS209559 rev K 5-29

Other Host Setup Procedures

The Host computer has several other important parameters that must be entered to assure proper
operation of the measurements system including the following:
• Scanning time, typically takes 15-30 seconds
• Number of profile points, typically takes 100-1200
• Standardize interval, typically takes 30-120 minutes
• Product code slopes, offset, compensations, and IR 4-filter flag
• Composite profile filter factor
• Requests for report printing
• Trend graphing of measurement and standardize results
Please refer to the appropriate system manuals for details.
5-30 3BUS209559 rev K

6 Measurement Setup
Measurement setup consists of a set of procedures that involve both the sensor and the Network
Platform. Specific sensors have additional hardware setup procedures that are located in the specific
sensor manuals. Refer to the Setup Checklists for the setup procedures sequence for each sensor.
Section ...............................................................................................................Page
Setup Checklists ...........................................................................................6-2
Operation of Service Workstation Health Reports .....................................6-7
Temperature Controller Setup for Basis Weight and Ash Sensors .........6-10
Setup of Customer Units ............................................................................6-14
Enter Calibration Head Constants .............................................................6-16
Standardize Limits ......................................................................................6-28
Verification ..................................................................................................6-41
Air Profile Compensation for Ash, Basis Weight, Caliper & OptiPak ......6-43
Default Compensations for IR Moisture, Microwave & Ash Sensors ......6-45
Calibrate Sample - Minimum Time Data Accumulation ............................6-46
Heated Air Wipe Installation.......................................................................6-47
3BUS209559 rev K 6-1

Setup Checklists
Newer sensor manuals may address all these sensor setup

activities in more detail. Always review your sensor manual for
information which may supersede the contents referred to here.
Basis Weight Sensor Setup

Procedure Refer To
Align the Sensor Heads on page 3-22
Set up the Temperature/Air Flow on page 6-10
Enter the Head Constants on page 6-16
Set the Standardize Limits on page 6-33
Verify the Sensor Function on page 6-41
Setup for Correct Ream Size on page 6-14
Air Profile Compensation on page 6-43
Table 6-1 Basis Weight Sensor Setup
IR Moisture Sensor Setup

Procedure Refer To
Align the Sensor Heads 3BUS209548 - IR Moisture Sensor
Manual
Set Up Cooling Unit on page 3-11
Adjust the Air Wipes 3BUS209548 - IR Moisture Sensor

Manual
Setup Default Compensation on page 6-45

Table 6-2 IR Moisture Sensor Setup
6-2 3BUS209559 rev K

High Performance IR (HPIR-T) Moisture Sensor Setup

Procedure Refer To
Align the Sensor Heads 3BUS212538 – HPIR-T Moisture
Sensor Manual
Enter the Head Constants
Set the Standardize Limits
Verify the Sensor Function
Setup Default Compensation
Table 6-3 HPIR-T Moisture Sensor Setup
OptiPak Sensor Setup

Procedure Refer To
Align the Sensor Heads OptiPak Sensor Manual, 3BUS

208 121
Air Pressure Verification
Calibration of the Head Constants on page 6-25
Set Up the Air Profile Compensation on page 6-43
Table 6-4 OptiPak Sensor Setup
Ash Sensor Setup

Procedure Refer To
Align the Sensor Heads on page 3-22
Set up the Temperature /Air on page 6-10

Flow
Verify Source High Voltage 3BUS209546 - Ash Sensor Manual
Supply Power–up and
Adjustment
Set Units on page 6-15

Table 6-5 Ash Sensor Setup
3BUS209559 rev K 6-3

Gloss Sensor Setup

Procedure Refer To
Align the Sensor Heads Gloss Sensor Manual, 3BUS 208 122
Adjust the Air Wipes RXX01
Filter Regulator Assembly

Air Supply Quality
Verification
Table 6-6 Gloss Sensor Setup
Apparent Density Setup

Procedure Refer To
Set up for Correct Density Units on page 6-14
Table 6-7 Apparent Density Setup
Caliper Sensor Setup

Procedure Refer To
Power Checks Caliper GT Sensor Manual,
3BUS 208 132 RXX01
Caliper Filter Regulator Assembly Smart Caliper GT Sensor
Manual, 3BUS 209 547
Air pressure Verification
Align the Sensor Heads

Set Up the Air Profile Compensation on page 6-43
Set Up for Correct Units on page 6-15

(Mils/Microns)
Table 6-8 Caliper Sensor Setup
6-4 3BUS209559 rev K

Sheet Temperature Sensor Setup

Procedure Refer To
Align the Sensor Heads Sheet Temperature Sensor
Air Purge
Power Checks
Calibrate and Enter the Head on page 6-20
Constants
Table 6-9 Sheet Temperature Sensor Setup
Microwave Sensor Setup

Procedure Refer To
Alignment of Sensor Heads 3BUS217035 - Microwave DS series
Sensor Manual For NP
Calibrate Temperature on page 6-23

Compensation
Verify Sensor Function 3BUS217035 - Microwave DS series
Sensor Manual For NP

Table 6-10 Microwave Sensor Setup
Smart Color Sensor Setup

Procedure Refer To
Alignment of Sensor Heads Smart Color Sensor Support
Enter the Head Constants
Set Standardize Limits
Verify Sensor Function
Table 6-11 Smart Color Sensor Setup
3BUS209559 rev K 6-5

IR CoatWeight Sensor Setup

Procedure Refer To
Alignment of Sensor Heads Smart ReflectionPlus CoatWeight
Sensor Manual, 3BUS 208 137
Enter the Head Constants RXX01
Set up Cooling Unit
Set Standardize Limits
Verify Sensor Function
Table 6-12 IR CoatWeight Sensor Setup
6-6 3BUS209559 rev K

Operation of Service Workstation Health Reports

Opening the Health Reports
To activate the Health Reports, double click the Health Report icon.
Figure 6-1 Health Report Icon
If there is only one Network Platform in the LAN the Health Report will display the Frame Health
Report for that scanner. If there is more than one Network Platform in the LAN, the first Network
Platform’s Frame Health Report will be opened. To select a different Network Platform click on the
“Select Scanner” icon at the lower right of the starting health page, and select the desired Network
Platform. See Figure 6-2 below
Figure 6-2 Frame Health Report – Selecting a NP
When the desired Network Platform has been selected, the Frame Health Report Overview for that
frame, along with a header panel and a footer (color bars) appear as shown in Figure 6-2 above
The header panel and color bars are always in view regardless of which sensor or frame page is
selected.
3BUS209559 rev K 6-7

Header Panel
The header panel provides the following information and control:
• Customer name, machine number, and frame number/designation
• Network Platform system release level
• Network Platform Health Report release level
• Current date and time
• Work Station command selector status and buttons to be used to control the Platform
when in workstation control.
• Status of End Column Control and selection of Host or Workstation control.
• Current shutter status
• In Workstation control, selection of Clean STDZ or APC Collection.
The color bars (footer) server several functions.
• They indicate the real sensor configuration compliment of the system.
• They give a color coded indication of sensor status: green for fully functional; red for
an alarm condition.
If the sensor name is flashing, the alarm condition is unacknowledged. Click the sensor
name to select the Health Report.
The central portion of each Health Report is unique for each of the sensors and frames. The specific
content varies. However, there are common features.
• Each report has a number of tabs listed at the top of the report. They are Measurement,
Alarms, Power/Temp History, and, in some cases, Heater.
• Under the Measurement tab, there will be a number of other tabs, each giving access to
data fields such as standardize limits and calibration.
• Also on the Measurement tab, located along the bottom, will be a display of subsystem
inputs and outputs and associated electronics power, and temperature status.
• All data fields where entry is permitted will have a white background.
• All other data fields will have a tan background.
• There are various status displays on the reports which give a color background to
indicated condition. Green indicates a good status; red indicates a problem. Text
relating to the condition is included in the status display.
6-8 3BUS209559 rev K

Figure 6-3 NP Workstation Frame Health Report - Overview

The first Health Report to appear after the Network Platform is selected is the Frame Health Report
(Overview tab). The Overview tab contains the following information:
• A graphic display of the Scanner complete with a dynamic head image that reflects the
current relative motion and position of the head.
• A representation of the Frame Control Panel (FCP) showing the condition of the LEDs
as they appear on the panel.
• A column of special input statuses showing the current condition of sheet break, host
communications, and BW and Ash inherent sheet break and head tracking conditions.
• A check box to show if invoke a sheet break override has been selected by the Host
System. Sheet break override can be selected when in workstation control.
• A data field entry for single point position in terms of percent of position between the
active scan limits, used when in workstation control.
3BUS209559 rev K 6-9

Temperature Controller Setup for Basis Weight and Ash

Sensors
Temperature control maintains the measurement area environment for critical internal components
and controls the temperature of the external air column (CAP). Standard operating conditions
include mill air temperature environments that vary between 10ºC and 85ºC and sheet temperature
up to 148ºC. The environment for internal components and the temperature of the external air
column are controlled by the microcontrollers in the ABB Smart Processing Center (ASPC). The
software control has an accuracy of ±2ºC and will maintain the set point within a precision of 0.5ºC.
Controller set up is done at the Service Workstation using the Ash, and Basis Weight Health
Reports. See Figure 6-4 on page 6-11 for an example of the Basis Weight Health Report (the Ash
Health Report is similar). For instructions on how to use the Health Reports, see Operation of Smart
Platform Health Reports on page 6-7. Do not change the kp, ki, or kd constants without consulting
a specialist.
Temperature controller tuning parameters are determined by the nature of the thermistor type and
the immediate heating environment involved. Use the Ash and Basis Weight Health Reports to
make the appropriate entries.
Temperature target should be between 45ºC and 65ºC (never

above 65ºC) or electronics damage may occur. Set
temperature about 10 to 20 degrees cooler than the
temperature four inches from the sheet.
6-10 3BUS209559 rev K

Figure 6-4 Service Workstation Basis Weight Health Report - Heater
Smart Ash and Smart Basis Weight

Temperature controller setup consists of setting control set points and adjusting the air flow. The set
point for both the source and detector module should be the same (see Table 6-13 Temperature
Controller Tuning Parameters on page 6-12). The air flow should be adjusted for 4 - 4.5 scfm
air flow for each module.
1. Set the temperature set point 20º lower than the current setpoint
2. Be sure that the Ash and Basis Weight sensor modules have been off-sheet and powered down
so that the heads are cold.
3. Set the temperature set point for each module.
Note: This adjustment must be made before the source controller begins to
operate. If additional time is required, move the source set point to a
higher temperature. Be sure not to leave the controller at this higher
temperature.
4. Adjust the source air flow while observing the source heater current at the Service
Workstation. Adjust flow for 2.2 amperes; this should correlate to about 4.0 scfm.
The on time duty cycle must be at 100. The valves are located on the air manifold on
the back of the basis weight source and detector modules. Valves should be marked.
5. Repeat Step 4 for the detector module flow and detector heater current.
6. Reset the temperature set points for the desired operating point as directed in Table
6-13 Temperature Controller Tuning Parameters.
3BUS209559 rev K 6-11

Table 6-13 Temperature Controller Tuning Parameters

Temperature Set Therm Gain Filter
Controller Point Type Delay (Kp) Ki Kd (alpha)
BW source head * 0 10 12.0 0.1 0 2.0

(STLK-11, STLP-3)
BW detect head * 0 0 12.0 0.1 0 2.0

(STLK-11, STLP-3)
Ash source head * 0 30 12.0 0.1 0 2.0

(STLXR)
Ash detect head * 0 20 12.0 0.1 0 2.0

(STLXR)
* Set to 55ºC as this is the calibration point for the sensor. If higher temperature is necessary
recheck calibration with check samples, recalibrate if necessary.
Note: A hot process requires higher set points. For basis weight and ash, the
CAP air system will provide both heating and cooling capabilities, different
from previous designs.
7. If ambient conditions are greater than 85 ºC, then air flow to each module must be increased. If
an air flow of 8.5 scfm is reached at about 3.5 amperes, refer to Table 6-14 below.
Table 6-14 Flow Versus Current with the Heater Fully On
PTC Heater Character at 30ºC Input Air
Amperes scfm
1.4 2.2
1.8 3.7
2.6 5.7
3.6 8.7
3.7 9.8
Flow ≈Amps * 2.8 - 1.8
8. Jog the head package to the coldest location, probably off–sheet, for at least one hour. Verify
that the source and detector heater duty cycle is less than 90%. See Figure 6-4 on page 6-11
for detector heater and source heater duty cycles.
9. Locate the head package in the hottest location for one hour. Verify that the source and
detector heater duty cycle is greater than 5%.
6-12 3BUS209559 rev K

10. If Step 6 or Step 9 fail, then repeat Step 4 and Step 6 to obtain reasonable operation. Increasing
air flow or control set point will increase duty cycle; lowering air flow or control set point will
reduce the duty cycle.
Note: When the sensors are cold, allow 20 minutes before control begins to
operate. One hour is required before the sensors are stable enough for
measurement or before duty cycle evaluation. The Basis Weight detector
sensor has a longer thermal time constant. It will take longer for it to come
into control.
3BUS209559 rev K 6-13

Setup of Customer Units

Positioning
By default all processing of positioning and positioning limits in Network Platform are done in mm.
Configuration file and debug will always display positioning in limits. However the distances can be
converted to arbitrary units for ASI tags (input and output) this conversion will be applied to all host
tags, SWS tags and reports (e.g. calibrate sample position).
The Frame is normally shipped with the desired distance unit already configured.
The three values of Customer Unit Conv. Factor normally used are:
a) “1” for millimeters.
b) “10” for centimeters.
c) “25.4” for inches.
Changing Positioning Units

1. Access the Frame Health Report from the Service Workstation.
2. Click the Measurement tab.
3. Click the Current tab.
4. Click the white field for “Customer Unit Conv. Factor”
5. Type the desired unit conversion.
6. Save configuration change.
Note: Many of the values associated with positioning are not automatically updated in SWS on a
time basis. If you want to see all values updated to the converted value you might have to close and
re-open SWS.
Figure 6-5 Positioning Customer units
Ream Size
The ream size conversion factor converts the internal computation of basis weight from grams per
square meter (g/m2) to customer units of pounds per ream. If customer units are to be g/m2, the
conversion factor is 1.0. Consult the Calibration Report for the correct value and enter it using the
Basis Weight Frame Health Report “Current” tab. Figure 6-6 on page 6-15
Ream size is, by default, controlled from the Network Platform Basis Weight Health Report. It is
possible to have the Host Computer determine the Ream Size by changing a flag called
HostReamSizeEnabled in the Scanner Configuration under the SensorManager tab. If this flag
6-14 3BUS209559 rev K

is set to a “1”, the ream size will be determined by what the host sends down at a grade change. If it
is a “0”, the default condition, then the Basis Weight Health Report controls it exclusively.
Changing Ream Size

7. Access the Basis Weight Health Report from the Service Workstation.
8. Click the Measurement tab.
9. Click the Current tab.
10. Click the white field for Ream Size.
11. Type the desired ream size. If ream size is set to zero, basis weight will be shown as grams per
square meter (g/m2)
Figure 6-6 SWS Basis Weight Ream Size Entry
Changing Caliper Output Units

To change the output units for the Caliper sensor, access the Caliper Health Report. See Figure 6-7
below.
1. Select the Measurement tab.
2. Select the Current tab.
3. In the Measurement Units area, click the desired units.
Figure 6-7 SWS Caliper Health Report
Ash Units Setup

Ash units are determined by the Host computer. Refer to the Host computer documentation for
setup of percent basis weight, percent bone dry weight, and ash weight. Most customers use percent
bone dry.
3BUS209559 rev K 6-15

Enter Calibration Head Constants

Calibration head constants have to be entered into the Network Platform software. The values for
these constants can be found on reports for the Basis Weight (includes Air Column), and Ash
sensors or tags for the IR Moisture and Caliper sensors. For the OptiPak and Gloss sensor, values
are entered through interactive functionality in SWS health pages that allows the software to
calibrate the constants it needs on line.
Basis Weight Sensor

The Basis Weight sensor head constants are K0, K1, K2, K3, Gap WCC, and Air Mass. These
constants may be different for every sensor. They may need to be changed if certain components in
the sensor geometry are repaired or replaced necessitating a recalibration of the sensor. Change
sensor constants using the Basis Weight Health Report, Figure 6-8 on page 6-17. See Operation
of Smart Platform Health Reports 0 on page 6-7. for an overview of the Health Reports.
The Basis Weight sensor employs an Air Column (Gap) sensor for compensation.
Head constants must be entered for that sensor also. See 0 on page 6-17.
Table 6-15 Basis Weight Calibration Constants

Value
Head Constant (Enter values from the Calibration Report)
K0
K1
K2
K3
Gap WCC1
(Smart Basis
Weight only)
Air Mass2
(Smart Basis
Weight only)
1. Listed under Enhancer Constants in the Basis Weight Calibration Report.

2. Listed under Enhancer Constants as AM in the Basis Weight Calibration Report.
6-16 3BUS209559 rev K

Figure 6-8 SWS Basis Weight Health Report – Calibration
Air Column Measurement

Air column measurement constants are changed using the Air Column (Gap) Sensor Health Report
in a manner similar to the way Basis Weight sensor constants are changed (see Figure 6-8 above
and Figure 6-9 below). There are five air column measurement sensor constants listed in the Basis
Weight calibration report, KZ0, KZ1, KZ2, KZ3, and gap offset. These constants are shown as K0,
K1, K2, K3 and Offset MM on the screen. Record the constants in Table 6-16 on page 6-18.
Figure 6-9 SWS Air Column Health Report – Setup
3BUS209559 rev K 6-17

Table 6-16 Air Column Measurement Constants

Value
Head Constant (Enter values from the Calibration Report)
KZ0
KZ1
KZ2
KZ3
gap offset
IR Moisture Sensor
Calibration head constants are found on the calibration tags on each IR sensor. Enter those values
into the Network Platform software using the appropriate Health Reports. The head constants are
listed in Table 6-17 on page 6-19.
Figure 6-10 SWS IR Moisture Health Report – Calibration
6-18 3BUS209559 rev K

Table 6-17 Head Constants

Nameplate Name Value to Enter
A1
A2
CW
B1
B2
WTBP
SDELTA or DELTA
DELTA1
DELTA2
KF1 or KF
KF2
A1
B1
C1
D1
CW1
A2
B2
C2
D2
CW2
A3
B3
C3
WTBP1
WTBP2
3BUS209559 rev K 6-19

Ash Sensor
The Ash sensor uses seven unique head constants for a flag-in operation and another unique seven
constants for a flag-out operation. If the sensor is a Smart Ash, there are two additional head
constants. These are listed in Table 6-18 below. The 14 values for flag-in/flag-out operation are
found in the Ash Calibration Report. The two additional constants for Smart Ash operation are
found in the Smart Basis Weight calibration report under Air Column data. Head constants from the
calibration report can be entered into the system using the Ash Sensor Health Report Figure 6-11
below. See Operation of Service Workstation Health Reports on page 6-7 for an overview of the
Health Reports..
Table 6-18 Ash Sensor Head Constants
Head Constant Flag-In Flag-Out
BW Corr Factor (A2)

Corr Offset (B2)
Mo Corr Factor (C2)
K0
K1
K2
K3
Gap WCC
Air Mass
Figure 6-11 SWS Ash Health Report - Calibration
Sheet Temperature Sensor

Use the Sheet Temperature Health Reports Figure 6-12 or the Configuration Tool Figure 6-13 to
change the calibration constants. Figure 6-12 shows an example of the Temperature Health Report.
6-20 3BUS209559 rev K

For instructions on calibrating the Sheet Temperature sensor, see the Sheet Temperature Sensor
Manual, 3BUS 209 557.
Figure 6-12 SWS Temperature Health Report – Calibration
Figure 6-13 NP Configuration Tool - Temperature
3BUS209559 rev K 6-21

Gloss Sensor
Table 6-19 below identifies the variable names of the two head constants. Enter the values you
read from the sensor head nameplate into the health pages see Figure 6-14 and save the
configuration.
Table 6-19 Head Constants for the Gloss Sensor
NamePlate Instance Variable
Name Name Value
GL1HC1 headConstant1
GL2HC2 headConstant2
Figure 6-14 SWS Gloss Health Report – Calibration
Gloss Sensor Head Constant Tuning

The gloss head constants are adjusted so that the sensor will correlate to the laboratory
measurements. Since the instruments used in the lab will read slightly different from one to another,
the head constants determined in Sensor manufacturing laboratory are attached to the sensor, but are
marked as approximate numbers.
The following procedure is to be used to fine tune the sensor response to the customer’s lab. It uses
readings of two sample in laboratory and on the Scanner.
1. Ensure that the laboratory instrument is calibrated with the calibration standards that
come with it.
2. Read the Gloss sensor’s check samples on the laboratory device, noting the proper
measurement area and direction of measurement. Take several readings and calculate
the average.
3. Allow the Gloss sensor to thermally stabilize for at least two hours. Clean the
windows and standardize.
6-22 3BUS209559 rev K

4. Read the Gloss sensor’s check samples with the Gloss sensor in Network Platform by
performing repeated check samples, ensuring direction of measurement is same as in
the lab. Take several readings and calculate the average for each sample. Readings can
be obtained either from the check sample report in SWS Health Pages or from the
Hosts System’s Check sample reports.
5. Calculate new head constants using the equations:
temp = (Lab 2 - Lab 1)/(Std 2 - Std 1)
GL1HC1(new) = GL1HC1(old) * temp
GL1HC2(new) = temp * [GL1HC2(old) - Std 1] + Lab 1
6. Enter the new Head Constants into SWS Health Pages.
7. Save configuration.
Error Conditions
 The absolute value of the difference between the two lab values
(Lab 2 - Lab 1) is less than or equal to 15.
 Calculated head constant GL1HC1 is less than 5 or greater than 50.
 Calculated head constant GL1HC2 is less than -15 or greater than 15.
Caliper Sensor
Use the Caliper Health Reports to change the calibration constants. Figure 6-15 shows an example
of the Caliper Health Report. Caliper calibration constants for your caliper sensor may be different.
See the 3BUS209547 - Caliper Sensor Manual.doc and your calibration report.
Figure 6-15 NP Workstation Caliper Health Report - Calibration
Microwave Moisture Sensor

The Calibration Head Constants for the Microwave sensor are currently fixed all DS20/DS20+
sensors are configured with 1 set and DS30/DS30+ sensors with another set. The choice of
calibration constants is automatically made when selecting DS20/DS20+ or DS30/DS30+ sensor in
configuration tool. The entries are summarized in Table 6-20 below. The constants are also
shown in the sensor health report.
Table 6-20 Microwave Moisture Calibration Constants

Head Constant Value
A (Offset)
B (Sensitivity)
3BUS209559 rev K 6-23

C (Weight compensation)
D (Low moisture linearity #1)
E (Low moisture linearity #2)
Temperature Conversion Unit
Figure 6-16 SWS Microwave Health Report – Head Constants DS30
Figure 6-17 SWS Microwave Health Report – Compensation
6-24 3BUS209559 rev K

Optipak Sensor
Table 6-21 below identifies the variable names of the head constants for Optipak sensor. Enter the
values you read from the sensor head nameplate into the specified text box and save configuration
using the tools menu.
Use the Optipak Sensor Health Report to change the calibration constants.
Table 6-21 Constants for the Optipak Sensor
Name Instance Variable
Name Value
FOHC1 Formation Head Constant 1 10
FOHC2 Formation Head Constant 2 0
BRHC1 Brightness Head Constant 1 0.5
OPHC1 Opacity Head Constant 1 100
Figure 6-18 NP Workstation Optipak Health Report – Calibration

To perform a recalibration of the sensor the steps that must be followed are listed below:
1. Allow the Optipak sensor to thermally stabilize for at least two hours. Clean the windows and
standardize.
2. Place brightness check sample # 1 that is provided with the Optipak calibration kit in the gap
and perform a check sample
3. Using the calibration utility in Optipak Health Report Page (Recalibration tab), get brightness
sample #1 ratio from check sample report using the marked button in Figure 6-19 and enter the
standard lab value for this sample:
3BUS209559 rev K 6-25

Figure 6-19 NP Workstation Optipak Health Report – Recalibration I

4. Place opacity sample # 1 that is provided with the Optipak calibration kit in the gap and
perform a check sample.
5. Using Get Opacity Sample #1 Ratio button, get opacity check sample ratio and enter the
standard lab value for this sample
Figure 6-20 NP Workstation Optipak Health Report – Recalibration II

6. Place opacity sample # 2 that is provided with the Optipak calibration kit in the gap and
perform a check sample
7. Using Get Opacity Sample Ratio #2, get opacity check sample ratio and enter the standard lab
value for this sample:
Figure 6-21 NP Workstation Optipak Health Report – Recalibration III

8. Once all necessary values for recalibration have been entered, the Calculate Head Constants
button will be enabled. Pressing this button new Optipak head constants will calculated and
displayed in their respective text boxes.
6-26 3BUS209559 rev K

Figure 6-22 NP Workstation Optipak Health Report – Recalibration IV

9. To apply these new head constants for measurement computing, the Apply Head Constant
button must be pressed.
10. Check in the Calibration tab Figure 6-18 on page 6-25 that values have been applied..
11. Save configuration to make changes persist.
3BUS209559 rev K 6-27

Standardize Limits
Standardize limits are entered via the Standardize Limits tab on each Sensor’s Health Report.
General Information
There are a number of options and scenarios available which control how the standardize feature is
to be operated. These are:
• Time interval between standardizes
• The selection of CLEAN or DIRTY standardize modes
• Standardize delay after long off-sheet periods
• Accelerated standardize after long off-sheet periods
• Reporting of "internal" check sample during standardize
Time Interval between Standardizes

The time interval between standardizes is generally controlled by the host computer, unless
connected to a 3rd party host that lacks this functionality. A minimum time interval should be 30
minutes.
If standardize interval needs to be controlled by scanner this can be achieved by setting the
configuration value StdzWaitTime to a non-zero value in any of the sensor configurations. The
Standardize Interval will be determined by the lowest non-zero value entered in one of the sensors.
Figure 6-23 NP Configuration tool - StdzWaitTime
The Selection of CLEAN or DIRTY Standardize Modes

CLEAN and DIRTY standardizes are selectable from the host computer and can be either manually
requested or defined at the time of automatic standardizes. Of all the sensors available in the system,
only Basis Weight, GT Caliper, and OptiPak (FOB) have any sensitivity to what mode of
standardize has been selected. It is possible to have one of these sensors responding to a DIRTY
standardize request while the others are held to doing only CLEAN standardizes. As an example, in
a system with both Basis Weight and GT Caliper, it may be desirable to have the Basis Weight
sensor only doing CLEAN standardizes while the GT Caliper must be doing DIRTY standardizes
due to the environmental aspects of the paper machine. In this case, the host would be set up to
request DIRTY standardizes while the Basis Weight sensor on the Network Platform is set up to do
a CLEAN standardize every time a DIRTY one is requested. In all cases after a system reset,
regardless of how the various CLEAN/DIRTY flags are set, the system will force a CLEAN
6-28 3BUS209559 rev K

standardize on all sensors which require one. The CLEAN request will continue until all of those
sensors have passed their initial standardize.
Figure 6-24 Standardize Mode Selection on page 6-31 describes the standardize
CLEAN/DIRTY mode selection that takes place when a standardize is requested from either the
Host, the Health Reports (HP), or the Frame Control Panel (FCP). To summarize the three
situations, whenever DIRT standardizes occur and are accepted by the sensors; the OptiPak sensor
can be set up to basically ignore standardize requests, the Basis Weight sensor will take into account
the effect on beam absorption when dust accumulates on the window, and the GT Caliper sensor
will filter the sensor zero (SZERO) results for GT Caliper to adjust for the effects caused by dust on
the probes.
Standardize initiated from the Frame Control Panel (FCP) is either CLEAN or DIRTY depending on
the setting of the Frame Health Report Overview tab entry Push Btn Stdz Type entry. See Figure
6-25 on page 6-32
In any CLEAN standardize request, an automatic internal check sample for those sensors so
equipped, is executed.
Note: Three sensor categories require a "good" CLEAN standardize before they
can be made operational after a restart. These are the OptiPak (FOB),
Caliper sensor, and Basis Weight sensors. After a restart, and regardless
of which kind of standardize is being requested from the host, Frame
Control Panel, or Health Reports, a CLEAN standardize will be scheduled
for these sensors until the initial standardize is passed. The individual
sensor manuals should be consulted to see the effect of a CLEAN or
DIRTY standardize selection.
3BUS209559 rev K 6-29

Standardize Delay After Long Off-Sheet Periods

There is a "delayed standardize feature" which allows the system to delay a DIRTY standardize
request until the head has scanned for a specified amount of time, after the head has been off-sheet
for a specified amount of time. See Standardize Off-Sheet Delay Setup on page 5-27.
Accelerated Standardize After Long Off-Sheet Periods

There is a "accelerated standardize feature" which allows the system to recover from the sensors
cooling off too much while off sheet. The new feature allows the system to be setup to perform
Standardizes at increasing time intervals until a time limit is reached. See Accelerated
Standardize on page 5-29.
Reporting of "Internal" Check Sample During Standardize

Several sensors have an internal check sample which is monitored at a CLEAN standardize request.
The internal check sample can be also monitored at selected DIRTY standardize intervals. The
sensors involved are Basis Weight, Ash, Caliper, Color and Smart ReflectionPlus CoatWeight.
There is a global variable controlling the type and frequency of the internal check samples
“NAUTO” which is set through SWS Health Report see Figure 6-25 on page 6-32. If it is set to
0, no internal check sample will take place during a DIRTY standardize request. If it is a positive
number, then the number will define the standardize interval of internal check samples done at
DIRTY standardizes. If the number is set to a negative value, then the internal check sample will
take place at the beginning and again at the end of the standardize sequence.
6-30 3BUS209559 rev K

Standardize
request from
FCP
Standardize
request from
HOST/HP
Set Standardize Mode to (clean/dirty)
localStdzMode
(fhi01)
All other FOB Basis Weight GT Caliper

Sensors Sensor Sensors Sensors
CLEAN NO CLEAN YES CLEAN YES

Standardize Request Standardize Request Standardize Request
? ? ?
YES NO NO
Is there
a valid current
NO standardize?
Is there NO Is there NO
YES
a valid CLEAN a valid CLEAN
standardize? standardize?
YES YES
Check
defaultStdz Type
=1
=0 Check =1 Check =1
defaultStdz Type defaultStdz Type
=0 =0
Do Do Do Do Do
Do Do Standardize DIRTY CLEAN DIRTY CLEAN
Standardize Standardize but do not Standardize Standardize Standardize Standardize
update results
Figure 6-24 Standardize Mode Selection
3BUS209559 rev K 6-31

Health Report Standardize Reports

There are two standardize reports available on the Health Report: Pending (STDZ Pend) and Current
(STDZ Curr). The STDZ Pend report is the last standardize results, either passed or failed, that
was executed. The STDZ Curr report is the last passed standardize and is the one the sensor
would be currently using while scanning or in single point. If the pending report shows failure, the
sensor will still be able to show a measurement on the Health Report; however, data sent to the host
will be marked invalid.
Changing the Standardize Mode of the FCP Standardize

Request
The default standardize mode requested from the FCP is CLEAN. This can be changed to be
DIRTY by changing the mode on the Frame Health Report Page under the Overview tab entry Push
Btn Stdz Type. See Figure 6-25 below.
Use the “Save Scanner Configuration” under the “Tools” menu above the header to save the
changes made on the Frame Health Report.
Figure 6-25 Frame Health Report - FCP Standardize Type
Controlling the Type of Standardize for a Specific Sensor

The system now has the ability of specifying for each sensor, what type of standardize is to be
performed when a DIRT standardize is requested from the Host. Most sensors do not perform
differently for either a CLEAN or DIRT standardize, but for those that do, it may be desirable at
times to always have a CLEAN standardize even when a DIRT standardize is requested. The
sensors in question which can sense the difference are the weight and caliper sensors.
With this feature turned on for the OptiPak, the sensor will ignore collecting new standardize data at
a DIRT standardize request. The only time the OptiPak sensor will actually establish new
standardize data is when a CLEAN one is selected.
The variable defaultStdzType, located in each sensor’s configuration, determines what type of
standardize the sensor will perform whenever a DIRT standardize has been requested by either the
host or the workstation. The selection code used to determine whether it is a CLEAN or DIRT
standardize, is “1” for CLEAN and “0” for DIRT. Therefore, if the defaultStdzType is set to a “1”,
the sensor will do a CLEAN standardize as requested, except of course the OptiPak sensor which
will not standardize at all. CLEAN standardizes are always responded to by the sensors as
requested. The default value of the defaultStdzType for all sensors except for OptiPak is a “0”. The
value for OptiPak is defaulted to a “1”.
6-32 3BUS209559 rev K

It should be noted that no capability in the standardize process has been lost. What this means is
more flexibility as to what type of standardize is done when a DIRT standardize has been requested.
Smart Basis Weight Sensors

See Table 6-22 on page 6-34 for the acceptable range of standardize limits for the Basis Weight
sensors.
Figure 6-26 NP Workstation BW Health Report - Standardize Limits
3BUS209559 rev K 6-33

Table 6-22 Range for Basis Weight Sensor Standardize Limits

Host Report Acceptable
Name Variable Name Function Values
AIZ AIZ Nominal Expected voltage with 0.0 VDC

shutter closed, no entry as it
should always be zero
0.1 VDC
AIZ Range Plus and minus limits for
AIZ
SIGMAZ Noise Z Standard deviation of the <0.00001 VDC 2

source closed signal
AIS AIS Nominal Expected voltage output of 3.0-9.0 VDC

the electrometer with nothing
in the gap
AIS Range Plus and minus limits for 0.5 VDC

AIS Nominal
SIGMAB Noise F Standard deviation of the <0.4 VDC2

electrometer output signal
with nothing in the gap.
SIGMAT Noise T Standard deviation of the

thermistors output signal
DIRT DIRT Nominal One half of the allowed dirt STLK - 18.5 g/m2 ± 21.25
accumulation permitted for STLP - 4.5 g/m2 ± 5.5
the sensor in g/m2 TLS - 45 g/m2 ± 5.5
DIRT Range Range of the Dirt Nominal

entry
Note: You have to observe source decay, which will reduce the AIS value by
3.4% per month for STLP and 0.7% per month for STLK sensors.
6-34 3BUS209559 rev K

GT Caliper Sensor
See Table 6-23 on page 6-36 for the acceptable range of standardize limits for the GT
Caliper Sensor.
Figure 6-27 NP Workstation Caliper Health Report - Standardize Limits
3BUS209559 rev K 6-35

Table 6-23 Range for Caliper Sensor Standardize Limits

Host Computer Variable Name In Variable Description Acceptable Range
Reporting Name Caliper Health
Report
SMAX Sensor Max Expected output 8.25 VDC ± 1.0

voltage of the
proximeter switch with
the heads unclamped
SNOISE Sen Max Noise Standard deviation of < 10 mV

the maximum sensor
signal noise in mV
SZERO Sensor Zero Expected voltage of 2.25 ± 1.0 VDC

the proximeter output
with nothing in the gap
and the heads clamped.
On GT Caliper, this
value is filtered by the
“Sensor Zero Filter
Factor Up/Down”
Sensor Zero Raw The unfiltered value of 2.25 ± 1.0 VDC

the GT Caliper signal
with the probe closed.
It is usually determined
from the GT Caliper
calibration report. On
GT Calipers calibration
reports without this
variable, it can be
determined by cleaning
the probes and doing a
CLEAN standardize.
The value to use will
be the resulting
measured Sensor Zero.
Pressure Top Pressure at top and 5.0 VDC -7.0 VDC

Pressure Bottom bottom heads of GT
Caliper, with air
solenoids engaged, in
milli-bars.
6-36 3BUS209559 rev K

IR Moisture Sensor
See Table 6-24 below for the acceptable range of standardize limits for the IR Moisture
Sensor.
Table 6-24 Range for IR Sensor Standardize Limits
Host Computer Variable Name
Reporting In IR Health
Name Report Description Acceptable Range
AAIR AAIR Standardize air gap reading 6.5 VDC ± 2.5

for the absorption signal on
transmission–type sensors.
RAIR RAIR Standardize air gap reading 6.5 VDC ± 2.5

for the reference signal on
transmission–type sensors.
AFLAG AFLAG Standardize flag reading for 5.7 ± 0.7

the absorption signal on
reflection–type sensors.
RFLAG RFLAG Standardize flag reading for 5.7 ± 0.7 VDC

the reference signal on
reflection–type sensors.
KC KC Standardize ratio 1.0 ± 0.2

A/R KC should not drift more
than 0.01 units from
standardize to standardize;
drift could indicate dirt or
condensation on the
windows.
SIGMIR SIGMIR This is one standard 0.00005 ± 0.00005

deviation of noise. It is Values outside of this range
reported in percent of noise indicates head or cabling
of the A/R ratio. problems.
IRGAIN IRGAIN Preamp gain required to HemiPlus and Lt Hemi -

achieve the RAIR reading; 4±3
applies only to Hvy Hemi - 11 ± 3
transmission–type sensors If the gain changes, it is an
indication of dirt buildup,
changes in the chiller,
problems with the detector,
or lamp problems.
3BUS209559 rev K 6-37

OptiPak Sensor
Table 6-25 Range for OptiPak Standardize Limits
Host Computer Variable Name In Acceptable

Reporting Name OptiPak Health Variable Description Range
Report
Full Scale Volts FULL Maximum output voltage of Formation: 0.17

each OptiPak component with ± 0.025 VDC
nothing in the gap. Opacity: 5.0 -
NOTE: Due to lamp brightness 9.5 VDC
decay, the signal strength may Brightness: 1.0 -
lose up to 15% in each year of 4.5 VDC
operation.
Zero Volt ZERO Minimum output voltage of the 0.18 ± 0.025

Brightness and Opacity sensors VDC
with the source turned off.
Vacuum Volts Vacuum The vacuum signal with no 5.0 ± 0.146

process in the gap. VDC
Full Scale Noise Variance of full scale voltage Formation: 0.0

during standardize ± 0.0000015
VDC
Opacity: 0.0 ±
0.000015 VDC
Brightness: 0.0
± 0.000007
VDC
Zero Noise Variance of voltage during Opacity: 0.0 ±

standardize with detector 0.000001VDC
clamped Brightness: 0.0
± 0.000001VDC
6-38 3BUS209559 rev K

Ash Sensor
Figure 6-28 Ash Sensor Health Report - Standardize Limits

See Table 6-26 below for the acceptable range of standardize limits for the Smart Ash Sensor
Table 6-26 Range for Ash Sensor Standardize Limits
Host Computer Variable Name In Variable Description Acceptable Range
Reporting Ash Health
Name Report
AIZ Zero Voltage output of the electrometer 0.0 ± 1.0 VDC

with shutter closed. (If BW exist in
system this value is measured with
BW shutter open.)
SIGMAZ Zero Noise Standard deviation of the <0.01 VDC

electrometer signal with shutter
closed.
AISOUT Nominal Flag Out Voltage output of the electrometer 7.3 ± 1.9 VDC
with nothing in the gap.
SIGMAGO Noise Range - Standard deviation of the TBD

Flag Out electrometer output signal with
nothing in the gap.
AISIN Nominal Flag In Voltage output of the electrometer (45% to 85% of

with nothing in the gap. AISOUT) ± 1.0 VDC
(See note below)
SIGMAGI Noise Range - Standard deviation of the TBD

Flag In electrometer output signal with
nothing in the gap.
Note: After determining what the AISOUT value is, make sure that the AISIN
value falls to within the 45% to 85% range of AISOUT. Determine the
percentage by calculation. Set nominal for AISIN so that it is the correct
percentage of AISOUT.
3BUS209559 rev K 6-39

Gloss Sensor
Table 6-27 Standardize Limits for the Gloss Sensor
Variable Name
Host Computer In Gloss Health Acceptable
Reporting Name Report Variable Description Range
stdzAdjNominal Nominal value for limit 1.71 VDC

checking the maximum signal
output on air. It should be
about 1.7 VDC.
stdzAdjRange Range limit of the maximum ± 1 VDC

signal output on air. It should
be set to 1 VDC.
stdzZeroOffset- Nominal value for limit 0.26 VDC

Nominal checking the minimum signal
output with the measurement
clamp. It should be about 0.06
VDC.
stdzZeroOffset-Range Range limit of the minimum ± 11 VDC

signal output with the
measurement clamped. It
should be set to 0.1 VDC.
6-40 3BUS209559 rev K

Verification
Background
Sensor verification is the process of determining if the measurement signals from the sensor are
being processed into correct measurement values at the Host. This can be done in an uncomplicated
manner by using standard check samples and comparing the results of on line measurements to
those known values.
If you have trouble verifying sensor performance, then you would want to use a more vigorous
methodology to examine sensor performance.
Initial verification of sensor performance can be accomplished using the Service Workstation and
the sensor Health Reports. For long-term verification for sensor performance, refer to the sensor
verification procedures in your Host documentation.
It is important to organize the sensor verification process into distinctive phases with a different set
of procedures and goals for each phase.
Phase I - Initial Static Verification

The purpose of this activity is to verify that the Network Platform and its associated sensors have
been properly installed and adjusted and that all calibration constants are correctly entered. During
this phase, the measurement system is also tested for stability and repeatability, to assure that it is
ready to start the on–line measurement. Typically, this program takes one day.
Phase II - Process Measurement Verification

This phase of the program has the goal of verifying on–line measurement during dynamic conditions
to the customer laboratory standards, on some of the key grades of paper being run in the process.
This phase is usually 1-4 weeks depending on the number and type of sensors.
Phase III - Continuing Certification

The purpose of this phase is to ensure that long-–term measurement performance is stable, and to
alert about any potential problems before any degradation can happen in measurement quality. This
phase is organized to give a reliable long-–term performance record to the system by means of
simple, periodic checks, and record keeping. By definition, this phase lasts for the life of the
system.
Implementation of the Sensor Verification Program

A major portion of Phase I can be implemented using only the Service Workstation and the Network
Platform.
Activities include:
• Reading of all of the check samples
• Recording standardize stability
• Recording check sample repeatability
• Recording internal check sample readings
• Verifying calibrate sample function operation
• Scanning on air gap and on samples to verify static profiles (requires Host system)
3BUS209559 rev K 6-41

• Generation of Phase I verification results report.

Phase II and Phase III are implemented using mostly the Host computer reporting and graphing
packages.
6-42 3BUS209559 rev K

Air Profile Compensation for Ash, Basis Weight, Caliper

& OptiPak
Air profile compensation (APC) allows for any mechanical misalignments of the platform without
degrading the measurement performance. During the data collection mode of the APC, the system
allows the sensor head to traverse the entire measure limits of the frame (the maximum values
allowed for scan limits) without any process in the gap. During this time the system measures
deflection related measurement data. This data can be used to smooth out any errors in the
measurement due to platform irregularities.
Air Profile Collection

To use APC the system needs to collect an average air profile. The data collection can be done by
using a combination of Host and Workstation commands.
To collect enough data the sensors must measure a minimum number of scans, the SWS controls
this operation and ensures 10 scans are completed. It is important that Head Package isn’t taken off
sheet until SWS has completed the 10 scans.
Note: Unless otherwise noted all steps are performed from the Service
Workstation.
1. If auto edge of sheet is in use, turn it off using the Host system command.
2. A sheet break must be present for APC to work. The frame digital input bit must see it.
3. Put the system in Work Station Control.
4. Perform a standardize
5. If an Optipak sensor is present, place a sample of the process that simulates the typical
process in the gap of the OptiPak.
6. Set the sheet-break override.
7. On the Frame Health Report specify that air profile collection is desired. Select the check
box labeled “APC Collection On”.
8. If necessary place the frame on sheet at the frame control panel.
9. Request the system to scan by selecting scan from the Workstation Control panel.
10. From the same Health Report, as in step 8 there will be a message indicating the system is
in air profile collection mode and it will indicate the number of scans that have been
completed.
11. Let the system scan 10 times and it will automatically terminate.
12. Select “Use Air Profile Compensation’ from the “Current” tab on the control panel for each
sensor to be compensated.
13. Use the “Save Scanner Configuration” under the “Tools” menu above the header to save
the changes.
14. Take the platform out of Workstation Control.
15. Turn auto edge of sheet back on if it was in use.
3BUS209559 rev K 6-43

Enabling/Disabling APC for Normal Measurement

1. Select “Use Air Profile Compensation” from the “Current” tab on the control panel for
each sensor to be compensated.
2. If this is to be the normal mode of operation, use the “Save Scanner Configuration”
under the “Tools” menu above the header to save the changes.
6-44 3BUS209559 rev K

Default Compensations for IR Moisture, Microwave & Ash

Sensors
IR Moisture, Microwave, and Ash sensors are dependent sensors requiring compensation from other
process parameters. The requirements for each sensor are as follows:
Dependent Sensor Compensation Required
Basis Weight (in 2-Filter mode)

IR Moisture Sensor
Ash (in 4-Filter mode)
Basis Weight
Microwave Sensor
Sheet Temperature (optional)
Basis Weight
Ash Sensor
Moisture
Table 6-28 Compensation Requirements
Each of these sensors must have their compensating input values established within the Host
Computer Grade File for each customer grade, even if the sensor has been configured to use the
internal (measured) value for its compensation. This is so that, if the internal (measured) value
becomes unavailable for one reason or another, there will be a reasonable compensation signal
available for the dependent sensor coming from the Grade File. Refer to the Host computer
documentation for details on setting up the respective Grade Files.
3BUS209559 rev K 6-45

Calibrate Sample - Minimum Time Data Accumulation

The Calibrate Sample function provides a real-time report of the active measurement performance
of all the operational sensors on the Network Platform. The data collection operates in parallel with
the normal measurement processing taking place so that there is no interference with data being
delivered to the host computer system. The Calibrate Sample procedure is available any time the
measurement head is on-sheet and measuring.
There are two methods of operation:
• Holding the Calibrate Sample push button down for the duration of the data collection.
The Calibrate Sample push button is the “scissors” push button located on the Frame
Control Panel. You can hold down the push button for as long as desired, with no
upper limit.
• Press and release the Calibrate Sample push button and allow the internal timer to
dictate the duration of the data collection.
The default time is 5 seconds. This time may be modified in the configuration under
the variable labeled “CalibrateSampleProcessTimeout”. The variable
CalibrateSampleProcessTimeout is located under Scanner in the SensorManager tab.
6-46 3BUS209559 rev K

Heated Air Wipe Installation

The heated air wipe feature helps alleviate measurement problems caused by steam condensate.
Typically the sensor measurements impacted are moisture hemi+ and microwave. On hemi and
reflection ir sensors the HAW replaces the existing non heated Coanda air wipe. In high steam
applications water may condense on sensor glass windows or the cooled aluminium top plate,
pooling, then flowing onto the measurement window. This causing high moisture profile spikes.
On NP frames the heated air wipes are powered directly from 120Vac. The AC power neutral side is
not switched. The amount of heating is controlled by adjusting the air supply flow. The air is usually
taken from the frame head package top and bottom manifolds. Adjust the manifold port valve to
adjust the air flow. A typical starting point setting for the air flow is to achieve an air temperature
exiting through the air wipes of 50 to 60 degrees Celsius. Alternatively, using a clamp on ampmeter,
adjust the air flow to achieve 1.5 ± 0.2 A of heater current. Then adjust the air flow to fine tune as
the application requires.
The air pressure at the top and bottom head package air manifolds should be 40 ± 1 PSI before and
after adjustment.
The heated air should blow in the opposite direction to the Basis Weight sensor as it can disturb its
stable air gap. In extreme cases where there is no alternative but to blow the heated air towards the
basis weight gap quantify any measurement disturbance by collecting profiles with the air on and
with the air off and compare results. Do similar for standardize. Adjust the air wipe to minimize any
disturbance.
Heated air wipes can also be mounted on the side of specially modified head package covers.
3BUS209559 rev K 6-47

7 Control Panel Operation

The basic operations of the Network Platform are managed by the control panel. This chapter
describes the operations that can be performed using the control panel.
Section ...............................................................................................................Page
Control Panel Description ............................................................................7-2
Network Platform Modes of Operation ........................................................7-3
Control Panel Functions ..............................................................................7-4
Head Separation ...........................................................................................7-7
Limit Switches ..............................................................................................7-8
3BUS209559 rev K 7-1

Control Panel Description

The control panel consists of a covered key pad with 12 keys and two sensor shutter indicator lights.
A control panel is located on each end column of the Network Platform. Refer to the control panel
in Figure 7-1 below.
Shutter Closed Shutter Open

Indicator Indicator
Off Sheet On Sheet Enable
Local Remote
Jog Reverse R F Jog Forward
Calibrate Sample Sample Check
Clean Standardize Maintenance
Set Reverse Limit R F Set Forward Limit
LED located on R
each push button
Figure 7-1 Network Platform Control Panel

When a control panel push button has been pressed, the request is acknowledged by a small LED
located in the upper left corner of the button, as shown in
Figure 7-1 above. For some control panel push buttons, the LED will remain on while the push
button is being pressed or while a function is being performed. For other control panel push
buttons, the LED will remain on until another push button has been pressed, placing the Network
Platform in another mode.
7-2 3BUS209559 rev K

Network Platform Modes of Operation

The control panel has four modes of operation that allow different levels of Host computer control.
The control panel’s modes of operation are described below.
Remote/On-Sheet
In the Remote/On Sheet mode, the Host computer has total control of the Network Platform. The
Host computer is able to request the Network Platform to measure, standardize, or other remote
operations.
While the Network Platform is in the Remote/On Sheet mode, the REMOTE and ON SHEET push
button LEDs are on.
Remote/Off-Sheet
In the Remote/Off-Sheet mode, the Network Platform is still communicating with the Host
computer system, but it will refuse any Host requests to measure or standardize, but permits sample
check and local mode operations.
While the Network Platform is in the Remote/Off–Sheet mode, the REMOTE and OFF SHEET
push button LEDs are on, and the sensor head package is in the off-sheet position on the Network
Platform.
When a sheet break is detected on the paper machine, the sensor shutters close, the sensor head
package moves to the off–sheet position, and the Network Platform enters the Remote/Off–Sheet
mode automatically. Head tracking errors, inherent sheet break, and AEOS errors will also cause
the platform to automatically enter the Remote/Off–Sheet mode.
The Network Platform must be in the Remote/Off–Sheet mode to perform sensor sample checks.
While in the Remote/Off–Sheet mode, the STANDARDIZE push button on the Network Platform
control panel is enabled, but any standardize results will be reported through the Service
Workstation, not the Host computer.
Local
In the Local mode, all communications with the Host computer are disabled. The sensor shutters
will not open and the Network Platform will not scan.
When the Network Platform is in the local mode, the LOCAL push button LED is on and the On
Sheet, Off–Sheet, and Remote LEDs are off.
The Local mode enables the control panel JOG and SET SCAN LIMIT push buttons.
Local/Head Split
In Local/Head Split mode, all communications with the Host computer are disabled, and the
Network Platform drive mechanism is disengaged. The exception is the Smart Color Senor, Primary
Calibration, Check Sample, Dye Sample and other utilities may be run while the heads are split.
The Network Platform enters Local/Head Split mode when the drive clutch is disengaged by
loosening the clutch nut on a manual clutch frame or by the head split switch, on air clutch frames,
located in each of the Network Platforms end columns. The Network Platform also enters this mode
when the air supply to the air clutch drops below the correct pressure.
Since the drive mechanism is disabled in local/head split mode, the sensor head package can only be
positioned by hand.
3BUS209559 rev K 7-3

Control Panel Functions

The functions of each of the control panel push buttons is described below.
Off-Sheet
If the Network Platform is in remote, pressing the OFF SHEET push button places the Network
Platform in Remote/Off–Sheet mode.
If the OFF SHEET push button is pressed while the Network Platform is scanning or standardizing,
the sensor shutters close and the head package moves to the off–sheet position.
On-Sheet
If the Network Platform is in remote, pressing the ON SHEET push button places the Network
Platform in Remote/On Sheet mode. When the ON SHEET LED is lit, it permits the Host to direct
the head to standardize or measure.
Local
Pressing the LOCAL push button places the Network Platform in Local mode.
If the Local push button is pressed while the Network Platform is scanning or standardizing, the
sensor shutters close and the head package remains in place.
Remote
Pressing the REMOTE push button places the Network Platform in Remote/Off-Sheet mode, if the
Network Platform is currently in Local mode.
R F
Jog
The JOG push buttons are used to position the sensor head package manually, anywhere between
the mechanical limit switches of the Network Platform. The FORWARD JOG push button (F)
moves the head package towards the far side end column. The REVERSE JOG push button (R)
moves the head package toward the home end column. If an illegal limit is requested the LED in the
pushbutton will flash until a legal limit is selected.
Calibrate Sample (Sample Cut)

While the CALIBRATE SAMPLE push button is pressed, the Network Platform begins a special
accumulation of measurement single point or profile data. When the push button is released, this
data is forwarded to the Host computer where a Calibrate Sample report is printed.
7-4 3BUS209559 rev K

The CALIBRATE SAMPLE push button LED is on while the measurement data is being
accumulated, and while the data is being sent to the Host computer.
The CALIBRATE SAMPLE push button functions only when the Network Platform is measuring in
the Remote/On Sheet mode and the sensor is in the measurement mode, either scanning or in single
point.
Sample Check
The SAMPLE CHECK push button requests the sensors to take a sample check measurement. The
push button LED is on while the measurement is being taken.
The SAMPLE CHECK push button operates only if the Network Platform is in the Remote/Off-
Sheet mode. No report will be sent unless the Sample Check mode is enabled at the Host computer.
However, a local report is available through the Sensor Health Report.
Standardize
Pressing the STANDARDIZE push button requests the sensors to perform a standardize. The
standardize will be either CLEAN or DIRTY depending on the setting of the
CleanSTDZDefaultFromPanels Frame configuration item. The push button LED is illuminated
during the standardize cycle. If any of the sensors fail the standardize, the LED flashed until the
sensors all pass standardize. Standardize reports are available through the HOST display, or through
the HEALTH REPORTS at the Service Workstation.
The sensors will do a CLEAN or DIRT standardize depending on the state of the Default Stdz Type
flag associated with each sensor object. If the flag is a “0”, the standardize will be a DIRT one. If
the flag is a “1”, then the standardize will be a CLEAN one.
Self Test
The Self Test push button serves as a lamp test for the LEDs on the panel, as well as being able to
initiate a check on the positioning subsystem operation when the scanner is in the LOCAL mode. In
all scanner modes except LOCAL, when the Self Test push button is pushed, the various LEDs on
the panel will sequentially light up momentarily to indicate their condition. This test has no impact
on what other functions the scanner is performing at the time.
When the scanner is in LOCAL, the function of the Self Test push button changes to include a check
on the positioning subsystem. Under the LOCAL condition, the initial push of the button will start
the usual LED lighting cycle, but when released, the OFF SHEET LED will extinguish and the
scanner will attempt to resynchronize the encoder. The following sequence will take place.
 unsynchronizes the encoder
 moves the head package to the home limit switch
 resynchronizes the encoder
 stops the head package immediately after coming off limit switch
Note: The test can be started with the head located anywhere along the frame.
When the test starts the head will move toward the home limit switch at a
slow speed. If there is a need to stop the head at any time during this
3BUS209559 rev K 7-5

transition, simply press the LOCAL push button once more, stopping the
head. This will terminate the self-test request.
The actual check being performed in this test, is to verify that the encoder count at the point of the
head coming off the limit switch, matches the count when the encoder was initially synchronized.
Any error in this will result in the push button LED flashing. In this case, run the test again to clear
the alarm and check the debug for position control logic to see the details of the encoder’s history.
It is possible that the test failure may only be the result of the system having lost some counts during
an earlier scan. In that case, the Encoder Diagnostic screen should be visited periodically to make
sure that the condition is not a chronic one. Some things which can cause failure (in order of likely
hood) are:
• Defective encoder
• Defective encoder mounting (slipping)
• Defective Home Limit Switch
• Defective cabling from encoder to the Standard Signal Interconnect Board (SSIB)
• Defective Standard Signal Conditioning Board (SSCB)
• Defective Data Acquisition Card
R F
Scan Limit Set
The LIMIT SET push buttons set the measured sheet edge limits for Smart Platforms without auto
edge–of–sheet (AEOS) or when AEOS is disabled.
The FORWARD LIMIT button (F) sets the limit near the drive (far) end column of the Network
Platform. The REVERSE LIMIT button (R) sets the limit near the idler (home) end column.
The LIMIT SET push buttons are enabled only when the Network Platform is in Local mode.
The LIMIT SET push buttons also serve to activate automatic frame tuning when the Network
Platform is in the Remote/Offsheet mode. Pressing these buttons together and holding for 10
seconds or more will invoke the utility. See Frame Tune on page 5-12
The LIMIT SET push buttons only function for setting scan limits when the Network Platform is in
Local mode.
7-6 3BUS209559 rev K

Head Separation
To Split the Heads
1. Move the sensor head package to the off sheet position.
2. Place the platform in Local by pressing the LOCAL push button on the control panel.
3. Activate the air clutch head split switch, located in either end column.
On manual clutches, disengage the clutch by loosening the clutch nut three turns.
Note: Deactivating the clutch trips a switch which also causes the platform to enter
the local mode.
4. Manually separate the lower head package.
To Restore the Heads

1. Move the sensor heads back as close as possible to their original position.
2. Return the air clutch switch to its original position.
On manual clutch frames, tighten the clutch nut until the washer is fully compressed,
then tighten the clutch nut one additional flat.
3. Return to normal system operation.
3BUS209559 rev K 7-7

Limit Switches
Limit switches are used to stop the motor before the mechanical limit. Two non-contacting devices
(proximity switches) are used in conjunction with metal targets as limit switches. The proximity
sensors sense the presence of metal and give a logic level output if metal is detected.
Figure 7-2 illustrates the mounting of the two switches (one on the drive column and one in the
idler end column top section)
Figure 7-2 Limit Switch Locations
Proximity Switch A is mounted in the upper beam at the idler end and will be activated by a metal
target on the carriage when the head is approximately 100 mm from the end column mechanical
stop. This proximity switch is also the position reference for the encoder system. See Figure 7-3.
Figure 7-3 Idler End Proximity Switch A
7-8 3BUS209559 rev K

Proximity switch B is mounted in the end column on the drive end, but is sensing the belt target, not
the carriage. See Figure 7-4. The metal target activates the proximity switch when the head is
approximately 100 mm from the drive end column mechanical stop. The metal target is adjustable
by its location on the belt.
Figure 7-4 Drive End Proximity Switch

Each proximity switch has a built-in LED indicator. The proximity switch model is using a normally
closed output function. With no target present, the output is closed and the LED is on. When a target
is present, the output is open and the LED is off.
The proximity switches should be adjusted to a normal sensing gap of approximately 3 mm (1/8”)
from the target. They are specified to operate up to at least 4 mm from a stainless steel target. A gap
that is too small can cause mechanical contact or damage. Check adjustment after replacement or
maintenance, and verify LED operation on the proximity switch with the target on and off.
Figure 7-5 Detail of Proximity Switch

The idler end proximity switch sets the absolute positioning of the encoder system for profile and
CMC operation, and cannot be relocated in the CD direction. The on sheet (drive side or front)
proximity switch can be adjusted to suit a safe maximum travel, considering ropes and other
obstructions.
The procedure to set the front limit switch is as follows:
1. Jog the heads to the position where the switch is to start engagement at the drive end of
the frame.
3BUS209559 rev K 7-9

2. Attach the stainless steel target strip to the belt with three small tie wraps at the drive
side, facing the proximity switch, such that the activating edge is at the proximity
switch.
Figure 7-6 Attachment of Metal Target

There is also a mechanical safety stop shipped with the frame. This should be mounted on the beam
at the drive end such that it acts as a final safety. The safety mechanical stop should be located
approximately 4 in. (100 mm) away from the electrical stop. See Figure 7-7.
Figure 7-7 Safety Mechanical Stop Position
7-10 3BUS209559 rev K

8 Startup Options
The Network Platform starts up automatically when powered on. For reset and options see the
Network Platform Software Procedures Manual 3BUS209544l.
3BUS209559 rev K 8-1

9 Maintenance Procedures
Section .............................................................................................................Page
Network Platform Maintenance Log ............................................................9-2
Inspecting the Incoming Power ...................................................................9-4
Inspecting the Drive System ........................................................................9-5
Carriage Wheel Inspection .........................................................................9-13
Platform Alignment Inspection ..................................................................9-14
Scan Direction Alignment Inspection ........................................................9-15
Air Purge Filter Inspection .........................................................................9-16
Inspecting the Compressed Air Filter Regulators & Filters .....................9-18
Inspecting the Water Filter .........................................................................9-21
Power and Temperature Checks ...............................................................9-22
3BUS209559 rev K 9-1

Network Platform Maintenance Log
(Subsequent Maintenance Log) START DATE

MAINTENANCE ITEM SCHEDULE (MONTHS)
1 2 3 4 5 6 7 8 9 10 11 12
DRIVE CHECKS
1. Check upper/lower drive

belts with tensiometer
2. No evidence of wear or
cracks in belts
3. Motor Drive Belt Tension

(Tight enough to eliminate
possibility of the belt
derailing)
4. Upper/lower Seal Belt

Tension (uniform seal
provided and no gaps in
seal exist) 2
5. Head Separation Clutch
Operation
WHEEL CHECKS
1. Upper/lower Carriage
Wheels

Roller Assembly
ALIGNMENT CHECKS
1. Air Profile Check 3
2. Scan Direction Alignment
UTILITY CHECKS
1. Air Purge Filter
2. Compressed Air Filters.
3. Water Filter
1 Check upon replacement and at three weeks after replacement.

2 Check upon replacement and at one week after replacement.
3 Check at four week intervals when the process is not running.
9-2 3BUS209559 rev K

Scanning Plat form Maintenance Log

(Subsequent Maintenance Log) START DA TE: ___________
SCHEDULE (MONTHS)
MAINTENANCE ITEM
1 2 3 4 5 6 7 8 9 10 11 12
DRIVE CHECKS
1. a. Check upper/lower drive

belts with tensiometer.
b. Check pulleys for lubrication
c. Check belt tracking on 1
on page 9-6
2. No evidence of wear or
cracks in belts
3. Motor Drive Belt Tension
(Belt should deflect .12 - .25 in.
(3.0 – 6.3 mm) with finger
pressure)
Tension (uniform seal
provided and no gaps in
seal exist) on page 9-9 2
5.
WHEEL CHECK
1. Upper/lower Carriage
Wheels
2. Upper/lower Seal
Belt Roller Assembly
ALIGNMENT CHECKS
1. 3
Air Profile Check
2. Scan Direction Alignment
UTILITY CHECKS
1.
Air Purge Filter on page 9-16
. 4
2. Compressed Air Filters

4
on page 9-18
3. Water Filter on page 9-21
4
1 Check upon replacement and at three weeks after replacement.

2 Check upon replacement and at one week after replacement.
3 Check at one month intervals when the process is not running.
4. Schedule for maintenance depends upon installation circumstances and mill conditions.
3BUS209559 rev K 9-3

Inspecting the Incoming Power

Verify the presence of incoming power at the idler end column. The power for the Network
Platform comes through a transformer. The voltage to the transformer must be of a nominal level
(200, 208, 220, 230, or 240 volts) to connect to one of the taps on the primary. The long-term
variations from the nominal voltage must not exceed ±10%.
Example: A 220 volt primary voltage must not average less than 198 VAC or
greater than 242 VAC for longer than one second.
9-4 3BUS209559 rev K

Inspecting the Drive System

The drive system consists of several belts that must be checked periodically for proper tension and
damage or defects. Complete the following procedures to perform the drive checks.
When performing any maintenance operation in the

carriages, always lock out the drive motor power
using the lock-out switch at the drive end column.
Refer to Figure 9-1 on page 9-5.
MOTOR ONLY
A
B
B
Lock Out
Switch
Figure 9-1 Network Platform Lockout Switch Location
3BUS209559 rev K 9-5

Carriage Drive Belt Tension Inspection and Measurement

1. Inspect the upper and lower opaque plastic steel wire reinforced scanner drive belts for evidence
of wear or damage.
2. If either the upper or lower drive belt exhibits serious cracks or edge wear , replace both drive
belts with a matched pair. Replacing both belts with a matched pair will prevent uneven wear
of the belts. Cracks may indicate a future failure of the drive belt.
3. These drive system pulleys and belts should be lightly lubricated with green Teflon® grease
part 100772-001. This to prevent friction and friction noise during scanning and aid long life
performance.
4. Use the ABB scanner belt tension measuring tool to measure and record the tension of these
upper and lower scanner drive belts.
5. Perform the belt tension check as follows.
6. Squeeze the handle of the tension gauge and place it on the drive belt making certain that the
pivot arm is centered on the belt during adjustment. The gauge must be applied to the portion
of the carriage drive belt that traverses the Network Platform.
7. Release the handle and read the tension indication on the gauge. The tension should be in the
range specified in Table 10-1 Belt tension for various scanner lengths. on page 10-8 .
8. If the tension is outside of that range, adjust the idler pulley tension adjustment screws until the
tension is proper. Refer to Figure 9-2 on page 9-7.
9. The belts are a matched pair. This means they have been cut side by side from one wider piece
of belt material. Each belt should measure the same tension.
10. Tighten the adjustment lock when finished.
Carriage Drive Belt Tension and Tip Adjustment

Refer to Figure 9-2 on page 9-7.
Observe the idler pulleys on the Network Platform while the sensor heads are scanning. If the drive
belt climbs up or down on the idler pulley, adjust the pulley tip by completing the following steps:
1. Loosen the tip adjustment lock.
2. Tighten the tip adjustment if the belt tracks to the upper edge of the pulley.
3. Loosen the tip adjustment if the belt tracks to the lower edge of the pulley.
4. Observe the idler pulleys while the sensor heads are scanning. If the drive belt climbs up or
down on the idler pulley, repeat Step 2 or 3.
5. Tighten the tip adjustment lock.
Note: Tighten the pulley shaft bolt. Do not make adjustments to the drive pulley.
The drive pulley has been factory adjusted to ensure precise dimensional
measurement between the drive shaft, the belts, and the pulley.
9-6 3BUS209559 rev K

Figure 9-2 Drive Belt Measurement and Adjustment
3BUS209559 rev K 9-7

Drive End Motor Belt Inspection

At each service inspection check the motor drive belt for:
 Surface cracks
 Corrrect belt tension
 Check that the belt is not mounting the pulley wheel side flanges
Refer to the Drive Motor Belt Replacement and Inspectionon page 10-2
Gear Reducer Drive Motor

Assembly
Motor
Mounting
Bracket
Drive Mounting
Adjustment Bolts
Figure 9-3 Drive Motor Belt Check and Adjustment
Drive Shaft Inspection

Lock the scanner drive motor rotary power switch to prevent scanner movement. Inspect the drive
shaft. Look under each bearing for any metal dust. The presence of dust indicates bearing and / or
drive shaft wear. Grab the shaft by hand at several locations and forcefully try to shake it. Any
movement indicates bearing wear. Split the heads and repeat. When bearing wear is suspected the
complete drive shaft assembly should be replaced. Grease the bearings if required.
These bearings are factory lubricated with a lithium or lithium complex base grease which is
suitable for most applications. However, extra protection is necessary if the bearing is subjected to
excessive moisture, dust, corrosive vapour or other harsh environments. In these cases, the bearing
should contain as much grease as speed will permit (a full bearing with consequent slight leakage
through the seal is the best protection against contaminant entry).
For re-lubrication, select a grease that is compatible with a lithium or lithium complex* grease. The
following table is a general guide for normal operating conditions. When establishing a relubrication
schedule, note that a small amount of grease at frequent intervals is preferable to a large amount at
infrequent intervals.
The amount of grease that the bearing will take for a particular high speed application can only be
determined by experience. If excess grease in the bearing causes overheating, it will be necessary to
remove grease fitting to permit excess grease to escape.
9-8 3BUS209559 rev K

Figure 9-4 Drive Motor Belt Check and Adjustment
Seal Belt Tension Inspection

Inspect the seal belts. The seal belts must have enough tension so that a seal is present along the length
of the platform but not too much so that the carriage seal belt roller is deflected up causing a break in the
cable seal. Refer to Figure 9-5 below. The tension on the seal belts must be even on each side of the
belt. If this is not the case, the carriage seal belt roller will be deflected up on one end.
Seal Tension Seal Belt

Adjusted Too
Tightly Carriage Seal
Belt Rollers
Extrusions
Seal Tension
Adjusted
Unevenly
Seal Belt
Seal Tension
Adjusted
Properly Seal Belt
Figure 9-5 Seal Belt Tension Checks
Head Separation and Limit Switch Inspection

Refer to Figure 9-7 on page 9-12 and Figure 9-6 on page 9-11. Verify the operation of the head
separation clutch by completing the following:
1. Move the sensor head package to the off-sheet position.
2. Place the platform in Local by pressing the LOCAL push button on the control panel.
3. Verify that the shutter closes on the Basis Weight and Ash sensors.
3BUS209559 rev K 9-9

4. Activate the head separation switch located at either end of the Network Platform in the service
outlet box. On manual clutch frames, disengage the clutch by loosening the clutch nut three
times.
5. Make sure the sensor heads can be separated by manually moving the bottom head.
6. Move the sensor heads back as close as possible to their original position.
7. Return the air clutch switch to its original position.
8. Manually position the sensor heads to make sure the air clutch has been properly seated and
locks when the proper position is reached. On manual clutch frames, check the clutch pins to
see if they need lubricating. Tighten the clutch nut until the washer is fully compressed then
tighten the clutch one additional turn.
9. Return to the normal system operation.
10. Manually jog the sensor package to the drive and idler ends slowing the rate of travel as they
reach the end of the platform.
11. Verify that the drive motor stops when the limit switch is tripped.
9-10 3BUS209559 rev K

Figure 9-6 Manual Clutch Head Separation
3BUS209559 rev K 9-11

Figure 9-7 Head Separation Switches
9-12 3BUS209559 rev K

Carriage Wheel Inspection

The carriage wheels should be checked periodically for wear or damage in the material. Failure to
do so may result in expensive damage to the scanner laser aligned waybar. Complete the following
steps to check the carriage wheels:
1. Put the Network Platform in Local mode.
2. Jog the sensor package to the drive end of the Network Platform so that the carriage wheels are
visible at that end.
3. Check for proper wheel and way bar contact.
4. Jog the sensor package slightly to inspect portions of the wheel that are hidden by the carriage.
5. Replace carriage wheels that exhibit wear, surface marks or holes or similar damage.
6. Jog the sensor package to the idler end of the Network Platform so that the carriage wheels are
visible at that end.
7. Check for proper wheel and way bar contact.
8. Jog the sensor package slightly to inspect portions of the wheel that are hidden by the carriage.
9. In extreme cases where the waybar has been marked by poorly maintained and/or damaged
wheel assemblies see the spare parts section of this manual for alternative extended length
wheel set part numbers. These re-position the wheels onto a previously unused part of the
waybar.
When performing maintenance operations to the

carriage or platform, always lock out the drive motor
power on the lock–out switch at the drive end
column.
MOTOR ONLY
3BUS209559 rev K 9-13

Platform Alignment Inspection

The alignment inspection recommended for the Network Platform consists of running an air profile
at four-week intervals during a time when the process is not running. Complete the following to
perform an air profile:
1. Scan the sensor package with at least ten scans without the process in the gap. The composite
profile weighting factor should be set up for 10 scans.
2. Select and observe the Basis Weight profile on the video monitor.
3. Compare the profile to the profile taken at installation. They should not differ more than 0.1
grams per square meter (g/m2). Consult your measurement specialist if the profiles differ more
than this amount.
9-14 3BUS209559 rev K

Scan Direction Alignment Inspection

Scan direction alignment is recommended at six-month intervals. To complete a scan direction
alignment, follow the steps below.
The scan direction alignment is checked both close to the drive end column and close to the idler
end column on the scanner.
Alignment at the drive end is set by drive pulley phase adjustment. Alignment at the idler end is
controlled by belt tension.
The scan direction alignment procedure is as follows:
1. Jog the sensor heads near the drive end column.
2. Apply a straight edge and feeler gauge to the machined surface on the upper and lower sensor
heads. Refer to Figure 3-18 on page 3-32.
The machined surface should be flush within ± 0.01 in. (0.25 mm). If they are not:
a. Loosen the upper drive belt pulley locking screws.
b. Adjust set screws for phasing of the pulley until the heads are parallel.
c. Tighten the screws when finished.
3. Jog the heads near the idler end column.
4. Apply a straight edge and feeler gauge to the machined surface on the upper and lower heads.
5. If they are not aligned in the scan direction within ± 0.010 in, adjust belt tension in upper or lower
belts by means of the idler bracket adjustment screws. See Figure 3-19 on page 3-33.
3BUS209559 rev K 9-15

Air Purge Filter Inspection

The Network Platform requires a constant flow of filtered air to keep the electronics and
mechanisms at a safe temperature and to prevent contaminants from entering the sealed platform.
If the platform is utilizing DC motor cooling air from the mill air system, there are no extra filters
needed.
If the platform is using the ABB supplied high capacity purge blower Part Number 101495-006, -
007 or -008 the filters need to be cleaned periodically to maintain good air flow. The frequency of
cleaning the filters depends upon mill conditions. The presence of good air flow is easily detected
by opening the doors on the idler side of the Network Platform.
The high capacity purge blower is intended to provide better SP Frame reliability under all
environmental conditions. The circuit breaker is rated at 15.0A for the high capacity purge blower.
The high capacity purge blower draws between 5 and 9 AMPs at 230 VAC during normal operation.
The highest current will be observed when the damper is fully open.
Purge Blower Replacement Process

Note: Purge blowers used before October 1995 used a low capacity purge
blower, Part Number 101495-003. This item is no longer being used. A
high capacity purge blower, Part Number 101495-007 is now being shipped
and replaces the low capacity purge blower.
If the low capacity purge blower fails, you will need to order the high capacity blower assembly.
The following assemblies are available for specific application requirements:
123595-008 Purge Blower Assembly without cabinet and

with High Capacity Purge Blower
127323-011 Blower Assembly without cabinet and with

High Capacity Purge Blower
127323-012 Blower Assembly with stainless steel cabinet

and High Capacity Purge Blower
Table 9-1 Purge Blower Part Numbers
Note: Some earlier shipments of the high capacity purge blower with Smart
Platform contained the wrong circuit breaker. If you replaced the low
capacity purge blower with the high capacity purge blower, check the circuit
breaker for the correct rating. If you are experiencing startup or run trips,
check the circuit breaker rating. If incorrect, order the correct rating, 15.0
A, ABB Part Number 014847-108.
9-16 3BUS209559 rev K

Cleaning the Air Purge Filter

Cleaning the Air Purge Filter depends on the paper dust levels. If there is a high level of dust, the
filter should be checked and cleaned at least once a day. If there are lesser amounts of paper dust,
then the interval should be a minimum of every other day.
If the Air Purge Filter requires frequent cleaning, you might consider relocation of the blower to a
cleaner environment. Failure to check and clean the filter will cause premature failure of the purge
blower motor and frame down time.
1. Turn off power to the purge blower using the switch on the blower.
2. Turn off the power at the power distribution center.
3. Remove the cylindrical fiber filter.
4. Blow compressed air into the inside of the filter to clean it.
5. If the metal screen filter is also dirty, clean it the same way.
6. Replace the filter. Restart the blower.
Note: Keep the Network Platform well sealed and the doors fully closed at all
times, except during maintenance. Positive air flow is required for reliable
operation.
3BUS209559 rev K 9-17

Inspecting the Compressed Air Filter Regulators & Filters

The Network Platform requires good quality compressed air. Air pressure to the platform must
never be below 4.5 bar (65 psi). Contaminants are filtered through the incoming air filters. The
frequency with which the compressed air filters are changed depends upon the amount of
contaminants in the mill air supply and the type of filter used. Inspect the filter once a week for the
first three weeks to gauge the frequency that the filter needs to be cleaned. The regulator has a
visual indicator showing the filter status. Green means the filter is should be ok. Check it at service
intervals anyhow. Red means the filter must be replaced. The air regulator has an automatic drain
feature, which means there is no requirement to manually drain water from the filter bowl.
Replacing the Scanner Compressed Air Filter

1. Press the OFF SHEET push button on the control panel.
2. Turn off the main AC circuit breaker at the Network Platform idler side power entrance
module.
3. Turn off the main air valve.
4. Remove the filter bowl(s) by turning anti-clockwise; See Figure 9-9 on page 9-20
5. To remove the pre-filter, unscrew the filter spool cap by turning anti-clockwise, the filter will
then slide off the filter spool.
6. To remove the main filter, unscrew it from the filter housing by turning anti-clockwise
7. To replace the filter(s), reverse the above procedure.
8. Use correct replacement filter catridge unit.
9. Turn on the main air valve.
10. Turn on power to the platform. Wait five minutes for stabilization, then perform a standardize.
11. The ABB scanner air regulator pressure gauges should be marked to highlight expected normal
operating pressures. Check the air pressure settings are correct.
9-18 3BUS209559 rev K

Figure 9-8 Air Filter Regulator and Status Indicators
3BUS209559 rev K 9-19

Figure 9-9 Filter Element Replacement
Note: If it is necessary to change the filter on a frequent basis, then the customer’s air supply
probably does not meet specifications. Water, oil, and dirt will cause maintenance
problems in the sensor’s hardware. If you suspect a problem, air quality/quantity testing
can be rerun. Running the test once yearly is a good idea to prevent future problems. Once
a system is contaminated, it stays contaminated.
9-20 3BUS209559 rev K

Inspecting the Water Filter

The maintenance schedule for the water filter will depend upon the amount of contamination in the
cooling water supply. Inspect the filter once a week for the first three weeks to gauge the frequency
that the filter needs to be cleaned. Follow the procedure below for maintenance to the water filter.
1. To perform maintenance that will take two hours or more, turn off the main AC circuit breaker.
2. When maintenance will be less than two hours, keep the Liquid Cooling Unit (LCU) pump
running and the platform scanning, while temporarily shutting down the mill water supply for
filter replacement.
The replacement procedure for the water filter will depend upon what type of unit was purchased.
When the filter unit becomes discolored replace it.
The replacement filter unit is shown in Table 10-9
3BUS209559 rev K 9-21

Power and Temperature Checks

Prepare weekly reports on the system power and board temperatures. Use the Voltage and
Temperature History tab of the Frames Health Report to print the last 20 occasions of DC power
levels and cabinet temperatures see Figure 9-10 below. Keep the weekly reports in a log for future
reference.
Figure 9-10 NP Workstation Frame Health Report

ASPC Power/Temp History
DC Voltage Level Checks

Check the four DC voltage levels. Any DC voltages exceeding limits will generate an Alarm in
SWS Health pages, make sure no alarms are reported. ±12V can be checked in Frame Health Report
under ASPC Power/Temp History. ±15 should be measured with DVM coming into ASPC
backplane on a monthly basis. The limits for each voltage are as follows:
± 12 volt supply ± 12.2 ± 0.6 VDC
± 15 volt supply ± 0.3 VDC
Cabinet Environmental Checks

Check the cabinet environmental temperature. Perform this check at least once a week using the
ASPC Power/Temp History under Frame Health.
Examine the report for excessive cyclical variations or heating trends. It may be possible to
correlate performance problems with heat problems.
9-22 3BUS209559 rev K

PROPRIETARY DATA: This document contains proprietary data of ABB Inc. No disclosure, distribution (electronic or otherwise), or other means
of dissemination may be made without written permission.
10 Replacement Procedures
Section ...............................................................................................................Page
Drive Motor Belt Replacement and Inspection .........................................10-2

Carriage Drive Belt Replacement...............................................................10-6
Idler Pulley Replacement ...........................................................................10-9
Carriage Wheel Assembly Replacement ................................................. 10-11
Seal Belt Replacement ............................................................................. 10-14
Seal Belt Roller Assembly Replacement ................................................. 10-16
Flex Cable Suspension Replacement ...................................................... 10-17
DC Power Supply Replacement ............................................................... 10-19
Motor Drive Controller Replacement – ACS to VLT................................ 10-27
Motor Drive Controller Replacement – Fincor or Lovejoy to VLT ......... 10-33
Position Encoder Replacement ............................................................... 10-34
Scanner Replacement Parts List ............................................................. 10-36
Replacement Parts for the ASPC ............................................................. 10-51
3BUS209559 rev K 10-1

Drive Motor Belt Replacement and Inspection

Use these procedures to replace the drive motor belt. Motor assemblys are factory fitted with a spare
belt which is wrapped around the drive shaft using a tie wrap. When this spare belt is available it is
easily fitted onto the motor pulley wheel. In such case one can skip steps 3 to 8 below. The belt is a
toothed timing belt. Increasing the belt's tension more than is required to keep it in contact with the
pulley is not recommended. The ideal belt tension setting is a lowest possible tension which does not
allow belt slip. Over tensioning the belt may lead to early belt failure and excessive stress load on the
drive system's parts which could result in earlier than expected failures.Belts can stretch or shrink with
age so check their tension and check for belt surface cracks at service intervals.
Refer to Figure 10-1, Figure 10-2,Figure 10-3, Figure 10-4.
1. Turn off the power to the drive motor.
2. Loosen the tension on the drive motor belt by completing the following:
a. Loosen the four drive motor mount bolts.
b. Loosen the drive adjustment screws.
c. Slide the assembly towards the drive shaft and take the belt off of the motor pulley.
Gear Reducer Drive Motor

Assembly
Motor
Mounting
Bracket
Drive Mounting
Adjustment Bolts
Figure 10-1 Drive Motor Belt

3. Disengage the air clutch by using the head separation switch so that the two drive shafts can move
independently.
4. Remove the two metric Allen screws that hold the collar to the shaft.
5. Remove the three SAE bolts on the mating collar.
6. Remove the collar which exposes a two–inch gap between the upper and lower drive shafts to
allow removal of the drive motor belt.
7. Replace the drive motor belt.
8. Replace the drive assembly and the carriage drive belts.
10-2 3BUS209559 rev K

There are three possible methods to set the drive belt tension.
Method ‘A’ using a Tension Meter measurement tool.

This is the recommended method and one used by the ABB manufacturing factory. The
recommended tool to use is a Sonic Tension Meter model 507C by Gates Corporation.
The value for the NP1200 scanner static tension range in newton is set to be 334 to 367 N
(34.06 to 37.42 Kgf., 75.09 to 82.50 lbf).
Instructions on using the tension meter are included with the device.
The recommended tension is the lowest tension within the range.
With the 4 mounting bolts loosened just enough to allow movement, tension the belt using the 2
position adjustment bolts.
When tensioning is set torque the 4 motor mounting screws to 8.47 Nm (75lbf-in).
Check the tension again after torqueing.
or
Method ‘B’ using a Force and Deflection method.
The objective is to set the deflection force to 2.4 to 2.63 Kgf (23.54 to 25.79 N, 5.29 to 5.80 lbf)
with a deflection distance of 2.54mm (0.1 inch). This correlates to the belt tension setup in method
‘A’.
The recommended tension is the lowest tension within the range.
Historically a variation of this method has been used.
It is now the least desirable of the two methods as it is difficult to be accurate and repeatable. Some
customers may wish to use this method until the method ‘A’ tension meter is available to confirm
correct belt tension.
With the 4 mounting bolts loosened just enough to allow movement, tension the belt using the 2
position adjustment bolts.
Apply firm thumb finger pressure centrally along the belt span between the pulleys. Try to
apply a thumb pressure force of approximately 2.5Kgf. This is the force required to lift a 2.6Kg
weight. Adjust the 2 motor belt tensioning screws to achieve approximately 2.5mm belt
deflection.
or
Alternatively see Figure 10-3 or the video available on ABB Solutions Bank which show an
alternative method. The Figure 10-3 method uses an SP/NP12 upper/lower carriage perspex
cover and a sensor gap gauge to check the belt tension/deflection. Mark the gap gauge at
2.54mm. Gently press the perspex cover against the belt/pulleys at the locations shown. Use
hand pressure to press the gap tool forward with a force of approximately 2.5Kgf. Adjust the
belt tension using the 2 position adjustment bolts until approximately 2.5mm of deflection is
achieved.
When adjustment is complete torque the 4 motor mounting screws to 8.47 Nm (75lbf-in).
Check the deflection again after torqueing the 4 screws.
It is recommended to follow this setup using the method ‘A’ tension meter as soon as possible to
confirm correct belt tension.
9. Use a bubble float to ensure the frame and then motor is level. Ensure the motor and drive
sprockets are properly aligned to ensure the belt does not move onto the sprocket sidewall during
normal frame scanning operation.
10. When available apply anti tamper glyptol fluid to all bolt heads.
11. Some SP700 may still have the manually operated clutch illustrated in Figure 10-4 Manual Clutch
Drive Assembly
3BUS209559 rev K 10-3

Figure 10-2 Air Clutch Drive Assembly
Figure 10-3 Alternative Method of Checking Drive Belt Tension
10-4 3BUS209559 rev K

Figure 10-4 Manual Clutch Drive Assembly
3BUS209559 rev K 10-5

Carriage Drive Belt Replacement

Use these procedures to replace the carriage drive belt. Once this procedure is completed, perform a
scan direction alignment to make certain that the sensor heads are tracking each other. Refer to Figure
10-5 Carriage Drive Belt on page 10-7. The carriage alignment in the drive direction may need to
be reset. To check the alignment, complete the “Process Direction Alignment” on page 3-28.
Note: When replacing a failed belt, it is required that both top and bottom belts be
replaced as a matched set. Replacing both belts at the same time maintains
sensor alignment by eliminating variation between belts due to wear. In an
emergency situation, it is acceptable to defer replacement of the second belt
until the first scheduled maintenance shutdown.
1. Disengage the air clutch so that the heads can be separated. Or in the case of a manual clutch
disengage the clutch by loosening the clutch nut three turns
3. Move the head carriage with the defective belt to the Network Platform idler end column.
4. Release the belt tension by loosening the idler pulley at the Network Platform idler end column.
5. Remove the end of the drive belt which is attached to the idler end of the carriage assembly.
6. Attach the new belt with strong tape to one end of the old belt which was removed in the
previous step.
7. Go to the drive end of the Network Platform and pull the new drive belt through the structure.
8. Apply a light coating of green Teflon® grease, Part Number 100772-001, to the outside face of
each cog and flange of the drive pulley and to flanges of the idler pulley. A tube of the required
grease is included in the Installation Kit, Part Number 128401-001.
Note: Lack of proper lubrication may lead to belt noise and premature failure of the
replacement belt.
9. Attach the other end of the new belt to the idler end of the carriage assembly.
10. Move the head carriage to the Network Platform drive end, and at the same time, pull the new
belt along with it.
11. Disconnect the two belts attached in Step 6 and discard the old belt.
12. Cut the new belt to a length such that when it is attached to the carriage assembly, the tension can
be adequately adjusted using the idler tension adjustments.
Use the following formulas for figuring the lengths of the carriage drive belts:
If you are using inches: 2 x center-to-center + 13.5 inches

If you are using millimeters: 2 x center-to-center + 344.0 mm (or 34.4 cm)
13. Attach the remaining loose end of the new belt to the drive end of the carriage assembly. Repeat
steps 2 to 12 for second belt.
14. Move the top and bottom heads together, center them, and tighten the idler pulley shaft bolt..
15. Tighten the new belt using the procedure outlined in the section Carriage Drive Belt Tensioning.
16. Check the head alignment in the drive direction by completing the “Scan Direction Alignment”
on page 3-32.
10-6 3BUS209559 rev K

Figure 10-5 Carriage Drive Belt
3BUS209559 rev K 10-7

Carriage Drive Belt Tensioning

The procedure outlined below should be used when tensioning the carriage belt.
1. The head package should be in the standardize position
2. Set the belt tensiometer (122146-004) so that it is directly underneath the belt at the Drive End
(between the Drive Shaft Pulley and the End of the beam).
3. Measure from this position several times until a consistent reading is obtained.
4. Adjust the tension according to Table 10-1.
Note – After eight hours of scanning verify the tension is still within the limits given by Table 10-1
and the difference between both belts should be less than 25lbs.
Metres (m) All

Tension (Lbs) 100 - 125
Table 10-1 Belt tension for various scanner lengths.
10-8 3BUS209559 rev K

Idler Pulley Replacement

Use these procedures to replace the idler pulley. Refer to Figure 10-6 on page 10-10.
Exercise care when working with toothed belt and

toothed gear equipment. Do not wear ties or loose
clothing while working near equipment.

2. Loosen the idler tension adjustment locks and the idler pulley.
3. Remove the bolt that secures the pulley and lift the pulley off the shaft.
4. Replace the pulley assembly.
5. Adjust the idler tension adjustment bolts.
6. Perform the “Scan Direction Alignment” on page 3-32.
Note: Do not make adjustments to the drive pulley. The drive pulley has been
factory adjusted to ensure precise dimensional measurement between the
drive shaft, the belts, and the pulley.
3BUS209559 rev K 10-9

Figure 10-6 Idler Pulley
10-10 3BUS209559 rev K

Carriage Wheel Assembly Replacement

Use this procedure to replace the carriage wheel. Refer to Figure 10-7 Carriage Wheel
Assembly Removal Pictures and Figure 10-8 on page 10-13.
1. Scan the frame to record starting status profile printout results for future reference.
Collect GAP, 30gsm weight check sample and perhaps air profile results
2. Move the carriage assembly to either the idler end or the drive end of the platform
depending upon which wheels need replaced. Pull the head package as far back as
possible to make access easier.
3. Figure shows the typical basic tools recommended.
M4 & M5 Allen head tools/sockets.
A circa 70cm long ratchet tool extension with an M5 Allen head. This to reach the wheel
assembly retaining bolt.
A short small flat bladed screw driver.
Wear gloves to protect hands in confined spaces.
Visibility is difficult. A flash lamp is required.
4. To gain access to some of the wheel assemblies it will be necessary to remove the cable
carrier attachment bracket which has 2 x M4 allen retaining bolts, the carriage stop
bracket which has 2 x M4 allen bolts and the bump stop which has 4 x M5 allen bolts.
5. Pull the head package back all the way to the end column. Place a wedge between the
platform and either the upper or lower head package (depending upon which wheel
assembly is being replaced). The wedge material must not damage the sensors. The
wedge must be placed on the side of the carriage which is closest to the end column. The
wedge removes the weight of the carriage from the wheel assembly which makes the
unloaded wheel assembly removal possible.
6. Remove the M5 Allen bolt which holds the carriage wheel to the assembly.
7. Thread the removed M5 bolt into the wheel assembly pulling bolt hole shown in below
Figure. Tightening this M5 bolt pulls the wheel assembly from the carriage. If you find the
assembly difficult to remove, try to pry the wheel assembly off with a very fine tipped
screw driver. It may sometimes be necessary to try pulling the wheel assembly straight out
using a rocking motion. Some very old frames may not have the threaded bolt hole.
8. Allow 4 hours to perform this task.
9. Replace the wheel and secure using the M5 bolt.
10. Replace all removed bolts. Remove the wedges
11. Check that all wheel assembly wheel loading springs are working effectively.
12. Scan the frame again to confirm profiles are good. Record profile printout results for
future reference.
3BUS209559 rev K 10-11

Remove this bracket
Figure 10-7 Carriage Wheel Assembly Removal Pictures
10-12 3BUS209559 rev K

Threaded M5 screw hole. Insert

M5 bolt to remove the wheel assy.
M5
Wheel
Mounting
Screw
Figure 10-8 Carriage Wheel
3BUS209559 rev K 10-13

Seal Belt Replacement

Use these procedures to replace the Seal Belt. See Figure 10-9 below through Figure 10-11 on page
10-15.
Exercise care when working with toothed belt and toothed gear
equipment. Do not wear ties or loose clothing while working near
equipment.
The Network Platform design allows replacement of this item while

the customer’s process is running. Exercise caution to ensure that
the seal belt is kept clear of the process while being removed and
replaced.
1. Loosen the seal belt clamp at the drive end.
Figure 10-9 Seal Belt Clamp and Adjustment Bolts

2. Attach the new seal belt to the old belt with strong tape.
10-14 3BUS209559 rev K

Note: It is extremely important to note that the seal belt should be centered between
the extrusions otherwise the belt may rub the side of the extrusions while the
sensor heads are scanning. This condition could result in unsteady scanning
and premature wear of the seal belt.
Carriage
Carriage Seal Belt Rollers

Seal Belt
Figure 10-10 Seal Belt

3. Secure the belt at the drive end of the carriage with tape.
4. Pull the seal belt from the idler end of the platform to remove any slack in the seal belt.
5. Turn on power to the Scanning Platform long enough to jog the sensor heads to the idler
end, carefully taking up slack in the seal belt.
6. Adjust tension such that the seal belt lays flat in the tray without any deflections in the
seal belt roller assembly.
Note: If the seal belt roller assembly is being lifted from the track, the seal belt
tension is too tight. Loosen the tension enough so that the assembly lays flat
in the track.
Carriage Seal
Belt Rollers
Seal Tension Seal Belt

Adjusted Too
Tightly
Extrusions
Seal Tension
Adjusted
Unevenly
Seal Belt
Seal Tension
Adjusted
Seal Belt
Properly
Figure 10-11 Seal Belt Tension Checks
3BUS209559 rev K 10-15

Seal Belt Roller Assembly Replacement

Use the following procedure to replace roller assembly. See Figure 10-12 below and Figure 10-11 on
page 10-15.
The Network Platform design allows replacement of this item while

the customer’s process is running. Exercise caution to ensure that
the seal belt is kept clear of the process while being removed and
replaced.
1. Jog the sensor heads to the end column that provides access to the roller that needs replaced.
2. Loosen the seal belt clamp.
Pull Out
Lift Up
Figure 10-12 Roller Assembly

3. Roll up the loose end of the seal belt and tuck it into the carriage.
4. Remove the roller assembly.
5. The seal belt roller assembly is removed from the platform through the bottom of the cable carrier
loop. See Figure 10-12 above.
6. Install the new roller assembly.
7. Pull the seal belt through the seal belt clamp to remove any slack in the seal belt.
8. Adjust tension such that the seal belt lays flat in the tray without any deflections in the seal belt
roller assembly. See Figure 10-11 on page 10-15.
10-16 3BUS209559 rev K

Flex Cable Suspension Replacement

Cable suspension part numbers are found on the Frame specification document supplied with the
scanner.
Complete the following steps to replace the cable suspension.
Exercise care when working with toothed belt and toothed gear
equipment. Do not wear ties or loose clothing while working near
equipment.
1. Put the platform in local mode and jog the head to the drive end column.
2. Turn off power to all sensor cabling.
3. Turn off the air and water at the idler end column.
4. Disconnect the air and water hoses at the idler end column.
5. Bleed off water if the water lines or the entire cable carrier is being replaced.
6. Disconnect the power and signal cables at the idler end column.
7. Remove the seal belt clip at the drive and idler end columns.
8. Remove the seal belt.
9. Remove the seal belt roller assembly by tilting the back end of the assembly upward until
it is free of the track and sliding the assembly forward. The seal belt roller assembly must
be removed from the bottom of the cable carrier loop. See Figure 10-12 on page 10-16.
10. At the drive end column, remove the two screws that hold the cable carrier to the carriage.
Remove the two screws that fold the cable tray to the carrier (use a 4 mm hex
screwdriver).
11. At the idler end column, remove the two screws that hold the cable tray to the carrier.
12. Remove all of the covers on the head package to expose the carriage boards and the air
manifold.
13. Disconnect the two air lines from the manifold and the two water lines from the IR sensor
(if present). Feed these hoses back into the beam.
14. Disconnect the power and signal ribbon cables from the carriage boards and feed them
back into the beam.
Note: Note the way that the cables and hoses lay and fold. The assembly must be
reassembled properly in order to fit back into the platform
3BUS209559 rev K 10-17

Disconnecting the cable carrier from the platform is a two-man

operation. With both ends of the cable carrier detached, the entire
suspension can fall through the beam. Make sure someone is
holding one end.
15. To straighten the loop out of the cable carrier (the loop is at the drive end), disconnect the
cable carrier from the idler end column and push it through the frame while pulling the
carriage cable tray out of the idler end column.
16. Replacement of the complete assembly, ribbon cables, or utility lines can be accomplished
at this time. If replacing the ribbon cable assembly, measure the length of cable exposed
at each end and terminate new cable at the same length
17. Damaged cables can be replaced by cutting off the idler end connector and taping the old
cable to the new cable using a high-strength tape. For example, use strapping or shipping
tape. See Figure 10-13 below
Old
New Cable
Cable
8”
To Cable
Carrier
20” Tape
Figure 10-13 Carriage Assembly (Top View)

18. While one person at the drive end guides the new cable through the cable carrier, another
person at the idler end column pulls the new cable through the platform. Once the cable is
all the way through, leave enough excess cable at both ends to allow for a cable dress.
19. Connector termination and cable length must be identical to that which is being replaced.
20. Keep the cable carrier, ribbon cables, and utility lines clean. Dust and dirt will cause
premature wear of the cables.
21. When the ribbon cables have been finally routed perform the following check. Bring the
heads to the Idler end. Look inside the beam and observe the ribbon cables routing. Ensure
that there is no potential for the ribbon cable to contact the Seal Belt. Contact between
ribbon cable and Seal Belt will result in damage to the cable. Repeat this check for both
top and bottom heads.
Note: Do not reuse signal cable connectors. They must be replaced each time a
new signal cable is installed.
Use the above procedure to replace the lower cable suspension or cable suspension components except
for Step 10 Instead remove the end column bottom plate. The motor controller disconnect is a part of
the bottom plate.
10-18 3BUS209559 rev K

DC Power Supply Replacement

There are two types of NP bulk DC power supply. Here we describe both units and provide a
replacement procedure.
NP Bulk DC power supply kit type 3BUS215432-001
In December 2013 ABB introduced a new NP bulk DC power supply kit 3BUS215432-001. This kit
contains a new type power supply part number 3BUS215138-001 shown in Figure 10-14. This kit
directly replaces the original 3BUS208859-xxx power supply shown in Figure 10-24 and its modular
variants.
Figure 10-14 3BUS215138-001 NP Bulk DC 12.5V 15V 24V 42V Power Supply 3BUS208968-101 NP
DC Power Supply link-up cable attached.
3BUS209559 rev K 10-19

The parts supplied in the new 3BUS215432-001 kit are listed in Table 10-2. These include a new
design 3BUS208968-101 NP DC power supply link-up cable shown in Figure 10-23. The cable is
delivered pre connected to the 3BUS215138-001 NP bulk DC 12.5V 15V 24V 42V power supply.
The cable lugs P4, P5 and P6 are extra narrow type. Re-using an older type cable would require
replacing the existing lugs with the narrow type. The new cable is also 40mm longer than the previous
cable, this to provide a better fit. Therefore ABB recommends to use the new cable.
Each new power supply is delivered with a full power supply module compliment. Each is preset to
ABB specific voltage requirements. The +/-12V is set to +/-12.5V and the Reflection IR Flag driver
supply voltage is set to 42V. Voltages may be adjusted using the potentiometer located above each
module. However this should not be necessary.
The individual modules are not customer or ABB replaceable. Do not disassemble to remove any of the
power supply modules. Removing them invalidates warranty.
When Optipak and/or Gloss and/or Reflection IR already exists a CSS constant supply source power
supply will be existing. It will be re-used. The CSS is shown in Figure 10-36 on page 10-53.
The new power supply is a direct physical replacement fit for the previous unit.
The new 3BUS215138-001 power supply without cable may also be purchased from ABB
Item Description Part Number Qty
1 Power Supply NP Bulk DC 12.5V 15V 24V 42V 3BUS215138-001 1
2 NP DC Power Supply Link-Up Cable 3BUS208968-101 1
3 Cable Ties 012918-001 6
4 NP Bulk DC Power Supply Kit 3BUS215432-001 Instructions 3BUS215432-900 1

Table 10-2 3BUS215432-001 Bulk DC supply kit contents
Figure 10-15 3BUS215138 NP Bulk DC 12.5V 15V 24V 42V Pwr S. Terminals
Customer Installation Advice
Customer installation may include the following steps.
Installers should refer to the NP frame power functional wiring drawing.
a) Make an NP software backup. The procedure to do this is available in 3BUS209544 Network
Platform Software Reference Manual.
b) Power down the NP frame.
c) Disconnect all cables going to the existing power tray white/clear plastic connectors.
10-20 3BUS209559 rev K

This to isolate the power tray from the NP frame.

d) Remove the existing power supply.
e) Remove the existing large clear plastic protective cover from the power supply 12.5V 15V
24V 42V terminals. It will be re-used.
f) Disconnect the existing power supply clear plastic a/c voltage safety cover.
This plastic shield shown in Figure 10-16 is not re used.
Figure 10-16 NP Bulk DC Power Supply shield is not re used

g) Disconnect the a/c power cable 3BUS208967-001 from the power supply L.N and Earth
terminals. The white plastic connector plugs into JDC1.
h) When Optipak or Gloss or Reflection IR exists remove the cable wires attached to the existing
power supply.
i) Take the new 3BUS215138-001 NP Bulk DC 12.5V 15V 24V 42V power supply with pre-
connected dc power cable to the assembly. The pre connected cable is shown in Figure 10-23.
j) Remove and store the new 3BUS215138-001 NP Bulk DC power supply small clear plastic a/c
voltage safety cover. This cover is identified with an arrow symbol on Figure 10-14. It is very
important and will be re-used.
k) Connect the existing a/c power cable to the new power supply Live, Neutral and Earth
terminals as shown in Figure 10-14.
l) Re install the small clear plastic a/c voltage safety cover.
m) Re connect the remaining cables to the new power supply. The power supply terminal
designations are shown in Figure 10-15.
When Optipak or Gloss and/or Reflection IR exist reconnect the existing 3BUS208997-001
DC Power to CSS link cable to the new power supply terminals. The cable is shown in Figure
10-20.
or
When only Reflection IR exists reconnect the 3BUS208973-001 NP 42V DC Power Link
Cable for Reflection IR. The cable is shown in Figure 10-21. Caution - Connect the lug
labeled M1 to the new power supply terminal N3 42V+ and lug labeled M2 connects to N4
0V.
or
When new cable type 3BUS208997-002 DC Power 24V to CSS 42V RIR hydra
cable for CSS & Reflection IR is existing or is newly supplied as part of an upgrade
connect it to the new power supply terminals. The cable is shown in Figure 10-22. When this
new cable type 3BUS208997-002 is used it replaces the 3BUS208997-001 and 3BUS208973-
001 cables so they are not required.
ABB introduced the 3BUS208997-002 cable as part of the new power supply integration
project. It gives the advantage of having just 1 lug connected on the power supply terminal N3
(42V) and 1 lug on N4 even if both CSS and Ref+ exist. JDC3 plugs into it's receptacle. ABB
3BUS209559 rev K 10-21

have several DC power assembly variations. When no CSS exists the JCSS1 cable leg may be
carefully tie wrapped to mounting posts or similar. The objective is to ensure it cannot get
damaged.
n) Re install the large existing clear plastic safety protective cover over the new power supply
12.5V 15V 24V 42V dc voltage terminals. It may be necessary to move some of the power
supply wire orientations to get a best fit. This as shown in Figure 10-17 for an NP7 assembly.
Figure 10-17 NP7 Assembly example with full cable compliment connected.
o) Re use the existing screws to attach the new 3BUS215138-001 NP Bulk DC 12.5V 15V 24V
42V power supply with pre connected cable to the existing power assembly metal chassis.
p) Route and position the new 3BUS215138-001 cables JDC2 connector as required to avoid
any possible cable damage.
q) Push the cable white/clear plastic connectors into their power tray locations.
Figure 10-18 NP12 Assembly example showing white cable connector locations.
r) Use the supplied tie wraps to secure any loose cabling to the mounting standoff posts etc.
This to avoid cable damage. See Figure 10-19.
10-22 3BUS209559 rev K

Figure 10-19 NP7 Assembly tie wrap example.

s) Turn sensor air off at the frame regulator. Disconnect and remove all sensors from their
buckets.
t) With the power supply outputs isolated from the frame - Power on the NP.
Check voltages on the power supply terminals and the cable white/clear plastic connectors.
u) Power down the NP
v) Connect all frame side cables to the existing power tray white/clear plastic type connectors.
w) Power up the NP
x) Re check the power supply voltages are still correct.
y) Check the sensor voltages are correct at the sensor buckets and plugs.
z) Power off.
aa) Re install and re connect the sensors. Re apply sensor air.
bb) Power on.
cc) Check standardize, air profiles and/or check samples.
dd) Record the measured voltages, standardize values and profile results in the customer log
book. Measure paper.
3BUS209559 rev K 10-23

Figure 10-20 3BUS208997-001 NP DC Power to CSS cable Optipak/Gloss/Ref IR
Figure 10-21 3BUS208973-001 DC 42V power link for Reflection IR cable.
When existing - Re-use

May be used to replace 3BUS208997-001
and 3BUS208973-001
Figure 10-22 3BUS208997-002 DC power 24V to CSS and 42V to Ref IR cable.
Figure 10-23 3BUS208968-101 NP DC Power Supply Link-Up cable connection.
NP Bulk DC power supply type 3BUS208859-xxx

The data here is provided as reference for customers having the now obsolete original NP power supply
type 3BUS208859-xxx shown in Figure 10-24.
10-24 3BUS209559 rev K

Figure 10-24 NP Bulk DC power supply type 3BUS208859-xxx (obs Dec 2013)
Depending on the sensor complement in the head package, the scanner’s bulk DC unit will be one of
the units in Table 10-3 below. Be aware that the unit can be expanded by the addition of extra modules
in the situation where additional sensors have been added to a system.
NP Bulk DC power supply variants

Voltage levels (V)
(slot position left to right) Additional detail-
(one or more of outlined
ABB ID 1 2 3 4 5 6
sensors in head package
P1 P2 P4 P5 N1 N3 compliment)
P2 P3 P5 P6 N2 N4
3BUS208859-010 +12 -12 +15 -15 - -
3BUS208859-020 +12 -12 +15 -15 +24 - Optipak ,Gloss
3BUS208859-030 +12 -12 +15 -15 +42 - Reflection IR
3BUS208859-040 +12 -12 +15 -15 +24 +42 Optipak, Gloss, Reflection IR
Table 10-3 3BUS208859-xxx Bulk DC supply variants
Note:
 +12V & -12V levels are set to +12.5V & -12.5V respectively to compensate for
possible line losses.
 Unused slots should have protection cover mounted.
 Unit is rated for 600W at 70°C (268°F). Circuit breaker on AC line to supply is rated
at 4A.
 Unit efficiency is up to 90%. Minimum loads not required for output voltage level
stability.
3BUS209559 rev K 10-25

Figure 10-25 End view for Bulk DC supply with module positions
10-26 3BUS209559 rev K

Motor Drive Controller Replacement – ACS to VLT

In the case where a VLT controller is being retrofitted for an ACS controller, the VLT unit
will have been supplied with an adapter plate as part of an upgrade kit. The upgrade kit for an
ACS controller irrespective of system configuration is:
134137-004 Upgrade kit for ACS to VLT

Installation of this upgrade kit is as follows:

- Ensure the power supply to the motor controller is isolated.
- Disconnect the wiring to the existing controller assembly (Filter + Controller +
De-coupling plate)
 Disconnect the input power from the line filter.
 Disconnect the signal cable (from connectors JSIG or J19) from the ACS
unit. (terminal X1)
 Disconnect the motor connector JDRV from the ACS unit.
 Disconnect the ventilator.
- Demount the motor controller assembly.
- Demount the thermistor from the ACS assembly.
- For an SP1200 assembly, disconnect and remove the earth strap from the rear of
the ACS mounting plate.
- Mount the new adapter plate using the mounting holes for the ACS assembly and
the supplied countersunk M4 screws; positioning the plate with the thermistor
bracket in the top position where previously the line filter was positioned.
Figure 10-26 VLT Adapter plate

- Mount the VLT controller onto the adapter plate using the supplied M4 pan-head
screws and washers.
- Mount the thermistor to the bracket on the mounting plate.
- For non-J-Box based scanners, using Figure 10-27 Connection of VLT on Pre July
2014 NP1200 and NP700 or Figure 10-28 Connection of VLT on Post July 2014
3BUS209559 rev K 10-27

NP1200 and NP700 Scanners as a reference: See also Table 5-2 Motor Drive
Parameter Settings (Scanner Defaults) and Note 1 on Page 1-4.
 connect the power cable JPOW to the VLT unit
 connect the signal cable JSIG to the VLT unit
- For J-Box based scanners, using Figure 10-29 Connection of VLT on Pre July
2014 Remote J-Box Based Scanners or Figure 10-30 Connection of VLT on Post
July 2014 Remote J-Box Based Scanners as a reference: See also Table 5-2 Motor
Drive Parameter Settings (Scanner Defaults) and Note 1 on Page 1-4.
 connect the power cable from the switch on the side of the J-Box to the
VLT unit
 connect the signal cable from J19 to the VLT unit
- Connect the motor cable to connector JDRV on the decoupling plate.
- For SP1200 assemblies connect the earth strap onto the adapter plate as shown in
Figure 10-26 VLT Adapter plate
-
- Turn on the power to the motor controller and verify that the display and green ON
LED illuminate.
- Set the parameters in the motor controller according to Comparison of Parameter
Settings for ACS versus VLT Controllers’.
- Perform frame tune as described in 5 Platform Tuning.
10-28 3BUS209559 rev K

Figure 10-27 Connection of VLT on Pre July 2014 NP1200 and NP700 Scanners
Figure 10-28 Connection of VLT on Post July 2014 NP1200 and NP700 Scanners
3BUS209559 rev K 10-29

Figure 10-29 Connection of VLT on Pre July 2014 Remote J-Box Based Scanners
Figure 10-30 Connection of VLT on Post July 2014 Remote J-Box Based Scanners
10-30 3BUS209559 rev K

Comparison of Parameter Settings for ACS versus VLT

Controllers
The table below outlines the parameters used on the ACS-101 motor controller and their
equivalents on the VLT motor controller. For the situation where an ACS controller is being
replaced by a VLT controller, the following procedure may be used to minimize the time
required for set-up and tuning optimization:
- Set the parameters on the VLT unit to match the default values in ‘Table 5-2 Motor
Drive Parameter Settings (Scanner Defaults)’.
- Set the highlighted parameters in Table 10-4 on the VLT controller to match the
parameters in the ACS controller (if these are available).
- Check movement of the scanner in both local and remote mode and ensure the
acceleration, braking and movement is smooth. Note the braking time (3-42) may
need to be increased on the VLT relative to the value used for the ACS, to ensure
smooth braking of the head package.
Note parameters which are not highlighted in the table

below while providing the same functionality between
controllers may use different scaling or settings. Consult
manufacturer documentation for exact descriptions of
these parameters.
ACS parameter VLT parameter Description

101 - fref
103 15-30 Last Fault
104 15-43 Version
201 1-22 Unom
202 1-23 fnom
203 1-24 Inom
204 1-25 Nom Speed
205 4-51 Imax
206 4-14 fmax
207 4-12 fmin
208 4-10 Dir Lock
209 14-01 Motor Noise
301 1-80 Stop
302 3-40 Ramp
303 3-41 Acc
304 3-42 Dec
305 1-55, 1-56 U/f Ratio
306 1-55 [0] IR Comp
3BUS209559 rev K 10-31

ACS parameter VLT parameter Description

307 2-02 DC Inj Time
308 2-17 UCmax Control
401 6-10, 6-12 AI min
402 6-11, 6-13 Al max
403 6-14 Ref min
404 6-15 Ref max
405 5-1 DI Config
406 3-11 Const speed
501 6-10 Al Fault
502 1-90 flim
503 0-4 Param Lock
Table 10-4 Motor Controller parameters ACS vs VLT
10-32 3BUS209559 rev K

Motor Drive Controller Replacement – Fincor or Lovejoy to

VLT
In the situation where a Fincor or Lovejoy motor controller is being replaced, an upgrade kit
will be delivered dependant on the system configuration:
134137-001 Upgrade kit for Remote Junction Box based system

134137-002 Upgrade kit for NP700 based system

Installation of the upgrade kit is as follows:

- With the power supply to the motor controller isolated; disconnect the JSIG, JPOW
and JMOT connectors from the existing motor controller assembly.
- Remove the old assembly.
- Mount the new assembly and reconnect the JSIG, JPOW and JMOT connectors to the
existing motor control assembly.
- Turn on the power to the motor controller and verify that the display and green ON
LED illuminate.
- Follow set-up procedure in 5 Platform Tuning
Note – If the motor happens to run backwards, swap the wires in JDRV-1 and JDRV-3.
3BUS209559 rev K 10-33

Position Encoder Replacement

Complete the following procedure to replace the Encoder.
See Figure 10-31 Encoder Drive End Pictures.
It is recommended to power down the scanner. First make sure you have a software backup.
1. Gain access by removing the frame top end cover.
2. Unplug the electrical encoder cable D connector.
3. Remove the two screws from the bracket which attaches the encoder assy to the frame.
4. Remove the four screws which are holding the encoder to the metal mounting plate.
5. Lift the encoder from the plate.
6. Install the new encoder.
7. Do not overtighten the toothed encoder belt. Avoid side loading the encoder pulley. This to avoid
damage to the encoder bearings.
8. Power up the scanner.
9. Synchronize the encoder by either restarting the Network Platform, or pressing the maintenance
push button on the end column control panel.
10. Belt tension can be set by thumb press at the centre of the belt span. The belt should deflect 7mm
+/- 0.5mm . The encoder bracket is made from light metal and may flex. Try to avoid flexing the
bracket as this will distort the 7mm deflection check. Figure 10-32 shows an alternative NP7 Belt
Tension & Belt Pulley Distance Setting Guage Kit 3BUS214905-100. The parts shown in Figure
11-18 pictures will be made from metal. A video showing how to use the kit is available on the
ABB Solutions Bank website.
11. Observe the encoder while scanning.
12. The encoder pulley belt system should not wobble.

Adjust the retaining bolts if it does.
Do not overtighten the toothed encoder to drive shaft belt. This timing belt should be tensioned
enough to avoid belt slippage but not overtensioned. Over tensioned belts will cause excessive side
loading and resulting early life damage to the position encoder bearing.
Avoid side loading the encoder pulley.
These steps to avoid damage to the encoder bearings.
10-34 3BUS209559 rev K

Figure 10-31 Encoder Drive End Pictures
->
Step1:Install spacer to maintain pulley distance. Step2: With step 1 spacer still in place. Press the
second tool against the pulley / belt as shown to
obtain 7mm timing belt deflection.
Figure 10-32 Belt Tension & Belt Pulley Distance Setting Kit 3BUS214905-100
3BUS209559 rev K 10-35

Scanner Replacement Parts List

Refer to:
 Table 10-5 Replacement Parts List
 Figure 10-33 Drive End Column Parts on page 10-50
Table 10-5 Replacement Parts List
Key NP Replacement Parts List / Picture Part #
Comments
END COLUMN, DRIVE-SIDE
A Frame Head Position Encoder 019775-004
E Drive Motor Belt (50Tooth) for SP/NP700 101709-001
All scanners ship with a spare belt tie wrapped to

the drive shaft.
B Upper Drive Pulley 128389-001
Key (2 required) ¼” square x ¾” long. 046102-013

Drive shaft internal part.
P Ball Bearing Flange (2 required) 011230-107
Torque the bearing setscrews to 10.17Nm (90 +/-

2lbf-in).
Do NOT over torque these screws.
10-36 3BUS209559 rev K


Comments
F NP700/SP700/MP700 Frame Drive Gear Motor 3BUS212258-002
kit incl. reducer, mounting plate, mounting
hardware and 3BUS208184 Install Instruction
sheet.
The motor is grey color.
100456-xxx motors are obsolete and replaced by

above.
ABB soultions bank document 3BUS213180

Motor Replacement Instruction Sheet contains
information about old and current motor types
part numbers and replacement techniques.
In rare cases the scanner door may contact the

new motor electrical box cap and not close fully.
Order a 3BUS214148-002 lower profile
electrical box cover to solve.
Torque the 4 x mounting hardware to 8.36

N.M.[74 In Lbs]
N Position Encoder to Drive Shaft Belt (55 Tooth) 014489-014
R Motor Pulley Sproket 128356-001
S Motor Pulley Tapered Bore Bushing 019108-005
3BUS209559 rev K 10-37


Comments
T Motor Driven Pulley Sprocket 128350-001
U Motor Driven Pulley Bushing 128349-001
V Encoder Timing Belt Pulley 014482-028
W Encoder Drive Pulley 014482-014
10-38 3BUS209559 rev K


Comments
A1 NP7 Drive assembly. 128391-002
This drive shaft assembly is ready to fit onto

your NP7.
This is the recommended Optimal Replacement

Unit (ORU) level replacement.
AIR CLUTCH PARTS

O Clutch 121824-001
3BUS209559 rev K 10-39


Comments
O Clutch pipe. 100451-100
This is the black hose pipe with brass fittings and
yellow plastic shrouds shown on the clutch
assembly item J above.
D Lower Drive Pulley 128389-002
X Air Pressure Head Separation Adjustable SC0001-001

Pressure Switch (15Amp)
Y Head Split Switch (Pneumatic) 017209-001
Z Drive Shaft 128347-002
Rotary Motor Safety Lockout Switch Yellow 100468-030

with Red Rotor.
MANUAL CLUTCH PARTS

1
O Clutch Plate 128341-002
D1 Lower Drive Pulley 128390-002
10-40 3BUS209559 rev K


Comments
X Head Separation Switch 013212-001
Z Drive Shaft 128347-001
MOTOR DRIVE
NP1200 Motor Drive Controller including
3BUS209323-100
Programming Panel.
There are many assembly types, Fincor, Lovejoy,

ABB ACS100
ABB may not supply this VLT unit at the
3BUS209323-100 part level.
To confirm correct replacement contact ABB
providing a picture of the existing motor
controller hardware or choose from below
assemblies.
NP700 VLT Motor Controller Drive Assembly 128855-104
including MDPanel and Filter
VLT Motor Controller Drive Subassembly 134137-004

(Remote Junction Box only)
VLT Motor Controller Drive Choke 086277-001

Assy.(Installed in Remote Junction Box only)
3BUS209559 rev K 10-41


Comments
Cooling Fan 240 VAC 117 CFM Axial 102258-001
DOOR HARDWARE
Left Hand Side Door Lift Off Door Hinge 100497-002
Right Hand Side Door Lift Off Door Hinge 100497-001
Door Closing Latch, adjustable 100498-001
SCANNING PLATFORM
Limit Switch Target. 128364-001
Thin metal foil plate which is tie wrapped to the
frame timing belt.
Limit Switches, Proximity, with cable 100243-003
A 90 Degree angeled version is available. It may

be used when there are problems getting the door
to close due to contact with the limit switch.
Contact ABB R&D.
Dust Seal Belt, 79.25mm [3.12”] wide polyester, 100434-005

white color.
This is the standard belt used in SP/NP700.
10-42 3BUS209559 rev K


Comments
Dust Seal Belt, polyester, white color, Extra 100434-006
Wide.3.2" [81.28mm].
May be used if standard belt tends to fall ot
easily.
Dust Seal Belt, polyester, white color, standard 100434-105

width 79.25mm [3.12”], Ultra Smooth Surface
on one side.
This special smooth surfaced belt may be used on
tissue or similar applications where the paper
product tends to adhere to the belt. May help
prevent dust adhesion.
Scanner Drive Belt Transparent Plastic with 100446-020

Internal Steel Wire. 25.4mm [1 inch] wide
Top and Bottom belts are cut by the supplier

from one single double width strip of belt. This
results in a matched belt pair with desirable
advantageous similar characteristics
One MUST use matched belt pairs.
Creaking/Noisy belts and pulleys may be

silenced by lubricating with green Teflon®
grease part 100772-001. The grease also helps
prevent belt cracking, deterioration and may help
reduce creep onto the pulley flange.
Re-align your pulleys immediately when belt

creep onto the pulley flange is noticed. This to
prevent belt edge stretching, stripping and fatal
damage.
Drive Belt Installation Instruction Sheet. 131720-001
This is a one page instruction sheet explaining
how to replace a drive belt.
It is available on ABB Solutions Bank.
3BUS209559 rev K 10-43


Comments
Carriage Light Assy. 084910-001
Red Frame Side Eccentric Way Bar Covering 128363-007

Trim Strip
CARRIAGE, INTERNAL
NP7 Cable Carrier Standard Assembly, Top 3BUS208993-201
Consult on site Frame Job Order Specification

document for correct part number and required
length
Cable Carrier Assembly, Bottom See -201 picture 130886-202
See -201 comment.
Cable Carrier Assembly, Top (Remote J-Box) See -201 picture 130886-202
See -201 comment.
Cable Carrier Assembly, Bottom (Remote J-Box) See -201 picture 130886-222
See -201 comment.
Cable Carrier, Divided (1 meter sections) 100490-004
Hose, Dual flat 101497-001

Braided Frame Internal Air/Water Hose, Dual
flat with strippable central bond
Inner Diameter 9.1mm (0.360±.010“)
Outer Diameter 13.5mm (0.530±.010”)
10-44 3BUS209559 rev K


Comments
Signal Cable, flat (for divided cable carrier) 101575-037
Power Cable, flat flex 100983-003
Signal Plug 101403-137
Signal Receptacle 101403-037
Stabilizer (37 pos) attached to the back of 101403-837

101403-037 & -137 ribbon cable connectors.
Connector (37 Pos) type 101403-xxx Screw 101403-901

Retainer Kit
Power Cable Plug 10 position (4 per scanner) 128662-003
Signal Connector Circuit Board 133712-001
Located at the side of the head package.

The flat signal ribbon cable and connector
101403 above connect to this board.
Power Connector Circuit Board 133713-001
Located at the side of the head package

The flat red and black power ribbon cable and
connector 128662-003 above connect to this
board.
3BUS209559 rev K 10-45


Comments
Wheel Assy., fixed 128682-001
2 per carriage
4 per frame
A special 128682-003 version is available which

has a longer 7.02mm extended axle. This can be
used if the way bar has been marked by poorly
maintained and/or damaged wheels.
Wheel Assy., Tension L.H. 128683-002
1 per carriage
2 per frame

Wheel Assy., Tension R.H. 128683-001
1 per carriage
2 per frame

Seal Belt Wheel Assembly 128684-001
END COLUMN, IDLER SIDE

NP7 Frame Idle End Pulley Assembly (2 3BUS210394-001
required)
10-46 3BUS209559 rev K


Comments
Idler end pulley sprocket with bearings and 128354-001
attachment screw used in 3BUS210394-001
above.
This is the standard part in SP/NP700 scanners.
The flange depth is 12.7mm [0.5”].
It is painted black.
2 required per frame.
Idler end pulley sprocket with extra deep 19mm 131242-001
[0.75”] side wall flange.
Used in assembly 3BUS210394-001 above.
This deep rimed option is used by some
customers instead of the standard 128354-001
above. This to help prevent timing belt travelling
up onto the pulley sidewall.
The pulley surface is Teflon® hard anodized.
The part number includes a pulley with bearing,
a special attachment shaft 128353-002 and
attachment screw.
2 2 required per frame.
Manifold 128627-002
Air & Water entry to frame including brass
fittings.
Consult on site Frame Job Order Specification

document for correct part number.
Quick Release Air and Water Fitting - Straight 103445-XXX

103445-009 1/4” Outer Diameter Tube 1/4”
NPTF Thread
NPTF Thread
NPTF Thread
NPTF Thread
NPTF Thread
NPTF Thread
CONTROL PANEL
Control Panel (Keypad) 100472-012
Does not include 086351-004 back side board.
Control Panel Interface Board (Serial). 086351-003

Fits onto the back of the 100472-012
3BUS209559 rev K 10-47


Comments
FRAME TEST AND MAINTENANCE

EQUIPMENT
Air Pressure Guage Kit 0-60Psi 2” diameter 3BUS209894-001
This guage can be used to check top and bottom

sensor air manifold pressures.
Cable electrical pin extractor AMP black 013745-001
Use to extract sensor pigtail cable pins.
Cable electrical pin 20-24AWG extractor AMP 100080-003

red/white
Use to extract sensor pigtail cable pins.

Frame Test Connectorised Signal Ribbon Cable 3BUS215046-001
37 pin. The cable has a black protective sleeve
(not shown) .
The cable is 4Metres long allowing one perform
a standardize.
Use this cable to test cable carrier signal cables.
Connect the cable between the ASPC and
Carriage board. This to bypass the cable carrier’s
own ribbon cable.
This picture shows how to use the cable on an

NP12. Use similarly on NP7.
10-48 3BUS209559 rev K


Comments
SP and NP12&7 Connectorised Frames Test 3BUS215047-001
Ribbon Power Cable Kit 4Metres.
The cable is 4Metres long allowing one perform

a standardize.
Use this cable kit to test cable carrier power

cables. Connect the cable between the ASPC and
carriage board similar to shown above for signal
cable.
Smart Sensor diagnostic test cable kit. 200972-001
This cable kit allows limited troubleshooting

operation and diagnosis of smart sensors outside
the sensor bucket.
The kit includes:
1 x electrical extension cable
1 x 101812-003 76cm (2.5ft) long piece of ¼”
inner dameter polyester air hose
4 x 012931-018 hose clamps
NP7 Position Encoder Belt Tension & Belt See picture on page 10-35 3BUS214905-100
Pulley Distance Setting Guage Kit
1
Upgraded frames shipped after 10/01/96 use a three-pin clutch in place of the older two-pin style.
To upgrade, order Kit GK-132085-001.
3BUS209559 rev K 10-49

A1
Figure 10-33 Drive End Column Parts
10-50 3BUS209559 rev K

Replacement Parts for the ASPC

Refer to: Figure 10-34 & Figure 10-35 below and Table 10-6 on page 10-54
H opt
I opt
L
A
M
B
B or C
D
N
E
O
F
P
Figure 10-34 Network Platform ASPC 3BUS208692-001
3BUS209559 rev K 10-51

H opt
I opt
L
A
M
B
B or C
D
N
E
O
S
P
F
Figure 10-35 Network Platform ASPC 3BUS208692-002 (HPIR-T & ATXC)
10-52 3BUS209559 rev K

Figure 10-36 Bulk DC Elements
3BUS209559 rev K 10-53

Plesase be aware that while Figure 10-34 and Figure 10-35 above outline the standard ASPC
configurations delivered by ABB; if a system upgrade or part replacement has occurred with the system
the part used in the system may not be the same as outlined in the Table 10-6. Please physically check
the part ID in the system before ordering a replacement part.
Table 10-6 ASPC Replacement Parts
Key Network Platform Part

Letters Electronics Numbers See Figure
A SBC (Single Board Computer) 3BUS209587-000 Figure 10-34

ASSY 3BUS213621-001 Figure 10-35
B 3BUS210778-000 Figure 10-34
DAQ CARD Assembly Figure 10-35
C 3BUS209702-001 Figure 10-34
HDLC PCI Interface Card
Figure 10-35
D 3BUS208800-001 Figure 10-34
RS485 Serial Card Figure 10-35
E Fiber Optic Ethernet Card 3BUS209375-001 (Obsolete) Figure 10-34
(FO-NIC)* (-001 obsolete, use -022) 3BUS209375-022 Figure 10-35
F 3BUS209064-001 Figure 10-34

PCI Backplane
Figure 10-35
G Standard Signal Interconnect Board 3BUS208728-001 Figure 10-34
(SSIB) 3BUS208728-002 Figure 10-35
H 3BUS208802-001 Figure 10-34
3BUS208802-002
Standard Signal Jumper Board
3BUS208802-002 Figure 10-35
(SSJB) **
3BUS208802-003
3BUS208802-013
I Standard Signal Conditioning Board 3BUS208797-001 Figure 10-34
(SSCB) Figure 10-35
J 3BUS209150-001 Figure 10-34

SBC Power Supply Figure 10-35
K 3BUS208988-001 Figure 10-34
Cable DAQ to SSCB Figure 10-35
L Power Signal Interconnect Board 3BUS208720-001 Figure 10-34
(PSIB) Figure 10-35
M Power Signal Conditioning Board 3BUS208796-001 Figure 10-34

(PSCB) Figure 10-35
10-54 3BUS209559 rev K

Key Network Platform Part

Letters Electronics Numbers See Figure
N 3BUS209090-010 Figure 10-34

FUSE, MINI 10A (RED)
Figure 10-35
O 3BUS209090-002 Figure 10-34

FUSE, MINI 2A (GREY)
Figure 10-35
P 3BUS209090-001 Figure 10-34

FUSE, MINI 1A (BLACK)
Figure 10-35
Q Figure 10-36
NP Bulk DC Power Supply Kit*** 3BUS215432-001
&
or or Figure 10-14
NP Bulk DC Power Supply **** 3BUS215138-001
R CSS Power Supply 3BUS208946-001 Figure 10-36
S ATX Converter Board (ATXC) 3BUS213393-001 Figure 10-35
* 3BUS209375-001 is obsoleted in December 2013; 3BUS209375-022 is its replacement

part. In many situations a software update is required to use this part. See 3BUS209544 -
Network Platform Software Reference Manual or Field Alert 3BUS209375-800 for further
information.
** Please check hardware ID label for exact model details.
*** 3BUS215432-001 is a new power supply kit introduced December 2013. It is a direct
replacement for the original power supply and any of its modules. To repair a failed power
supply or module, replace the complete power supply. See section DC Power Supply
Replacement on page 10-19. The original and now obsolete modular power supply is shown
in Figure 10-24 on page 10-25.
**** New type power supply without its special connecting cable. See section DC Power
Supply Replacement on page 10-19. Use when this power supply type already exists.
3BUS209559 rev K 10-55

Replacement Parts List

Table 10-7 Idler End Replacement Parts
Idler End Replacement
Key Letters Part Numbers
Parts
A Shunt Trip Coil 101901-802
B Circuit Breaker 16 Amp 101901-216
C Circuit Breaker 10 Amp 102104-010
D Circuit Breaker 4 Amp 102104-004
E Circuit Breaker 2 Amp 102104-202
F Power Line Filter 240V, 20 Amp 100376-504
Figure 10-37 Idler End replacement Parts
10-56 3BUS209559 rev K

Table 10-8 Air Filter Regulator Replacement Service Parts

Key Letters Replacement Part Part Numbers
5 um replacement filter element, 80C (176F)

A 103447-200
rated, to suit F73G
0.01 um oil removing replacement filter

B 103447-203
element, 80C (176F) rated, to suit F74H
Figure 10-38 Air Filter Regulator Replacement Service Parts
3BUS209559 rev K 10-57

Table 10-9 Liquid Cooling Unit Water Supply Pre Filter Replacement Service Part
Key Letters Replacement Part Picture Part Numbers
Water filter unit replacement 50 micron ,

508mm (20”) long internal filter.
The filter element fits inside this water supply

101544-001
inline filter unit
10-58 3BUS209559 rev K

11 Troubleshooting
This chapter describes basic troubleshooting. Much of the troubleshooting can be done using the
LEDs in the Network Platform electronics cabinet and through console messages that are displayed
at startup.
Section ...................................................................................................... Page
Alarm Messages .........................................................................................11-2
ASPC LEDs .................................................................................................11-3
Power Down and DC Power Analysis ........................................................11-6
AI Self Test feature .....................................................................................11-7
Diagnostic Card Operation....................................................................... 11-11
Basic Troubleshooting and Supportline Data Collection Steps ............ 11-22
Troubleshooting Data Collection Requirements for ABB Supportline . 11-25
VLT Motor controller troubleshooting ..................................................... 11-26
3BUS209559 rev K 11-1

Alarm Messages
Alarm messages are associated with each of the Service Workstation Health Reports. These alarms
will appear as a part of the Frame Health Report (Alarms tab, then Electronics or Frame tab).
Alarms from other health reports are explained in manuals describing operation and maintenance for
those features.
Note: Most actions suggested below assume the hardware path leading back into
the software is functioning. This includes the SSCB board, the SSJB
board, and the SSPB board. These are also candidates for replacement
during any troubleshooting.
Electronics Alarm Messages

A Board Temperature is Out of Limits
The temperature in the ASPC box has risen over the specified temperature. This temperature
measurement comes from the 1st SSCB.
Chiller Flow Out of Limits
The digital input indicating the state of flow (on/off) from the chiller flow unit is showing no flow.
The chiller flow unit provides cooling for the IR Moisture sensor mounted on the scanner.
Voltage Level Out of Limits
Will be raised if the +12V or -12V are outside limits defined in Frame Configuration or if +15V or -
15V fails hardware limit checks in SSCB.
Frame page in SWS Health Pages shows the +12V or -12V voltage levels and the status of +15V or
-15V as do LED’s on SSCB.
Motor Stopped by Obstacle
The head package has failed to follow computed trajectory causing an excessive position error.
Possible areas of investigation are the motor controller, a mechanical failure of the drive train,
incorrect setup of the motor controller.
Head Position Verify Test - Timeout
The ‘Self Test’ push button on the Frame Control Panel has been pushed with the frame in LOCAL
(hand) and the sequence of re-synchronizing and positioning to off-sheet has not been able to
complete. Check for defective motor controller, encoder, SSCB, 1st DAQ or home limit switch.
The red LED on the panel push button should be flashing.
Head Position Verify Outside Limits
The ‘Self Test’ results are not within acceptable limits. The resultant off-sheet position reached was
not within 5mm (configurable) of the original position. The red LED on the push button will remain
flashing. Possible problem with the encoder slipping, home limit switch, SSCB or 1st DAQ card.
Beam Air Flow Off
There currently is no air flow switch monitoring the beam air flow. If this alarm appears, it means
that the bit for air purge to the Network Platform is being set. If this input is not being used, you can
use the Network Platform Diagnostics Tool or Configuration Tool to invert the input.
11-2 3BUS209559 rev K

ASPC LEDs
There are several LEDs in the ASPC. Below are described the LEDs that can be helpful in trouble
shooting.
PCI backplane LEDs

At the bottom right hand corner of the PCI backplanes are six (6) LEDs. Each of them provide an
indication of presence of the corresponding power on the backplane, however the LED does not
indicate whether voltage level is correct. In NP only 5VSB (see below), -12V, +12V, +5V and
+3.3V should be lit. If any of these LEDs are not illuminated it can indicate either:
a) No power to SBC power supply.
b) Faulty SBC power supply or AXTC board.
c) Faulty connection from SBC power supply to PCI backplane.
d) Faulty PCI backplane.
e) SBC has not asked for power on (see below).
The behavior of 5VSB is different depending on what version of Single Board Computer (SBC) and
associated power supply is used.
For SBC part 3BUS213621-001 (newer SBC)

The 5VSB (+5V Standby) should always be lit, if it’s not illuminated ensure the
ATXC(3BUS213393-001) adapter board is present.
If only 5VSB (+5V Standby) is lit, this indicates that the single board computer has not asked for
power to be turned on, please see 3BUS209544 - Network Platform Software Reference Manual for
further troubleshooting.
For SBC part 3BUS209587-000 (older SBC)

The 5VSB (+5V Standby) should always be off, if it’s illuminated ensure that the ATX adapter
board is not present.
PCI backplane
5VSB -12V -5V +12V +5V +3.3V
Figure 11-1 PCI backplane LEDs
3BUS209559 rev K 11-3

ATXC LED
The ATXC (3BUS213393-001) has one LED with the following functionality:
LED Status Details
Not illuminated SBC power supply (3BUS209150-001) not functioning or

ATXC not functioning.
No PCI backplane LED illuminated
Illuminated GREEN SBC power supply functioning.

No PS_On signal received from SBC.
PCI backplane LED for +5VSB illuminated
Illuminated RED SBC power supply functioning.

PS_On signal received from SBC.
PCI backplane LEDs for+5VSB, +5V, +3V3 & -+12V
illuminated.
Table 11-1 ATXC LED details
RS485 Serial Card LEDs

On the RS485 card are sixteen (16) LEDs. Each pair of LEDs corresponds to one communication
channel, where the TX LED indicated whether NP software is transmitting information and the RX
LED indicates whether NP software is receiving information from a device connected to that
channel. All LEDs will be OFF until Network Platform Software is fully running. See Table 11-2
for normal channel configuration.
Table 11-2 RS485 Serial Card LEDs

LED name Standard assigment
TX1 and RX1 IDLER END CONTROL PANEL
TX2 and RX2 DRIVE END CONTROL PANEL
TX3 and RX3 REMOTE CONTROL PANEL
TX4 and RX4 COLOR TOP COMM CABLE
TX5 and RX5 COLOR BOTTOM COMM CABLE
TX6 and RX6 FUTURE USE
11-4 3BUS209559 rev K

Power Signal Conditioning Board (PSCB) LEDs

On the edge of the board are sixteen (16) LEDs in three (3) groups.
Top group DH1, …, DH4 indicating DC power switching.
Middle group AH1, …, AH10 indicating AC power switching.
Bottom group PWM1, PWM2 indicating DC high speed pulse width modulation.
The status of the the LED indicates whether the switching circuit is commanded closed (ON) or
commanded open (OFF). For the PWM channels ON indicates that circuit is closed with more than
0% duty cycle.
Refer to functional diagrams for appropriate sensor in 3BUS209281 – Network Platform NP1200
and RNP 1200 Print book or functional diagrams in System Data Book for the Frame.
The LEDs do NOT indicate presence of power signals being switched or whether the switching
circuit on PSCB is operational.
Standard Signal Conditioning Board (SSCB) LEDs

On the edge of the board are six (6) LEDs. Functionality of each LED is described in Table 11-3.
Limits in Table 11-3 are for SSCB 3BUS208797-001 rev B.
Table 11-3 SSCB LEDs

LED Description
“Steady State” this LED is illuminated RED if SSCB has power and
software has not yet started. When software has fully started this LED
will go off.
When LED is RED all digital outputs from SSCB are disabled.
The LED will stay RED after software start under the following
conditions:
SS
1. Critical error detected by software, use SWS or ABB Debug Client to
further trouble shoot.
2. Faulty DAQ Card or DAQ output channel.
3. Faulty connection between DAQ card and SSCB.
4. Incorrect channel assigned for Watchdog in configuration.
+5V GREEN indicates presence of +5V supplied by the DAQ card.

GREEN indicates that +12V supplied from Modular Power Supply is
+12V
measured as more than +11.00V.
GREEN indicates that -12V supplied from Modular Power Supply is
-12V
measured as less than -11.00V.
GREEN indicates that +15V supplied from Modular Power Supply is
+15V
measured as more than +14.00V.
GREEN indicates that -15V supplied from Modular Power Supply is
-15V
measured as less than -14.00V.
3BUS209559 rev K 11-5

Power Down and DC Power Analysis

If the system resets because of a power down condition, the cause can be determined by retrieving
or viewing the stored debug information. The temperature values within the system are monitored
and checked against safety limits. When a safety limit is violated, the system will issue an alarm
message. When the power down limit is exceeded, temperature data and voltage data is written to
event log and event log is exported to the data partition of SBC. After power up the event log can
be viewed by connecting to the Scanner using Scanner update Tool, see 3BUS209544 -
Network Platform Software Reference Manual.
11-6 3BUS209559 rev K

AI Self Test feature

Usage
Network Platform software contains an AI self test feature. The self test feature is enabled through
SWS and results can be retrieved from Diagnostics tool.
The self test feature is a trouble shooting tool and should be used as such. The integrity of
measurements should be ensured by regular check samples, not by the self test feature.
The self test feature is recommended for use in the following situations:
a) An analog input reports incorrect value.
b) An analog input seems noisy.
c) There is a suspected problem with thermistor reference.
d) There is a suspected problem with AC current measurements.
Result of the self test will show whether problem exists in ASPC electronics or outside the ASPC
box.
Details
When self test sequence is enabled. NP software will for a few seconds instruct electronics to:
a) Output a self test signal with selected voltage.
b) Switch majority of used analog input channels to measure the self test voltage.
c) Switch current measurements on Power Signal Conditioning board to use the self test
voltage.
d) Switch the ASPC Temperature channel to measure Thermistor reference voltage.
SSIB
SSCB PSIB
DAQ
PSCB
Self Test Out
SSJB
BW Electrometer
Heater Current
ASPC Temperature +5V_ref
Figure 11-2 Self test functional example

See Figure 11-2 for a functional example see Table 10-6 ASPC Replacement Parts for
explanation of abbreviations.
3BUS209559 rev K 11-7

Instructions
a) Take scanner off sheet.
b) Open Service Workstation.
c) Select page Frame -> Measurements -> Current
d) Type in a self-test voltage between -10V and +10V e.g. 2.5 V.
e) Select the “Enable Electronics Self Test” check box.
Figure 11-3 Self test SWS controls

f) Self test will run for 2-4 seconds, it’s normal to see alarms appearing for sensors.
g) Open “ABB NP Scanner Diagnostics” tool.
h) Select “IO Signals” -> “AI signals” on the scanner where test was run.
i) Review 1 second average of AI signals where suspected problems exists.
11-8 3BUS209559 rev K

Figure 11-4 Example self test result with 2.5V Self test voltage
Expected results
ASPC Temperature
Frame Logic ASPC Temperature should report twice the thermistor reference voltage i.e. 10+/-0.2V.
Values outside these limits indicates a problem with one of the following:
a) Thermistor reference or analog input AI2 on SSCB.
b) Cable between DAQ and SSCB.
c) DAQ card
d) Connection or insertion of any above.
Analog inputs for current measurement
Please refer to functional diagram for your sensor complement.
Any current measurement from an AC current switching circuit (AH-1..10 in functional), connected
to a Current Monitoring Analog Input (AI CM in functional), should report a positive voltage of
same magnitude as the self test voltage +/- 200mV
Values outside these limits indicates a problem with one of the following:
a) Jumper configuration (most likely candidate).
b) Current monitoring circuit on PSCB.
c) Interconnect between PSIB and SSIB.
d) Signal conditioning on SSCB
e) Cable between DAQ and SSCB
f) DAQ card
g) Connection or insertion of any above.
Other analog inputs
3BUS209559 rev K 11-9

Please refer to functional diagram for your sensor complement.

All other types of analog inputs i.e.
a) Standard Analog Input, "AI S" in functional diagram
b) Analog Input for thermistors, “AI T” in functional diagram.
c) High Speed Analog Inputs, “AI HS” in functional diagram
Should report the same voltage as the self test voltage +/- 200mV
Values outside these limits suggest a problem with one of the following:
a) Signal conditioning on SSCB
b) Cable between DAQ and SSCB
c) DAQ card
d) Connection or insertion of any above.
11-10 3BUS209559 rev K

Diagnostic Card Operation

The Network Platform diagnostic card (See Diagnostic Card on page 11-14) slides into a plug-in
unit that provides a source for easy checks for voltages and signals. The Smart Processing Center
and the Sensor Electrical Interconnect board (SEI) have diagnostic connectors with which the plug-
in unit connects.
Test Card Kit
Test Board Kit

Smart Processing Center Scanning Platform
Top Signal
TOP
J1 SIGNAL
DIAGNOSTICS
J2
TOP SIGNAL
J3
J4
TOP POWER
DVM
Figure 11-5 Test Board Hookup
3BUS209559 rev K 11-11

Diagnostics Performed at the Sensor

Reference Figure 11-6 below and Figure 11-7 on page 11-13.
The Sensor Electrical Interconnect board (SEI) is a printed circuit board used in basis weight and
ash source and detector modules. The SEI distributes signals and power to the proper connectors. It
contains the sensor diagnostics plug which allows external access to internal signals for
troubleshooting. Electrical ORUs have cables or plugs that interface to this board. The air
solenoids, PTC module, and the CAP thermistor make connections to this board in the source
module. The Gap sensor printed circuit board, ELHV board, PTC power and CAP thermistor all
plug into this board in the detector module.
The diagnostic access port is the cover located in the sensor module housing allowing external
access to the diagnostic connector located on the SEI. Head package sheet guides may have to be
removed to gain access to this panel.
The sensor diagnostic plug is a 37-pin connector designed to accept the diagnostic tool typically
used to troubleshoot Smart Platforms and Smart Processing Centers. This diagnostic access is
important for STLK-11 and STLP-3 sensors since it is impossible to gain internal access to powered
up assemblies. Side plate access to internal assemblies does not exist. Sensor power is
automatically disconnected through the connector if internal access is required.
There are three Light Emitting Diodes (LEDs) on the SEI board. The LEDs indicate the shutter
status, internal check sample and PTC heater assembly on the source module. On the detector
module the status of the PTC heater assembly is indicated, the other two lights are not used. They
can be viewed through acrylic windows at the end of the sensor housing. Removal of the sheet
guides may be necessary for clear viewing of the
LEDs.
CAP
Diagnostic Plug
Electrical
Interconnect
Board Diagnostic
Access
P TC Heater Port
Module Diagnostic
LEDs
Air Solenoid
Figure 11-6 Basis Weight Source Module
11-12 3BUS209559 rev K

ELHV
Board
Electrical
Interconnect
Board
Diagnostic
LEDs
Diagnostic
Access Port
Diagnostic
Plug
Figure 11-7 Basis Weight Detector Module
3BUS209559 rev K 11-13

Diagnostic Cards
The function measured on the Diagnostic Card test points will be determined by the location the
card is plugged into. Use the appropriate function drawing to reference the test point number to the
voltage to be measured.
The pictured diagnostic cards may not represent those for

your system.
The Top Power card is to be used for diagnostics performed at the sensor only. Refer to Figure
10-9 on page 10-14.
1 POWER COMMON
SYSTEM
20 -12 VDC LO 19
IR
2 HV TESTCARRIAGE
ONLY
120 VAC HI 37
21 +12 VDC
SYSTEM CALIPER
PRESSURE LO 36
22 RETURN
HEATED
AIR WIPE LO 35
GLOSS LAMP
23 POWER 120 VAC
HI 34
24 RETURN ASH
OPTIPAK LAMP HEATER LO 33
25 POWER 120 VAC

HI 32
28 -15 VDC
BW
HEATER LO 31
27 SIGNAL
COMMON
SYSTEM CALIPER
HEAD LIFT
28 +15 VDC
LO 30
SCANNING PLA TFORM

TOP POWER
086086-052, SIDE 1, REV A
Figure 11-8 Sample Diagnostic Card: Top Power
11-14 3BUS209559 rev K

The Bottom Power card is to be used for diagnostics performed at the sensor only. Refer to Figure
11-9 below.
1 POWER COMMON
20 -12 VDC 19
SYSTEM 37
21 +12 VDC
BW SHUTTER
LO 36
22 SHUTTER CALIPER HEATER/

VACUUM/PURGE LO 35
ASH
23 FLAG 120 VAC
HI 34
24 RETURN
ASH
HEATER LO 33
GLOSS LAMP
25 POWER
120 VAC
HI 32
26 -15 VDC
BW
HEATER LO 31
27 SIGNAL SYSTEM
COMMON
HEATED
AIR WIPE LO 30
28 +15 VDC
SCANNING PLA TFORM

BOTT OM POWER
086086-052, SIDE 2, REV A
Figure 11-9 Sample Diagnostic Card: Bottom Power
3BUS209559 rev K 11-15

The Top Signal card is to be used for diagnostics performed both at the sensor and the ABB Smart
Processing Center backplane. Refer to Figure 10-11 on page 10-15.
1 ASH (Purge)
20 COMMON DIAGNOSTIC IR LAMP SENSOR 19
2 BW (Purge) GLOSS CLAMP 37
21 HI OPTIPAK CLAMP 18
BW 36
3 LO
22 HI 17
ASH OFF
4 LO AUTO EDGE 35
23 HI OF SHEET ON 16
BRIGHTNESS ASH 34
5 LO ELECTROMETER
24 HI GAP ATC GAP TEST/CLAMP BW 15
BW
6 LO SENSOR INTERLOCK SHEET LO 33
25 HI TEMPERATURE HI 14
GLOSS THERMISTOR 32
7 LO ASH
26 +4.5V BIAS 13
8 IR LO 31
27 HI CALIPER LOGIC HI 12
AIR
9 LO 30
CAP 11
28
or ATC COLUMN
BW
10 +4.5V BIAS THERMISTOR 29
SCANNING PLA TFORM

TOP SIGNAL
086086-051, SIDE 1, REV A
Figure 11-10 Sample Diagnostic Card: Top Signal
11-16 3BUS209559 rev K

The Bottom Signal card is to be used for diagnostics performed both at the sensor and the ABB
Smart Processing Center backplane. Refer to Figure 11-11 below and to Figure 11-12 on page
11-18 for the Backplane diagnostic card.
1 ASH (Purge)
19
20 COMMON DIAGNOSTIC
2 BW (Purge) GLOSS CLAMP 37
21 HI (-) OPTIPAK CLAMP 18

CALIPER
SHUTTER
PROXIMITER 36
3 LO SWITCH
CURRENT 17
22 HI MONITOR
FORMATION ASH MONITOR 35
4 LO COMMON
X-RAY H.V.
23 HI MONITOR 16
OPACITY 34
5 LO
24 INTERNAL CAP 15
or ATC COLUMN
BW ALARM
33
6 +4.5V BIAS GRID
THERMISTOR SHUTTER
BW 14
25 HI SWITCH
GLOSS INT. CHECK
32
7 LO SAMPLE
GAIN 13
26 HI OPTIPAK MONITOR
8 LO VACUUM LO 31
SIGNAL
27 HI CALIPER HI 12
VACUUM/ IR DECREASE
9 LO GAIN
30
GAIN
28 THERMISTOR 11
+15V
ASH INCREASE
10 +4.5V BIAS 29
GAIN
SCANNING PLA TFORM

BOTT OM SIGNAL
086086-051, SIDE 2, REV A
Figure 11-11 Sample Diagnostic Card: Bottom Signal Sensor
3BUS209559 rev K 11-17

J 17
J 18
Figure 11-12 Power Cable Connectors
11-18 3BUS209559 rev K

The Bottom Auxiliary Power card is to be used for diagnostics performed at the sensor only.
1 ASH +15V
20 -12 VDC VOLTAGE 19
ASH
RETURN 37
SYSTEM
21 +12 VDC
36
22 ASH COMMON
ASH +28V
35
23 ASH -15V 120 VAC

HI 34
24 LO ASH +28V
ASH RETURN 33
H.V.
25 WIPER 120 VAC HI 32
26 -15 VDC
31
SIGNAL
27 COMMON SYSTEM 30
28 +15 VDC
SCANNING PLATFORM
BOTTOM AUX POWER
(ASH WITH REMOTE J-BOX) ONLY
086086-053 SIDE 2, REV A
Figure 11-13 Sample Diagnostics Card: Bottom Auxiliary Power
3BUS209559 rev K 11-19

The Detector Module test points to be used for diagnostics performed at the sensor only.
1 +12 VDC
20 Purge Sensor Volts 19
2 -12 VDC (not used) PTC Monitor (Switch) 37

ELHV PcBd ºC/10 Chassis Ground 18
21
3 Chassis Ground PTC Monitor (High) 36
22 CAP Thermistor Low 17
4 +15 VDC Chassis Ground 35
23 CAP Thermistor High 16

2
5 -15 VDC GAP Signal Low 34
24 15
Gap Signal High 2 33

6 Signal Common
25 Signal Common ELHV Test (Test=Low) 14
7 Gap PcBd ºC/10 32
26 13
8 31
27 Electrometer Low 12
9 30
28 Chamber HV/100 Electrometer High 11
10 Gap Oscillator 29
(TOP) Detector Module, STLK11, STLP3, STLXR3

STLXR3 only
Figure 11-14 Sample Diagnostics Card: Detector Module
11-20 3BUS209559 rev K

The Source Module test point to be used for diagnostics performed at the sensor only.
1 +12 VDC
20 Alarm Grid, STLP3 Purge Sensor Volts 19
2 -12 VDC PTC Monitor (Switch) 37
21 Chassis Ground 18
3 Chassis Ground PTC Monitor (High) 36
22 CAP Thermistor Low 17
4 Chassis Ground 35
23 CAP Thermistor High 16
5 34
24 NC Shutter Stat (Red) 15

6 33
25 NO Shutter Stat (Grn) 14

7 Filament Monitor 32
26 Chk Samp Stat (Future) 13
8 Ctrl, Shutter Monitor Common 31
+5V Ref 12
27
9 Ctrl, Int Chk Samp Anode Curr. Mon. 30

28 11
10 X-ray HV/1000 29
(BOTTOM) Source Module, STLK11, STLP3, STLXR3

STLXR3 only
Figure 11-15 Sample Diagnostics Card: Source Module
3BUS209559 rev K 11-21

Basic Troubleshooting and Supportline Data Collection

Steps
 Arrive on site prepared with necessary knowledge about the issue. Take required safety clothing,
safety pass, tools, documentation and test parts to site.
 At site start by discussing the issue with the customer. Re-confirm all collected data relating to the
issue is correct and add to it if incomplete.
 ABB Service and Technical supportline engineers require basic data including:
 The scanner job number in the form example AG45F1.
 Customer name, frame number and paper machine number.
 Describe the issue. Discuss with the customer what has happened, when and how.
Document this for the supportline engineer. Include relevant photographs, SWS
screenshots, host system screenshots. Identify when the problem first occurred and if
anything unusual occurred preceding the issue.
 When and what was the last change(s) made to the system.
 Confirm who services the scanner.
 What is the NP software release, the SWS release, the Host system type and software
release in use?
 Is the process producing a lot of steam condensate? Does it contain contaminants which
might corrode components? Use a small inspection mirror to check the back side of the
larger circuit boards such as the end column and carriage boards. Carry a magnifying glass
to inspect detail. Check Hemi Ir green military plug and socket for green contamination of
the gold pins. Is the process environment extreme in any way. For example very high
temperature or high frequency vibration. Does the product contain very corrosive
ingredients. Are there signs of corrosion on other nearby parts of the paper machine?
 The issue type may be software, electrical/electronic, electromechanical or mechanical.

Dependant on the issue type one may deploy some of the following troubleshooting steps.
Exercise great care when working with a/c voltages and moving parts.
 Start by visually inspecting the scanner. Is it well serviced?

Look for any signs of damage. For example burns. Look for evidence of corrosion.
Perhaps check the top and bottom head package side interface boards for water ,
contaminant ingress, burn marks etc.
 Try to eliminate large items such as the frame cable carrier and sensors as quickly as
possible.
 The service engineering cables listed in the spare parts section of this manual can be used
to troubleshoot these cable carrier and sensor hardware issues. This with the scanner wiring
schematic drawings.
 Isolate the cable carrier wiring and sensors from the rest of the frame. This is easily
accomplished by power down and unplugging the cable carrier power cables from the
ASPC end J3, J4 (Top wiring) J17 and J18 (Bottom wiring). Similarly try unplugging the
signal cable from ASPC end J1 (Top) and J16 (Bottom). Also unplug only top or only
bottom connector. Try various permutations e.g. only Top signal unplugged.
 Try temporary unplugging the IR 12V transformer located in the upper carriage.
 When troubleshooting Hemi IR sensor related issues try the following. Confirm water flow
is present. Check the SWS displays correct lamp current circa 1 amp, correct lamp voltage
circa 12v (or 18v), the motor revolutions are 50 (50 Hz) or 60(60Hz). Power down. With
the 12V transformer plugged in try unplugging the Hemi IR sensor top source head pigtail
cable. Use a small insulated wire jumper to connect the pins H to K (simulates bypassing
11-22 3BUS209559 rev K

the over temperature protection circuit). Power up and measure the transformer output 12
volts a/c between pins J (Hi) and L (Lo).
 Unplug or remove all/some sensors from their buckets and check if it solves the issue.
 Unplug any non core circuit boards and check if it solves the issue.
 Identify if the issue is coming from an external source such as via the reel turn up or sheet
break cables. Unplug the cable to check if the issue disappears.
 Check all voltages.
 Power off/on. Check that a good current backup exists before powering off.
 Where relevant power off and check for short circuit to chassis earth.
 Occasionally circuit board and cable connector parts can make bad/intermittent contact.
Try unplugging and plugging boards.
Carefully wiggle cables and observe if the problem ceases.
Always confirm the root cause and fix the problem to avoid re-occurrences.
 Enable /toggle digital outputs and observe digital Inputs as explained in the 3BUS209544
NP Software manual.
 When the issue is in the NP computer electronics enable, collect and analyze the NP data
collected per 3BUS212816 NP Troubleshooting Data Collection Requirements for
Supportline document. This is available on ABB SolutionsBank.
 Frame synchronization and movement issues. Check the SWS for correct head position
measurement. Inspect the position encoder and it’s drive shaft coupling assembly. Look for
any loose retaining hardware.
 Check the white dust seal belt. Make sure it is not binding and is free to move through it’s
head package rollers.
 Check the head package waybar wheels, carbon brushes and timing drive belt tension.
 Software issues may be solved by current software releases. The current software release
may be downloaded from ABB SolutionsBank. Read the release notes to discover what
issues have been addressed in the release. Update site software if necessary.
 Software issues may be due to incompatibility between Host and Scanner software releases.
Upgrading both sides to current releases may solve.
 When the reported issue is on the Host side check if the issue exists on the SWS frame side
also.
 The 3BUS209560 NP Alarms Reference manual, 3BUS209544 NP Software manual and

Accuray Data Dictonary Reference Manual are supplied with each SWS ABB Industrial IT
800xA software. See Figure 11-16 below. Check ABB SolutionsBank to find the latest
versions. Some of the sensor manuals also contain alarm information.
Collected spxxxx Debug file tags such as sp1631 are explained in the Accuray Data
Dictonary Reference Manual.
3BUS209559 rev K 11-23

Figure 11-16 ABB Alarms and Software Documentation is available in the SWS
11-24 3BUS209559 rev K

Troubleshooting Data Collection Requirements for ABB

Supportline
When ABB L1 & L2 service engineers require further assistance they may contact ABB supportline.
Engineers contacting ABB supportline with NP issues should first read and follow the data collection
recommendations in 3BUS212816 NP Troubleshooting Data Collection Requirements for Supportline
available on solutionsbank and ABB library.
3BUS209559 rev K 11-25

VLT Motor controller troubleshooting

Notes on Motor Controller Tuning
The table below outlines some common issues observed with the motor controller and a list
of possible causes and reasons. It also outlines the tuning actions required to deliver
optimal movement, for a variety of situations observed on the frame.
Issue Information
- No movement possible - Verify the [ON] LED is illuminated and the [Alarm] LED is
when VLT unit is extinguished on the VLT unit.
powered. - Ensure the correct mode on the VLT is chosen, The [Auto
On] LED must be illuminated for movement to be possible.
- Ensure all wires are securely fastened to the terminals on the
VLT unit.
- Start signal is not present; verify the signal level between
terminals 18 & 20 is about 0V. If this is not the situation the
head split signal may not be present.
- Verify jumper settings on S200 switch are correctly set.
- Measure signal level between terminals 53 & 55, while
pushing either the or jog buttons in local

mode. This value should be greater than ±3V.
- Apparent delay in - To overcome initial inertia of the head package it is

direction change during necessary to ‘preload’ the signal to the motor. If this
normal scanning. ‘preload’ is not present or it is too small, the motor appears
to delay responding to requested movement commands, until
the signal applied to the motor is sufficient to allow
movement. In extreme cases movement may not occur.
- Verify parameter 1-55 is set according to the value given in
‘Table 5-2 Motor Drive Parameter Settings (Scanner Defaults)’,
noting that this value may have been optimized during
commissioning.
Refer to the section ‘Motor Controller Adjustment of U/f
Characteristic – U’ for further details on setting this parameter.
- Motor ‘creepage’ when - To overcome initial inertia of the head package it is

in parked position. necessary to ‘preload’ the signal to the motor. If this
‘preload’ value is too large, when the head package is in a
rest position it may move very small distances.
- Verify parameter 1-55 is set according to the value given in
‘Table 5-2 Motor Drive Parameter Settings (Scanner Defaults)’,
noting that this value may have been optimized during
commissioning.
Refer to the section ‘Motor Controller Adjustment of U/f
Characteristic – U’ for further details on setting this parameter.
11-26 3BUS209559 rev K

Issue Information
- Alarm message - Verify that parameters 3-03 and 4-04 are set to the correct
indicating blockage to values according to Table 5-2 Motor Drive Parameter Settings
head movement, when (Scanner Defaults) on page 5-8. Both of these values are the
no blockage appears to same. These values limit the maximum speed of the motor
be present. and thereby the head package movement. If either of these is
set too low the head package will not be able to follow the
desired movement profile.
- Abrupt braking or - If the stopping action of the frame appears aggressive

overshoot of system especially during jogging movements in local mode it may
when stopping be necessary to adjust the braking time for the motor
movement. controller.
Setting a larger value in parameter 3-42, increases the time
used for the motor to come to a standstill.
Be aware that increasing this value may cause overshoot of
limit switches.
- If overshoot of the rest position occurs during stopping of the
head package with scan movement; it may be necessary to
adjust the braking time for the motor controller.
Setting a smaller value in parameter 3-42, reduces the time
used for the motor to come to a standstill and will reduce
overshoot.
- Small movement in On system initialization, a small motion of the motor may be

motor on power up sometimes observed. This is normal.
- Display showing - Ensure that parameter 6-10 is not set to 0 V, this should be
frequency value when set to 0.07 V.
motor not moving.
 AL7 message on panel  Occurs during braking from high speed, normally during
and controller in alarm frame tune activity.
mode Software change in 02.70 of VLT software changed the
default setting of a parameter leading to this issue in some
instances.
 To resolve, ensure parameter 14-26 is set to value 1.
Table 11-4 Addressing Issues
3BUS209559 rev K 11-27

Alarm and Fault reporting (VLT)

In the case of a warning, alarm or trip situation it is required to use the [OFF Reset] key to
acknowledge/reset the state after the situation has been addressed. The table below gives an outline
of the possible warning, alarm and trip situations for the VLT motor controller.
In the situation where it is required to work on the

controller to address an alarm, warning or trip situation;
ensure power has been isolated from the controller
before commencing this work.
Trip
No. Description Warning Alarm
Lock Cause of Problem
Signal on terminal 53 or 60 is less than 50%
2 Live zero error X X
of value set in par. 6-10, 6-12 and 6-22.
Missing phase on supply side, or too high
4 Mains phase loss X X X
voltage imbalance. Check supply voltage.
7 DC over voltage X X Intermediate circuit voltage exceeds limit.
Intermediate circuit voltage drops below
8 DC under voltage X X
“voltage warning low” limit.
9 Inverter overloaded X X More than 100% load for too long.
Motor ETR over Motor is too hot due to more than 100% load
10 X X
temperature for too long.
Motor thermistor Thermistor or thermistor connection is
11 X X
over temperature disconnected.
Torque exceeds value set in either par. 4-16
12 Torque limit X
or 4-17.
13 Over Current X X X Inverter peak current limit is exceeded.
14 Earth fault X X Discharge from output phases to ground.
16 Short Circuit X X Short-circuit in motor or on motor terminals.
17 Control word timeout X X No communication to frequency converter.
Brake resistor short- Brake resistor is short-circuited, thus brake
25 X X
circuited function is disconnected.
Brake chopper short- Brake transistor is short-circuited, thus brake
27 X X
circuited function is disconnected.
28 Brake check Brake resistor is not connected/working
Power board over Heat-sink cut-out temperature has been
29 X X X
temp reached.
Motor phase U
30 X X Motor phase U is missing. Check the phase.
missing
Motor phase V
31 X X Motor phase V is missing. Check the phase.
missing
Motor phase W
32 X X Motor phase W is missing. Check the phase.
missing
38 Internal fault X X Contact local ABB service engineer.
47 Control Voltage Fault X X X 24 V DC may be overloaded.
AMT check Unom and Wrong setting for motor voltage, motor
51 X
Inom current and motor voltage.
52 AMT low Inom X Motor current is too low. Check settings.
59 Current limit X VLT overload.
11-28 3BUS209559 rev K

Trip
No. Description Warning Alarm
Lock Cause of Problem
Actual motor current has not exceeded
Mechanical Brake
63 X “release brake” current within “start delay”
Low
time window.
Drive Initialized to All parameter settings are initialized to
80 X
Default Value default settings
Table 11-5 VLT Warning & Alarm List
3BUS209559 rev K 11-29

Default Vendor Parameter Settings (VLT)

The list of parameters given in the section ‘Motor Drive Parameters’ are those which vary from the
default settings as delivered by the motor controller vender. There are many other parameters
available in the VLT controller, however these are either not influential for the ABB application or
the default setting of these parameters as delivered from the supplier is the desired setting for the
ABB application.
As the lifecycle of this controller evolves, more parameters may become available as functionality is
added or changed. ABB monitors these changes with respect to the ABB application. Where
necessary; parameter settings will be updated and a field notice will be issued regarding this change.
In all other situations the default settings of these parameters are suitable for the ABB application.
Further information regarding the latest parameters settings and description should be taken from
the VLT manufacturer’s website, as this is updated regularly with the latest details.
Resetting vender default parameters should only be

executed in the situation where actual parameter
settings cannot be restored from the LCP unit and many
settings appear incorrect.
The procedure for restoring vender default values is as follows:
2. Select Group 0 and Parameter 51.
3. Choose option [9] and press [OK] to select it.
4. The display now indicates an alarm message [AL80], the alarm LED illuminates and
the mode is now [Auto On].
5. Press [Off Reset] to acknowledge the alarm and [OK] to remove the message from the
display.
6. Re-enter the motor drive parameter settings outlined in Table 5-2 Motor Drive
Parameter Settings (Scanner Defaults).
11-30 3BUS209559 rev K

3BUS209559 K en NP 700 Installation and Maintenance Manual

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Network Platform 700

Installation and Maintenance Manual

Produced by QCS Product Development.

Document Version History

Renamed several headings in Section 10 Replacement Procedures to better describe their

Added text to Flex Cable Suspension Replacement on page 10-17

3BUS209559 rev K iii

Version Effective By Changes

GK Change 3bus214905-001NP7 PosEncoderBeltTensionCheck Tool deflection from 10mm to

Caution and Warning Symbols

Geometric Form Meaning

General Meaning of Safety Colors

Red Stop Stop signs

This color is also used for fire-prevention and fire-fighting equipment

Blue1 Mandatory action Obligation to wear personal

Yellow Caution, risk of danger Indications of dangers,

Green Safe condition Escape routes

1. Blue is considered a safety color only if used in a circular shape.

Definition of Cautions and Warning Symbols

This symbol warns of dangerous voltage. This symbol

This is a radiation warning and is used when ionizing

This is a general warning symbol and is to be used if

This symbol warns of potential electrostatic

This symbol warns of a potential crushing hazard.

This symbol warns of a potential hand or

3BUS209559 rev K vii

This symbol warns that equipment may

This symbol is a reminder that the motor must be

This symbol is a reminder that it is mandatory to

See WARNING text.

Exposed moving parts can

This symbol indicates the maximum

viii 3BUS209559 rev K

1 PRODUCT OVERVIEW ............................................................................ 1-1

2 RADIOLOGICAL SAFETY ........................................................................ 2-1

3 HARDWARE INSTALLATION .................................................................. 3-1

4 UTILITY SERVICE INSTALLATION ......................................................... 4-1

Air and Water Supply ................................................................................... 4-3

5 PLATFORM TUNING ............................................................................... 5-1

6 MEASUREMENT SETUP ......................................................................... 6-1

7 CONTROL PANEL OPERATION ............................................................. 7-1

8 STARTUP OPTIONS ................................................................................ 8-1

9 MAINTENANCE PROCEDURES .............................................................. 9-1

10 REPLACEMENT PROCEDURES ........................................................... 10-1

11 TROUBLESHOOTING ............................................................................ 11-1

xii 3BUS209559 rev K

Figure 5-13 Automatic Edge-of-Sheet Position Measurements 5-24

3BUS209559 rev K xiii

Figure 10-3 Alternative Method of Checking Drive Belt Tension 10-4

xiv 3BUS209559 rev K

Figure 11-14 Sample Diagnostics Card: Detector Module 11-20

xvi 3BUS209559 rev K

Table 10-8 Air Filter Regulator Replacement Service Parts ..........................................10-57

3BUS209559 rev K xvii

3BUS209559 rev K 1-1

Host Computer System

Figure 1-1 System Overview

1-2 3BUS209559 rev K

3BUS209559 rev K 1-3

ABB Smart Processing Center (ASCP)

Fuse 1 + 12 Volts DC Fused (Used for Digital Inputs to the NP)

Fuse 2 - 12 Volts DC Fused (Used for Digital Inputs to the NP)

1-4 3BUS209559 rev K

Figure 1-2 Network Platform ASPC Block Diagram