1190 Setup&Installation

IndustrialIT Quality ControlSetup and Installation Manual(Release 5.0 & later)

PROPRIETARY DATAThis document contains proprietary data of ABB Inc.

No disclosure, distribution (electronic or otherwise), reproduction,or other means of dissemination may be made without written permission.

Produced by QCS Product Development.Writer: Robert MacchiaIllustrator: Robert MacchiaTechnical Contributor: Don Barger, Alan Czarnecki, Jay Johnson, Geoff Ledin, Al Luckman,

Steve Lumen, and Walt Schager

1998, 2002 by ABB Inc. All rights reserved. 1190, OptiPak, and Smart Platform are trademarks of ABB Inc. ABB MasterView, Advant, and AdvaBuild are registered trademarks and service marks of ABB Inc.

April 2002103049-001Version B

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

VDocument Version HistoryIndustrialIT Quality Control

Setup and Installation Manual(Release 5.0 & later)

ersionLevel

EffectiveDate

Sections Changedby Revision

Sections Addedby Revision

Sections Deletedby Revision

A October 1998 Original Release

B April 2002 cover art, header, product names103049-001 Document Version History

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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.PrefaceThis manual is designed to aid ABB field personnel in the installation, setup, and startup of the hardware and software of the 1190. For installation of platforms, sensors, and profilers; see their specific documentation. This manual only applies to 1190 Release 5.0 and Later. For earlier releases, refer to the ABB 1190 Setup and Installation Manual, 101763-002You may need the System Software Data Book (103036-001), the System Hardware Data Book (103036-002), and the System PC Program Listing Book (103036-003). These books are specific to each site and are compiled by the project and system engineers.Other manuals that may be of use:

Platform, actuator, and sensor specific documentation

operator manuals (103014-00x) and tuning guides (103043-00x) S100 I/O Hardware Reference Manual, 3BSE 002 413 S800 I/O Users Guide, 3BSE 008 878

Advant Controller 450 Users Guide, 3BSE 002 415

Advant Controller 450 Product Guide, 3BSE 015 953

Master Net Users Guide, 3BSE 003 839

Advant Fieldbus 100 Users Guide, 3BSE 000 506

LCU Reference Manual, 101333-003 Radiation Safety Manual, 019406-001 1190 PMM Reference Manual, 101764-002 Computed Sensor Variables, 101766-014

AAM Technical Manual, 101033-001103049-001 Preface i

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103049-001Preface ........................................................................................... iList of Figures ............................................................................ vii1 Overview ................................................................................... 1

Compatibility .................................................................................................2Cabinet Layout ..............................................................................................3Processor and Communications Rack Layout...........................................5

Main Processor ......................................................................................................7PCMCIA Flash Card ......................................................................................7

Serial Link Submodules ........................................................................................8ABB Processor ......................................................................................................9

ABB PCMCIA Flash Card.............................................................................9Maximum CD Actuator Count by type ........................................................10

Equipment Location....................................................................................11Cabinet.................................................................................................................11Operator Station...................................................................................................11

2 Preparation ............................................................................. 13Environmental Requirements ....................................................................14

Overview .............................................................................................................14Temperature .................................................................................................14Humidity.......................................................................................................14Vibration.......................................................................................................15Altitude.........................................................................................................16Enclosure Rating ..........................................................................................17Contamination ..............................................................................................17

Operator Station Requirements ...........................................................................19Cabinet and Enclosure Requirements..................................................................19Interior Unit Requirements..................................................................................19Platform Requirements........................................................................................20

Smart Platform .............................................................................................20Smart Color Platform ...................................................................................20HyperScan ....................................................................................................20

Checking Equipment Environmental Specifications...........................................22Rectifying Adverse Environmental Conditions........................................23

Decontamination Units........................................................................................23Verify Necessary Utilities ...........................................................................24

Power Requirements............................................................................................24Grounding Requirements.....................................................................................25

Table of ContentsTable of Contents iii


ivAir and Water Requirements ...............................................................................26Air Quantity..................................................................................................26Air Quality....................................................................................................26Water Quantity .............................................................................................26Water Quality ...............................................................................................26

Air Requirements Calculation Work Sheet for Smart Platforms ........................27Verifying Electrostatic Discharge Control ................................................29Receiving the Equipment ...........................................................................30

3 Hardware Installation & Setup .............................................. 31Electronics Cabinet Installation.................................................................32

Handling the Cabinet...........................................................................................32Mount the Cabinet ...............................................................................................32Wiring Internal to Cabinet...................................................................................32Connect Cables and Utilities ...............................................................................33

Platform Installation....................................................................................34Power Distribution Panel Installation........................................................35

Mount the Power Distribution Panel ...................................................................35Connect the Cables ..............................................................................................35

Tachometer Installation..............................................................................36Install Flexible Couplings ...................................................................................36Align Directly Connected Shafts.........................................................................37

Actuator Installation ...................................................................................38Wiring Connections ....................................................................................39

Wire Power to Converter.....................................................................................40Wire Controller to Platforms & Actuators ..........................................................41

Hardware Setup...........................................................................................44Port Allocations ...................................................................................................44

Basic Function..............................................................................................44Item Definitions for Class ID = Port ............................................................45Port Type Configuration...............................................................................49Item Definitions for Class ID = INET..........................................................50

Application Port Assignment ..............................................................................51Hardcopy Printer Setup .......................................................................................52

I/O Subrack ..................................................................................................54Fieldbus Information...................................................................................56MasterBus Information ...............................................................................56

4 Software Installation & Setup ............................................... 57Overview ......................................................................................................58Toolbox Commands....................................................................................59Licenses.......................................................................................................60Table of Contents 103049-001


103049-001Configuration & Setup Displays ................................................................61Advant Start-Up Display .....................................................................................61Advant Orderly Shutdown...................................................................................64Product Code/Grade Data Setup Display ............................................................64UPS Setup Display ..............................................................................................64Object References................................................................................................66

Advant Procedures .....................................................................................69CPIO Backup Procedure......................................................................................69Station Backup Procedure ...................................................................................69Restore Station Backup Procedure ......................................................................69

Application Dump/Load Procedures .........................................................70

5 System Startup....................................................................... 71Startup Checklist.........................................................................................72Smart Platform Data Setup.........................................................................73PMM-Based Frame Data Setup ..................................................................75

Set Up Scan Speed...............................................................................................75Set Up Coldstart Variables ..................................................................................77

Determine Fixed Home and Far EOS ..........................................................78Determine Off-Sheet, STDZ, Single Point, Current Home EOS, and Current

Far EOS Values.....................................................................................78Determine Delta for On-Sheet Move ...........................................................78Set Current EOS Positions ...........................................................................79

Servo Set Up........................................................................................................82Tuning Guidelines ........................................................................................82Tune the Single Point Measurement Mode ..................................................82Tune the Scanning Gain ...............................................................................83

Set Up Auto Edge-Of-Sheet (AEOS) ..................................................................84Changing Measured Sheet Width.................................................................86

Setting Sheet-Break Override..............................................................................87Setting Global Sheet-Break Override...........................................................87Setting Local Sheet-Break Override ............................................................88

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

Index ........................................................................................... 93Table of Contents v

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103049-001List of FiguresFigure .............................................................................................................Page

Figure 1-1 Single Cabinet Layout ........................................................................ 3Figure 1-2 Typical Dual Cabinet Layout .............................................................. 4Figure 1-3 Rack Layout ........................................................................................ 6Figure 2-1 Air Requirements Calculation Work Sheet for SPs ............................ 27Figure 3-1 RS232/20ma Converter ....................................................................... 39Figure 3-2 Power Supply Out to Converter .......................................................... 40Figure 3-3 Power in to DIN Rail .......................................................................... 40Figure 3-4 Power from DIN Rail to Converter ..................................................... 41Figure 3-5 Point-to-Point Wiring (Converter to Client) ....................................... 43Figure 3-6 Sample Layout for S800 I/O ............................................................... 54Figure 3-7 Sample Wiring for S800 I/O ............................................................... 55Figure 4-1 Command Sequence ........................................................................... 59Figure 5-1 Frame Setup Display ........................................................................... 74Figure 5-2 PMM Frame Setup Display ................................................................ 76Figure 5-3 Frame Limits ....................................................................................... 77Figure 5-4 Frame Coldstart Positions on Frame and Video Profile ..................... 79Figure 5-5 Measurement Platform Control Panel ................................................. 81Figure 5-6 Auto Edge-of-Sheet Parameters .......................................................... 84Figure 5-7 Frame Object Display ......................................................................... 88Figure 5-8 Grade Grouping Display ..................................................................... 90Figure 5-9 Grade Data Display ............................................................................. 91Figure 5-10 Grade Dependent Basis Weight Display Example ............................. 92viiList of Figures

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103049-0011Overview

This chapter gives an overview of the control system and includes the following major sections:Section............................................................................................... PageCompatibility ................................................................................................. 2Cabinet Layout .............................................................................................. 3Processor and Communications Rack Layout ............................................... 5Equipment Location ...................................................................................... 111Overview


2CompatibilityThe IndustrialIT Quality Control Release 5.0 and later using the Advant Controller 450 (AC450) is compatible with the following hardware and software: On-line Builder *2.4/0 or later

MV850 - FP *5.0/7

Advant OS Version: SW *1.7/1 or later

ES120 & ES130 with AdvaBuild 1/3/0 or later

Note: An AC450-based system will only be connected to a ABBMasterView or PMM in an upgrade situation.Overview 103049-001


103049-001Cabinet LayoutThe Advant Controller 450 with S100 I/O are installed in RM500 cabinets. There are two different versions, RM500V1 and RM500V2, with different footprints. See Table 1-1 for the dimensions. For dual cabinet configurations, two single cabinets are bolted together. For examples of single and dual cabinet layouts, see Figure 1-1 and Figure 1-2, respectively. Cabinets used are subject to change.

Table 1-1

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

RM500V1 cabinets are provided with single or double doors (double door consists of two doors, each half the size of a single door. RM500V2 cabinets are provided with only single doors. For complete details, refer to the Advant Controller 450 Product Guide, 3BSE 015 953.

Figure 1-1 Single Cabinet Layout

Cabinet Width1 Depth2 Height3

RM500V1 800 mm (31.5 in.) 512 mm (20.1 in) 2125 mm (83.7 in)800 mm (31.5 in.) 512 mm (20.1 in) 1925 mm (75.8 in)

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

Processors

Communications

Power Supply

and

Rack

Modem

I/O Nest

Rack

(if in thiscabinet) 3Overview


4Figure 1-2 Typical Dual Cabinet Layout

Processors

Communications

Power Supply

I/O Nest

and

Rack

Connection Units

Power Switchand Distribution

Modem Subrack

Processors andCommunications

Rack

Power Supply

Power Switchand Distribution

Mains Net Filter(CE-MarkedVersions Only)

I/O Subrack

Connection

Field Power Supply

Units

Modem RackOverview 103049-001


103049-001 See Processor and Communications Rack Layout for details about specific boards.

Power Supply - The power supply is a 115 Volt 15%.

I/O Nest - The I/O will typically be a S100 or S800 depending on the number of I/O required for the system. Refer to the S100 I/O Hardware Reference Manual, 3BSE 002 413 or the S800 I/O Users Guide, 3BSE 008 878, respectively.

Processor and Communications Rack LayoutThe processor and communications rack can contain: a main processor, a redundant main processor, four serial link carriers, two ABB processors, a power supply, a battery backup with charger, and a status card. See Figure 1-3. The power supply is a 5 volt regulator. The backup is a 5 volt RAM battery with a 12 volt charger. The status card monitors the fans. The processor and communication cards are detailed in subsections following Figure 1-3.5Overview

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103049-001

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ABB SB510

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ABB SR511

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ABB PM511

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ABB SC510

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103049-001Main ProcessorThe main processor contains the AMPL library flash card.

PCMCIA Flash CardThis PCMCIA flash card contains the AC450 controller software load.

RUN

ABB PM511

F

HLTBC

TODUAL

2 31 4

SERV.X10

X11I/O

AUTO

P1 is normal

Switch set to AutoInit (1)

PCMCIA flash card

Advant 130 connector

Connector to local I/O bus on card

-- L means it is loading from

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

flash card7Overview


8Serial Link Submodules

Each submodule consists of two RS232 ports which supports ABB serial protocol. Two submodules can be mounted in each carrier (shown at left) for a total of four ports per carrier. A maximum of five carriers can exist in the system if only one ABB Processor board is used.) This configuration provides 18 ports plus a MasterBus connection. The MasterBus submodule contains one port and takes the place of one submodule (two ports).

HyperScan communication requires two ports. They must be on the same submodule. One port of a submodule can be used to communicate with a Smart Platform and the other one to communicate with a Smart Profiler or third party CD.

RS232/20mA serial converters are mounted below the processor and communications rack.

The bottom submodule of the last carrier will contain the appropriate card (slot 6 in Figure 1-3) for a connection to a MasterBus distributed control network. The AUI cable connects to the ethernet transceiver. See MasterBus Information on page 56.

RUN

ABB SC510

F

1

2

X4

X5

F R

ABBCI532

X4

X5

F R

ABBCI532Overview 103049-001


103049-001ABB Processor

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

RUN

ABB PM511

F

HLTBC

TODUAL

2 31 4

SERV.X10

X11I/O

CLEAR

A 1 is normal

Switch set to Clear (3)

ABB PCMCIA flash card

Advant 130 connector

NOT used

-- L means it is loading from

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

flash card

A9Overview


10Maximum CD Actuator Count by type Sequential Linear Steppers 66

Parallel Linear Steppers 150

Smart Weight Profiler (SWP) 200 IR Profiler 216

ThermoProfiler 120

Air/Water Spray 108

ScaniValve 96

Serial 255

Smart Calender Profiler 200

Dilution SWP 400Overview 103049-001


103049-001Equipment LocationCabinet

Follow the steps below to prepare the cabinet location.

1. Install the electronics cabinet at a location predetermined by the customer and the ABB Installation Engineer.

2. Verify the cabinet is readily accessible to paper machine operating personnel and maintenance and service personnel.

3. Verify sufficient space is available for the installation of cables.

4. Verify all environmental requirements. See Cabinet and Enclosure Requirements on page 19.

5. Verify the base support structure allows the electronics cabinet to be bolted down firmly and permits cable entries from the bottom of the cabinet.

6. Refer to the cabinets Dimensional Drawing for information on specifying cable entries, securing bolt hole locations, and determining space requirements and weight specifications.

7. See Vibration on page 15 to determine if isolation mountings must be used.

Note: If the electronics cabinets are located where damage may be causedby tow motors, forklift trucks, or pushcarts; some type of protectivebarrier must be installed.

Operator StationOperator stations are located as required by each site.11Overview

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103049-0012Preparation

Section............................................................................................... PageEnvironmental Requirements ........................................................................ 14Rectifying Adverse Environmental Conditions ............................................. 23Verify Necessary Utilities .............................................................................. 24Verifying Electrostatic Discharge Control .................................................... 29Receiving the Equipment .............................................................................. 3013Preparation


14Environmental RequirementsOverview

The conditions that characterize an operating environment and that are critical to the operation and reliability equipment are listed below:

Temperature

Humidity

Vibration

Altitude

Enclosure Rating

Contamination

Each environmental parameter has been divided into classifications that define the severity of the parameter. The classes are defined in detail so that the class number for each environmental factor can be used to describe the conditions a unit is designed to withstand.TemperatureTemperature is defined as the maximum ambient temperature, in degrees Centigrade (C) or degrees Fahrenheit (F), where ambient refers to the air which surrounds or impacts the frame or enclosure. For a large frame or enclosure, the ambient temperature may not be uniform. In that case, the temperature specification reflects the average observed or predicted value. Factors which affect the ambient temperature include the following:

Seasonal Weather Variation

Location of Heat Sources

Open Windows

Ventilators

Heat generated by system equipment and/or radiated from nearby heat sources

The four classes of temperature are as follows:Class Centigrade FahrenheitClass 1 19C to 27C 65F to 80FClass 2 27C to 45C 80F to 110FClass 3 45C to 60C 110F to 140FClass 4 Above 60C Above 140FHumidityHumidity, also referred to as relative humidity, is the ratio, expressed as a percent, of the actual water vapor present in the air to the maximum vapor possible at the same temperature and pressure. Relative humidity values greater than 90% have little practical meaning because they are difficult to measure.Preparation 103049-001


103049-001Unless controlled by special equipment, humidity may normally vary from extremely dry (less than 10%) in the winter to saturated conditions (greater than 90%) in the summer. Uncontrolled humidity may cause the following problems: Condensation

Accelerated Corrosion

Changes in materials properties such as weight, dimensions, and resistivity

The three classes of relative humidity are as follows:Class Percent DescriptionClass 1 30 to 70% A controlled humidity condition; typically

includes devices which use paper (printer) and require humidity control.

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

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

VibrationVibration is specified by the following three variables:

Frequency (F) in Hertz (Hz) or cycles per second Amplitude (A) in inches (peak-to-peak) Acceleration (G) in Gs (peak value) where the relationship between variables

is G = 0.0511 AF2

If either amplitude or acceleration is defined in root-mean-square (rms) units, the rms units can be converted to peak value by multiplying each by 1.414. Peak value units can be converted to peak-to-peak by multiplying by 2.000.Excessive vibration may cause cyclic stressing, which can lead to fatigue failure of parts. Printed circuit board connectors may also become dislodged, causing open circuit failure or contact arcing. Vibration to sensors can cause several problems, including the following:

Signal Oscillations

Incomplete Standardize

Unwanted Sheet Flutter

The two classes of vibration are as follows:Class DescriptionClass 1 Less than 0.01 inch (0.254 mm) amplitude (0-14 Hz) and less than

0.1 G (14 to 100 Hz) is considered normal; vibrations that are noticeable but not troublesome are in this class.15Preparation


16Class 2 Greater than 0.01 inch (0.254 mm) amplitude (0-14 Hz) or greater than 0.1 gram (14 to 100 Hz) is severe enough to warrant vibration and/or shock isolation.

AltitudeAltitude is the elevation above sea level measured in feet. The relationship between altitude and atmospheric pressure is shown in Table 2-2 below.

Table 2-2 Relationship between Altitude and Atmospheric Pressure

* Kilopascals (KiloNewtons per square meter) is the unit of measure for pressure in the international system of units.

Note: Pressure will vary +0.5 psi due to weather, in addition to the altitudeeffect. Atmospheric pressure has a slight effect upon heat transfer,and altitude reflects atmospheric pressure. At 5,000 feet, naturalconvection is reduced by about 10%, and air mass flow from a fanmight be reduced by about 15%.

The three classes of altitude are as follows:Class DescriptionClass 1 0-900 meters (0-2,950 feet)Class 2 900-1,500 meters (2,950 - 4,920 feet)Class 3 Above 1,500 meters (above 4,920 feet)

Altitude in Meters

Altitude inFeet

Pressure inPounds/in2

Pressure in kPa*

0 0 14.7 101.35300 985 14.2 97.90600 1970 13.7 94.45900 2950 13.2 91.01

1200 3940 12.7 87.561500 4920 12.2 84.121800 5905 11.3 77.913000 9840 10.1 69.64Preparation 103049-001


103049-001Enclosure RatingThe enclosure rating defines enclosure resistance to common industrial environments. The four classes of ratings are as follows:Class DescriptionClass 1 Dust Resistant - the enclosure will resist dust to the degree specified

under Particulate on page 18.Class 2 Water/Oil Resistant - the enclosure will resist dust (see Class 1

above) and occasional spray of oil or water. Occasional means the equipment could be doused with oil or water less than once a week during maintenance of the process equipment.

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

Class 4 Hazardous - if the customer has a hazardous environment, special treatment is required. Normally the customer will have a defined set of requirements, such as a NEMA. Obtain these requirements from the customer.

ContaminationNormally there are two major categories of contamination, gaseous and particulate, as explained below.

Gaseous - Gaseous contamination is measured as concentration in parts per million (ppm). Any gas which may cause metal to tarnish or corrode should be considered as gaseous.

The most obvious problem with gaseous contamination is corrosion. There are a large number of electrical connectors in a system which can develop a thin layer of tarnish or oxide when exposed to certain gaseous contaminants, such as hydrogen sulfide (H2S), chlorine (CL2), and sulphur dioxide (SO2). This tarnish or oxide can act as an insulator or capacitor and greatly affect system reliability.The three classes of gaseous contamination are listed below and explained in Table 2-3 on the next page. The classes are measured in ppm.

Class 1 is considered mild.

Class 2 may require some type of contaminant removal.

Class 3 is considered severe and/or unsafe for humans.17Preparation


18Table 2-3 Classes of Gaseous Contamination

Particulate - Dust (paper dust, metal particles, process material) is difficult to measure and classify for a given environment. Typically, particulate contamination is either not noticeable or is severe. Dust concentrations are defined in milligrams per cubic meter (mg/m3). A high concentration of dust may cause the following problems:

Increased wear on rubbing or rolling surfaces

High contact resistance in plugs and connectors

Shorts on printed circuit boards

Increased maintenance costs for cleaning, changing filters, and repairs

The three classes of particulate contamination are as follows:Class Measurement Description

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

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

Class 3 SEVERE All those not in Class 1 and 2; requires special consideration. The type of particulate contamination in this class (residue, quantity, size, distribution, stickiness, chemistry, and so on) should be considered and noted to the ABB Engineering Department.

Type of Gas Class 1 Class 2 Class 3Sulfur Dioxide 0.00-0.05 ppm 0.05-5.00 ppm 5+ ppmHydrogen Sulfide 0.00-0.03 0.03-10.00 10+Hydrogen Fluoride 0.00-0.02 0.02-3.00 3+Chlorine and Halogenated Compounds

0.00-0.03 0.03-1.00 1+

Oxides of Nitrogen (NOx) 0.00-0.08 0.08-5.00 5+Carbon Monoxide (CO) 0-10 10-50 50+Ammonia 0.0-0.2 2-50 50+Aldehydes 0.0-0.2 0.2-5.0 5+Oxidents (Ozones) 0.00-0.05 0.05-0.10 0.1+Preparation 103049-001


103049-001Operator Station RequirementsPut operator station hardware in an enclosure with specifications as described below if the location does not meet the specifications defined by the hardware manufacturer or if it will be on the mill floor.

Cabinet and Enclosure RequirementsThe following requirements are for cabinets and enclosures:Temperature:

Low: non-condensing 0 CHigh: +40 CGradients: 3 C/min

Humidity:Relative: 5% - 95%Absolute: 1 - 29 g/m3, non-condensing

Vibration:0.075 mm, 10-57 Hz10 m/s2, 57-150 Hz; x, y, z direction

Shock:

150 m/s2 for 11ms, half sine; x, y, z directionAltitude:

2000 metersPollution Degree:

Degree 2 acc. to IEC 664 and 664AEmitted Noise:

< 55 dB

Interior Unit RequirementsThe following requirements are for subracks, plug-in units, and printed circuit boards:Temperature:


Humidity:Relative: 5% - 95%Absolute: 1 - 29 g/m3, non-condensing

Vibration:0.15 mm, 10-57 Hz20 m/s2, 57-150 Hz; x, y, z direction19Preparation


20Shock:

150 m/s2 for 11ms, half sine; x, y, z directionAltitude:

2000 metersPollution Degree:

Degree 2 acc. to IEC 664 and 664A

Platform RequirementsSmart PlatformTemperature:


Humidity:Relative: 5% - 90%

Vibration:0.01 , 0-14 Hz0.1 G, 14-100 Hz

Smart Color PlatformTemperature:



Vibration:0.01 , 0-14 Hz0.1 G, 14-100 Hz

HyperScanTemperature:



Vibration:0.01 in, 0-14 Hz0.1 G, 14-100 HzPreparation 103049-001


103049-001

Equi

pmen

t

Operator SEnclosure

Internal U

Smart Pla

HyperSca

Smart ColPlatform

Liquid CoUnitBecause these are general specifications, they are always superseded by job order engineering documentation. If the environment exceeds the ratings, special engineering is usually required.

For more specific guidelines refer to the Advant OCS Product Guide, 3BSE 008 434 latest revision.

Table 2-4 Summary of Environmental Specifications

Note: 1. Air conditioners on electronics cabinets are derated 1.6 C (3 F)per 300 meters (1,000 ft.) over 750 meters (2,500 ft.) above meansea level.2. Water-cooled air conditioners, when present on full electronics, allow operation in Class 3 dust environments.

Normally, air conditioned offices and/or rooms housing electronicboards with air conditioners require one additional ton of refrigerationper unit to compensate for cabinet heat dissipation.

Tem

p. ( C

)

Rel

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mid

ity

(%)

Vibr

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Shoc

k(m

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Alti

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Pollu

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tation See manufacturers documentation.0 - 40 5 - 95 0.075 mm / 10 m/s2 150 2000 2 acc.

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

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

-- -- 5000 (A/yr.)

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

-- -- --

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

-- -- --

oling < 43 5 - 90 -- -- -- --21Preparation


22Checking Equipment Environmental SpecificationsUse the following measurement techniques for measuring the environment:

Specification Suggested Measurement TechniquePower power line analyzerAir Quality Test kit 73512-001Air Quantity Test kit 73528-001

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

Temperature Calibrated temperature sensing device

Contaminant LevelsContamination Kits:

Enclosure for samples: 121288-001Samples: 082932-001

Vibration Use a hand held vibration monitoring devicePreparation 103049-001


103049-001Rectifying Adverse Environmental ConditionsDecontamination Units

If coupon tests show greater than 300 angstroms per month (28 days), decontamination units are required. Most floor installed Advant Operator Stations (Advants in enclosures) should have decontamination units.AC450s that require decontamination units must have the sealed cabinet option (probably with air conditioning). Normally, closed cabinets have insufficient air circulation to provide proper cooling.23Preparation


24Verify Necessary Utilities

The following sections contain utility guidelines. They are always superseded by job order engineering documentation.

Power RequirementsVoltage dropouts cannot exceed 10ms. Total harmonic distortion cannot exceed 5% at no load.

Table 2-5 Power Requirements

1 KVA is for one scanner/two scanners/three scanners. Exact requirement will be determined

during the development of the system configuration.2 KVA is for 1-6 cameras and 7-11 cameras.

Equipment VAC KVA HzSystem Cabinet 115 15/25/351 60Smart Platform 200-240 10 50 or 60

HyperScan (3-Phase) 380/415 or 480/575 29/582 50/60

HyperScan (Single Phase) 240 -- 50 or 60Smart Color Platform 240 1.5 50 or 60Actuators Refer to specific actuator documentationPreparation 103049-001


103049-001Grounding RequirementsThe system is designed for protected installations. All cables included in the system are tray-rated, meaning that they can be run in trays. The tray and internal shielding of the ABB cables provide protection against both high and low frequency interference.The combination of shielding and cabinets meets the requirement for interference free functionality for industrial equipment. For complete details about grounding and EMC compliance, refer to the Users Guide for Compliance with the EMC Requirements, 3BSE 009 178.For interference free operations, it is important that good grounding arrangements are maintained.

All components - backplane, power supply units, power supply filters (where applicable), connection units, modems, and grounding bars must be connected directly to the chassis with screws (not long wires). The best technique to ensure a good electrical contact is to use thread cutting screws or screws with star washers under the head.

Pairs of cabinets or enclosures that are used as a reference ground (chassis) must have good and permanent electrical bonding. Painted or anodized parts must also have good ground bonding. This can be achieved, for example, by scraping the surfaces or using thread-cutting screws. In aluminum, thread-cutting screws must be used.

In the same way as mounting rails, all units such as subracks, power supplies, and terminal rails must be bonded to the chassis by means of approved mounting screws or short connecting wires (maximum 5 cm (2 inch) length) on both sides of the unit.Other units must be grounded in a suitable manner (maximum 5 cm long connections) to the chassis plate or to the copper grounding bar. In ABB cabinets, all these connections must be made with tapered self-tapping screws with teeth under the head. Incorrectly mounted units provide very poor protection against high frequency interference and electrostatic discharges (ESD).In the EU and EFTA countries, there must be the connection of the cable shield to the cabinet fitted by 360 connection. The latter is the place where the cables penetrate the cabinet. It is normally made by special sealing. The shields shall continue in the cabinet. In other than EU countries, the requirement on the 360 shield connection can be omitted.Shielded communication cables which are not directly grounded in the cabinet and shielded cables for analog signals with the signal circuit and shield grounded in the field are to be handled in a special way. The cable shield, in these cases, should be connected to the ground via a capacitive decoupling device located in the bottom of the cabinet. 25Preparation


26Air and Water RequirementsThe utilities required by the system vary with the equipment you have available. Ask the ABB Installation Engineer for the options that are on your system. The utility requirements are summarized below. Refer to the specific Installation Drawings for air/water line size, type, and routing.Air Quantity flow rate: 10 - 60 SCFM (see Figure 2-1) line pressure: 65 - 100 PSI

Air Quality maximum 1 ppm by weight of oil and water

maximum 5 micron ppm of solid particulate

temperature must be within 20 C of ambient air

Water Quantity flow rate: 42 - 76 liters/hr (11 - 20 gal/hr) at Liquid Cooling Unit (LCU) line pressure: 138 - 551 KPa (20 - 80 psig) at device

Note: 1. Both the IR cooling units and the air conditioners require onewater drain for spent cooling water and another to eliminatecondensate from the air conditioner.

2. If the water supply is not cool enough, a drinking fountain watercooler may be used to pre-cool the water.

temperature: 27 C (80 F) max at LCUWater Quality drinking water purity with pH 6.0 - 8.0

hardness: less than 85 ppm

drains required below device

Note: Improper cooling and extra cooling servicing will result if dirty water(containing iron and calcium) is used.

Grit may be imbedded in the rubber seats of the pressure regulatorand the temperature valve of the cooling unit, or the flow control valveof the air conditioning unit, causing improper performance.

Strainers may clog and stop all cooling.

Excessive temperature will cause the sensor to shut off, or blockageof water flow will cause the A/C to shut off. This shut off will requireresetting and correction before restarting.Preparation 103049-001


103049-001

SBasis Weiwith Std. Awith AGCBW with CSmart BasIR Moisturwith Std. Awith HeateReflectionwith Std. Awith HeateCaliper (SAir BearingVacuum PlProbe HeaCaliper (DLift-Off TubVacuum PlProbe HeaCaliper (NTop Air BeaBottom AirCaliper GTOptiPakPurgeVacuum PlAir BearingFigure 2-1 Air Requirements Calculation Work Sheet for SPs

(continued on next page)

Air Flow Per Sensor Totalsensor SCFM M3/HR Pressure # In System # Times Flowghtir Wipe 4.0/wipe 6.8/wipe


28

SmartRoll HGlossAir WipAir PurSheet MP/SPSmartMicrowSingle-Dual-sSmootNormaHigh TTempeFigure 2-1 (continued)

Air Flow Per Sensor TotalsSensor SCFM M3/HR Pressure # In System # Times Flow

Ash 4.0/head 6.8/headardness 8.5 14.5

es 5.0 8.5ge/Sensor 3.5 5.9 40 PSIGGuides (4) 24.0 40.8 20 PSIG Clutch 0.0 0.0 40-50 PSIG Color 4.0/head 6.8

ave

sided 0.18 0.3ided 0.18 0.3hnessl None Noneemperature 0.001 N 0.001 Nrature 1.5 2.6 30 psig

TOTAL =Preparation 103049-001


103049-001Verifying Electrostatic Discharge ControlNote: All maintenance in the cabinet is only allowed when protective ESD

restrap, fitted to the cabinet is used.

The equipment contains many static-sensitive devices such as transistors, diodes, integrated circuits (ICs), resistors, capacitors, and printed circuit boards. These devices must be protected from damage caused by the discharge of static electricity.Electrostatic charging is likely to occur whenever two materials are brought into contact and separated. The goal of static protection for static sensitive devices is to prevent static buildup where possible and quickly and reliably remove existing charges. This goal can be accomplished by using conductive wrist straps, work mats, and conductive bags shipped with the system.A warning label is placed in a highly visible location on all equipment containing static sensitive devices to remind you of the potential damage that can result from electrostatic discharge.

When handling a static-sensitive device such as an integrated circuit (IC) or a printed circuit board which contains ICs, you must be properly connected to ground by wearing the conductive wrist strap. The wrist strap MUST be in direct contact with bare skin. NEVER WEAR THE WRIST STRAP OVER CLOTHING.

The connecting wire of the wrist strap MUST be connected to a grounded conductive bench top or system ground. A series resistor in the connecting wire at the snap protects you from electrical shock should equipment fault occur.

Remember the following:

The wrist strap is always FIRST ON and LAST OFF. The wrist strap MUST be attached in direct contact with bare skin, NEVER

OVER CLOTHING. PC boards MUST be placed in an anti-static bag whenever removed from a

cabinet.

DO NOT remove wrist straps until after the board has been placed in the anti-static bag.

Place the bagged PC board on the conductive work mat or attach the conductive wrist strap BEFORE removing the PC board from the anti-static bag.29Preparation


30Receiving the EquipmentWhen equipment arrives, follow the steps below:

1. Check off all equipment and boxes on the shipping manifest. ABB personnel should be present to verify arrival conditions of the equipment.

2. Remove outer shipping covers, if present, from equipment and note any damaged or missing items before signing the manifest.

3. Notify the carrier and ABB Industrial Systems Inc. of damages and/or missing equipment.

4. If the system is to operate on 50 Hertz (Hz), verify that the applicable system units are converted to 50 Hz operation.Preparation 103049-001


103049-0013Hardware Installation & Setup

Section............................................................................................... PageElectronics Cabinet Installation ..................................................................... 32Platform Installation ...................................................................................... 34Power Distribution Panel Installation ............................................................ 35Tachometer Installation ................................................................................. 36Actuator Installation ...................................................................................... 38Wiring Connections ....................................................................................... 39Hardware Setup ............................................................................................. 44I/O Subrack .................................................................................................... 54Fieldbus Information ..................................................................................... 56MasterBus Information .................................................................................. 5631Hardware Installation & Setup


32Electronics Cabinet InstallationFollow the general guidelines below for all electronic cabinets. For information on Master electronics cabinets, see the Advant Controller 450 Users Guide, 3BSE 002 415.

Handling the CabinetSpecial handling is required before and during installation because the operator stations and electronics cabinets contain very sensitive electronic and mechanical components which may be damaged by rough handling. Use the following guidelines when handling the cabinet.

DO NOT bump or drop the cabinets.

DO NOT store the electronics cabinet where it may be moved without proper supervision.

DO NOT store or install the electronics cabinet in wet areas, on wet floors, or in extremely hot or cold areas.

DO NOT open the door of the electronics cabinet until the unit is bolted down, braced against tipping, or partially bolted down through the front door.

DO keep all doors to the electronics cabinet locked when not present.

Mount the CabinetTo mount the electronics cabinet, follow the steps below. For detailed information, see the Advant Controller 450 Users Guide, 3BSE 002 415.

1. Transport the unit while still mounted on the shipping skid to the mounting site with a forklift truck using the quickest, safest route possible. Be careful to observe the orientation arrows on the outside of the crate. For crated shipments (all international and special domestic), transport the electronics cabinet to the mounting site while still in the crate.

2. Remove the fastening devices that secure the unit to its shipping skid and lift the unit onto the prepared mounting base. Lifting eyelets are provided on the cabinet to allow lifting from above.

3. Open the front door to access the securing bolt holes.

4. Bolt the cabinet down securely to prevent it from tipping or sliding.

Wiring Internal to CabinetRefer to the ABB Conduit/Cable Summary and System Wirelist for termination information. Point-to-point and connection diagrams may be provided instead of the conduit/cable summary and system wirelist.Hardware Installation & Setup 103049-001


103049-001Connect Cables and UtilitiesFollow the steps below to connect the cables and utilities.

1. Use the slides in the bottom of the cabinet for cable entry.

See the Advant Controller 450 Users Guide (3BSE 002 415) for information on connecting cables in the cabinets.

CAUTION

Do not allow metal chips to scatter within the cabinet.

Do not use hole saws, sabre saws, or other cutting devices that would create excessive vibration of the internal circuitry.

Avoid contact with the internal wiring and terminals.2. Pull and terminate all cables.

All wiring to the electronics cabinet is shown on the point-to-point drawing in the System Hardware Data Book which is shipped with your system.

3. Seal the cable entries to the cabinet to prevent contamination and to allow more efficient operation of the air conditioning and decontamination units.

4. Verify that all internal power cables are connected to the local load center as described in the System Hardware Data Book. 33Hardware Installation & Setup


34Platform InstallationSeveral types of platforms are used to support/position the various sensors of the quality control system. Each platform is equipped with various sensor configurations depending upon the system application. Installation information for all platforms is in the appropriate platform manual.

Smart Platform 700 101764-004Smart Platform 1200 101764-003HyperScan 103045-001

CAUTION

Special handling and care of platforms is required before and during installation. The platforms receive critical alignment and adjustment at the factory prior to shipment. Special precautions must be taken during shipping, handling, and installation to preserve the integrity of these adjustments. These precautions are outlined in the applicable platform manual.Hardware Installation & Setup 103049-001


103049-001Power Distribution Panel InstallationFollow the guidelines below for Power Distribution Panel (PDP) installation techniques.

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

Connect the CablesCabling and connection of AC power from the customers source to the system units is made through the power distribution panel. Before beginning the cabling and utilities connections to any of the system units, verify that the customer power source and earth ground meet the requirements.Power cabling to and from the power distribution panel should be wired in accordance with the point-to-point drawings in the System Hardware Data Book. Wiring should be made first from the power distribution panel to the system units, and then to the customer power disconnect switch or breaker. Power cabling must be in accordance with local code specifications.35Hardware Installation & Setup


36Tachometer InstallationFor more information on the DSDP170 Pulse Board, refer to the S100 I/O Hardware Reference Manual, 3BSE 002 413.For best accuracy, tachometers should be driven by positive drives, including any of the following:

Gearing

Timing belt

Direct shaft coupling

The type of drive takeoff you use should be determined by the desired ratio of tachometer speed to shaft speed. If the ratio is not in unity, then use a timing belt drive. With a unity ratio, use direct shaft flexible couplings.If you use a timing belt, make sure that belt tension is not excessive, since very little torque is required to turn the tachometer. Belts over 3/8 inch wide are not recommended. The tachometer can normally be directly belted off the machine or sectional drive motor shaft. However, if the distance between the machine and tachometer is so great that excessive belt tension is required, consider using a jack shaft arrangement.If direct shaft coupling is used, use flexible coupling and align the shafts as accurately as possible. Regardless of which type of drive is used, make sure that the tachometer is not subjected to any axial thrust and as little side thrust as possible.In order to maintain a long and trouble-free life for the tachometer, you must minimize vibration and bearing load due to misalignment, end float, or over-hung load. Because of the tendency to under-design this aspect, we are providing the following installation guidelines.

Install Flexible Couplings1. Accomplish a direct connection between two shafts using flexible couplings.

2. Size the flexible couplings to permit a light interference fit to the shafts for installation.

CAUTION

Do not drive or force the couplings onto the tachometer shaft because damage to its bearing may result.

3. Shaft ends should not meet or, in the case of Thomas couplings, extend beyond the face of the shaft-mounted hub.Hardware Installation & Setup 103049-001


103049-001Align Directly Connected ShaftsMake four measurements on each of the following coupling installations:

1. Shaft Runout - Using a dial indicator mounted to a base common to the machine frame, set the indicator tip on a ground portion of the shaft, near the shaft end. Rotating the shaft through 360 will indicate the shaft runout.

Note: Shaft runout must be held to less than 0.001 inch.

2. Parallel Misalignment - With the tachometer on its mounting pad, attach the dial indicator to the shaft of the tachometer. The dial indicator tip is allowed to contact the machine shaft as near the bearings as possible (to eliminate runout). The tachometer shaft and dial indicator should then be rotated, and the high or low spots noted.

Note: A V block facilitates this setup. Use shims between the tachometerand mounting bracket.

3. Angular Misalignment - Set up according to the instructions for parallel misalignment.

4. End Play - With the tachometer mounted on its pad and the dial indicator on the end of the machine shaft, clamp the machine shaft with the suitable nomarring device (for example,V block and clamp) and manually attempt to move the shaft in and out of the machine, noting dial indicator movement.

When conditions make it impossible to check alignment in this manner, make it with a straight-edge and feeler gauge. Check for angular misalignment by inserting the feeler gauge between the faces of the coupling hubs at four equidistant points. Check for runout by placing a straight-edge across the ground or closely machined diameters of both coupling hubs. This method is not recommended unless a check with a dial indicator is impossible.37Hardware Installation & Setup


38Actuator InstallationSee appropriate Actuator documentation.

Smart Weight Profiler 101794-003Smart CoatWeight Profiler 103007-003Smart Calender Profiler 103020-002Smart Consistency Profiler 103046-002Hardware Installation & Setup 103049-001


103049-001Wiring ConnectionsThe RS232/20ma converter is the bridge between the controller and the platforms and actuators. The converter is used for bi-directional signal conversion (transmission rate determined by the interface with the lower capacity) and long distance transmission. It is located below the processor and communications rack. You need one converter for each port (two per submodule). The cable connects from the submodule port to the RS232 connection on the converter (#1, see Figure 3-1), the cable from the client (e.g. Smart Platform or Smart Actuator) is connected to the 8 screw terminals (#4) along the bottom of the converter (labeled TTY). 24 volt DC power is connected to the converter via two terminal strips (#5) on the top left of the unit.

Figure 3-1 RS232/20ma Converter

Yellow LED = transmitGreen LED = receive

to communications submodule port

24 V DC powerUNUSED

UNUSED

8 screw terminals for 20 mA loop39Hardware Installation & Setup


40

fWire Power to Converter1. Wire power from the power supply to the converter. See Figure 3-2.

Figure 3-2 Power Supply Out to Converter

2. Connect wiring from power supply to DIN rail. See Figure 3-3.

Figure 3-3 Power in to DIN Rail

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

rom Power SupplyGROUND WIREHardware Installation & Setup 103049-001


103049-0014. Tighten the connector that ties 4,5, and 6 together (3-screw bar near center). 5. Connect power from DIN rail to each converter. See Figure 3-4.

Connect one wire from any of the 24V terminals available on the DIN rail to the 24V screw terminal on the top left of the converter.Connect one wire from any of the 0V terminals available on the DIN rail to the 0V screw terminal on the top left of the converter.

Figure 3-4 Power from DIN Rail to Converter

6. Connect ground for each converter. See Figure 3-3.

Wire Controller to Platforms & Actuators

CAUTION

You cannot use the terminal strip AND the CORRESPONDING 9-pin connector at the same time.

1. Plug in 9-pin connector at the submodule.

2. Plug in 9-pin connector at the converter (RS232).Shielding takes place via the connector frame, which is permanently connected to the ground terminal. If needed, see the pin assignments in Table 3-1.

0V 24V41Hardware Installation & Setup


42Table 3-1 RS-232 Pin Assignments

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

3. If necessary, set the DTE/DCE switch to DTE (factory default).Switch S1 is used to cross the TxD and RxD connection internally, allowing the adaptation to be carried out conveniently. If the connected interface type is unknown, you can determine the correct configuration by trial and error.

4. Leave CTS/RTS jumper AS IS (4-2).The control wires CTS/RTS can be jumpered on the jumper field X7 or as an option actively set to logical 1. The control lines DSR/DTR are permanently bridged internally. This requires the RS-232 cable to have these lines wired as well.

5. Connect wiring from client (i.e. Smart Platform, Smart Actuator, etc.) as described in Figure 3-5 and Table 3-2.

Note: DONT forget to set the S1+ to T+ jumper.

Description AbbreviationScrew

Terminal (from left)

9-pin Connector

Supply Voltage 24 V pin 1 --0 V pin 2 --

Transmit Data TxD pin 4 pin 3Receive Data RxD pin 5 pin 2Clear to Send CTS pin 6 pin 8Request to Send RTS pin 7 pin 7Functional Ground GND pin 8 pin 5Data Terminal Ready STR -- pin 4Data Set Ready DSR -- pin 6Ground -- See note. ShieldHardware Installation & Setup 103049-001


103049-001Note: The ground connection is actually the screw on the TTY 9-pinconnector.

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

Table 3-2 TTY Pin Assignments

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

Description AbbreviationScrew

Terminal (from right)

9-pin Connector

current source 2 neg. polarity S1- pin 3 pin7current source 2 pos. polarity S1+ pin 4 pin 3current source 1 neg. polarity S2- pin 1 pin 9current source 1 pos. polarity S2+ pin 2 pin 5transmit data neg. polarity T- pin 7 pin 6transmit data pos. polarity T+ pin 8 pin 2receive data neg. polarity R- pin 5 pin 8receive data pos. polarity R+ pin 6 pin 4Ground -- See note. Shield43Hardware Installation & Setup


44Hardware SetupThe following PORT and INET definitions are current as of the release date of this manual. Other IDs may have been added since then. The existing IDs will not have changed.

Port AllocationsThis section describes a facility within the ABB Processor that defines the location and nature of the communication ports accessible from all ABB Processors in an AC450 node. This port configuration is performed by application AMPL software within the AC450. Basic FunctionPer communication port, an ABB Processor object of the class PORT is defined in the ABB Processor where a device handler will manage the communication port. Each such object is populated by an AMPL application with all the information required to define external communication paths also called logical ports. Communication handlers in the ABB Processor locate and examine the object to determine what functionality is required. Examples of communication ports are RS232 serial links attached to a submodule on the FutureBus or to a daughterboard on the ABB Processor, and TCP/IP connections likewise via a submodule or a daughterboard. The requirements to configure each port differ, so some dedicated items and a set of general purpose items are allocated to allow for expansion, ideally, without changing this definition.In the case of TCP/IP connections, logical ports can share physical ports; but each logical port will require a different device handler in the ABB Processor. However, because of the AC450 architecture, all logical ports on the same TCP/IP physical port must be assigned to the same ABB Processor for device handling.TCP/IP connections require an ABB Processor object of the class INET to define the submodules IP address. This address is the same for all logical ports assigned to that submodule.Hardware Installation & Setup 103049-001


103049-001

ItePORTYP

SLOLPRIPBAUCHASTO

PRT

CFG

CFGItem Definitions for Class ID = PortTable 3-3 Port Item Definitions

m Type DescriptionT I Port logical ID (1 - 255)E I Type:

1 = ABB standard serial via FB+2 = AccuRay Direct serial via FB+3 = Time-based serial via FB+ (output only implemented)4 = ABB Standard Protocol - ASI/AD emulation5 = AccuRay Sockets Interface client via FB+6 = AccuRay Sockets Interface server via FB+

T I Slot no. & subModule no. of physical port (decimal SM)T I Physical port no. on submodule (1 or 2) or local TCP/IP port number

C16 TCP/IP address of remote port in dot notationD L Baud rate (150 to 38400)R I Number of data (character) bits (7 or 8)P 1 Number of stop bits:

5 = .5 stop bit1 or 10 = 1 stop bit15 = 1.5 stop bits 2 or 20 = 2 stop bits

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

1 I Configuration parameter 1Type 1 serial setup options:

0 = ABB standard (use defaults: CHAR=8, PRTY=2, STOP=1)1 = user-defined (use all BAUD, CHAR, STOP, PRTY inputs)

Type 2 (or 4) serial setup options:0 = AccuRay Direct standard (use defaults: CHAR=8, PRTY=0, STOP=1)1 = user-defined (use all BAUD, CHAR, STOP, PRTY inputs)

Type 6 ASI server maximum clients supported2 I Configuration parameter 2

Type 1: Use new hardware settings flag (when value changed)Type 2 (or 4): Maximum queued input messages (defaults to 50 if set to 0)45Hardware Installation & Setup


46

CFG

CFGCFGCFGSTS

Ite

3 I Configuration parameter 3

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

4 L Configuration parameter 45 L Configuration parameter 56 L Configuration parameter 6

I Port status:0 = OK1 = Port type code error2 = Instance limit exceeded for this device handler3 = Device handler signal channel creation failure4 = Device handler task creation failure5 = Instance limit exceeded for transceiver drivers6 = Transceiver driver task creation failure7 = Device could not be initialized (perhaps nonexistent)8 = No response from submodule9 = bad client count10 = No INET class defined11 = No INET object defined12 = Network setup failure (reported by port doing the setup)13 = Network is not setup (reported by port not doing the setup)14 = No connection to remote server

m Type DescriptionHardware Installation & Setup 103049-001


103049-001

ERRIteI Last communication error code$0001 = IORB busy$0002 = device not found$0003 = bad port ID$0004 = no response from device (timeout seconds expired)$0005 = invalid operation for defined protocol variant$0006 = no response from device handler (5*timeout secs. expired)$0007 = unsolicited input handler already defined$0008 = message too large$0009 = invalid request$000A = device handler transmission time-out$000B = no path to device formed (check PORT object STS for error)$000C = transceiver signal queue full$000D = logical port disabled$000E = slave request timeout (timeout + 1 secs. expired)$000F = transceiver signal failure (timeout + 1 secs. expired)$0010 = no start-of-message (SOM) character received$0011 = no end-of-message (EOM) character received$0012 = block checksum error$0013 = wrong device responded (device ID mismatch)$0014 = unrecognizable response$0015 = input data count differs from expected$0016 = UART reported overrun error$0017 = UART reported parity error$0018 = UART reported framing error$0019 = no block checksum after end-of-message (EOM)$001A = device queue full$001B = invalid slave protocol model $001C = invalid slave request$001D = slave failed to be initialized$001E = slave UART setup failed$001F = communication manager is offline$0020 = no slave buffer available for request$0021 = slave unable to spawn asynchronous task$0022 = device returned an ACK/NAK code (between driver and slave)$0023 = duplicate AccuRay Direct field number$0024 = serial emulation pass thru message bad command field$0025 = serial emulation pass thru message missing data$0026 = no AccuRay Direct connection (link is down)$0027 = undefined AccuRay Direct group$0028 = unimplemented AccuRay Direct function$0029 = undefine AccuRay Direct function$002A = unable to queue AccuRay Direct request

m Type Description47Hardware Installation & Setup


48

ERR(con

Ite

t)

I $002B = (undefined)$002C = AccuRay direct packet error$002D = AccuRay Direct packer format error$002E = serial emulation field type differs from groups type already defined$002F = serial emulation bad field conversion type$0030 = bad group reference (AccuRay Direct device reported an error)$0031 = bad field reference (Accuray Direct device reported an error)$1yxx = device responded with command-not-accepted (CNA)

y = reason code 1 = invalid command byte 2 = buffer overflow (AMS) 4 = too much data (AMS) 5 = access violation (AMS) 6 = invalid CFN (AMS) or block number (DIU) 7 = data locked (AMS) or invalid block offset (DIU) 8 = length exceeds block (DIU) or file (AMS) boundary xx = received command code

$2yxx = device responded with not-accept/negative-acknowledge (NAC) y = reason code 0 = none provided 2 = buffer overrun xx = 01, message too long 02, buffer not available 3 = format error (too much data) xx = received data byte count 5 = overrun error 6 = parity error 7 = character framing error 8 = block checksum error xx = received block checksum character (BCC)

$30xx = device responded with error code xx = error code C8 = operation cannot be performed in offline mode C9 = initialization required other = single byte ACK/NAK code (usually expected)

$400D = AccuRay Direct disconnect just occurred$400E = no AccuRay Direct messages currently available

m Type DescriptionHardware Installation & Setup 103049-001


103049-001

HISTItePort Type ConfigurationThe following configuration parameters are required for ports of a particular type. Type 1: ABB Standard Protocol

LPRT physical port number on CI532V09 (1 or 2)BAUD many applications override this baud rate with their own (see CFG1)CHAR number of data bits (default per CFG1)STOP number of stop bits (default per CFG1)PRTY parity (default per CFG1)CFG1 0 = ABB standard (use defaults: CHAR=8, PRTY=2, STOP=1) 1 = user-defined (use all BAUD, CHAR, STOP, PRTY inputs)CFG2 use new hardware settings flag when this value changes (permits

runtime changes)Type 2: AccuRay Direct

LPRT physical port number on CI532V09 (1 or 2)BAUD baud rate (see CFG1)CHAR number of data bits (default per CFG1)STOP number of stop bits (default per CFG1)PRTY parity (default per CFG1)CFG1 0 = AccuRay Direct standard (defaults: CHAR=8, PRTY=0, STOP=1) 1 = user-defined (use all BAUD, CHAR, STOP, PRTY inputs)CFG2 maximum queued input messages (defaults to 50 if set to 0)

Type 3: BIOS serialLPRT physical port number on CI532V09 (1 or 2)BAUD baud rateCHAR number of data bits STOP number of stop bits PRTY parity

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

m Type Description49Hardware Installation & Setup


50

IteSL

IMAGANA

STType 4: ABB Standard to AccuRay Direct emulationCFG3 0 = AccuRay Sockets Interface (TCP/IP) (must also set type 5

parameters) 1 = AccuRay Direct (serial) (must also set type 2 parameters)CFG4 timeout override in seconds (defaults to applications serial timeout)

Type 5: ASI client sideLPRT remote IP port number of serverIP remote server IP addressCFG2 maximum queued input messages (defaults to 50 if set to 0)

Type 6: ASI server sideLPRT local IP port number of serverCFG1 maximum clients supported (defaults to 1 if set to 0)

Item Definitions for Class ID = INETTable 3-4 INET Item Definitions

Subnet masking default to one of the standard IP address classes (A, B, or C). If a nonstandard mask is used, see Table 3-5 for conversion from decimal to hexadecimal. each of the octets in the dot notation corresponds to a pair of hexadecimal digits in the subnet mask format reading from left to right. For example, 255.255.128.0 = FFFF8000.

Table 3-5 Decimal to Hexidecimal Conversions

m Type DescriptionOT I Slot number & subModule number of physical port (decimal SM)P C16 IP address of local port in dot notationSK C16 Subnet mask in hexadecimal long format (e.g. FFFF0000) (optional)TE C16 IP address of default gateway in dot notation (optional)ME C16 Name of local host (optional)S

INetwork setup status:

0 = OK1 = port type conflict

Decimal Binary Hexidecimal255 11111111 FF254 11111110 FE252 11111100 FC248 11111000 F8240 11110000 F0224 11100000 E0192 11000000 C0128 10000000 80

0 00000000 00Hardware Installation & Setup 103049-001


103049-001If ABB applications need to connect to IP ports on another subnet, a router must be attached to the local network. This router is known as a gateway and must be assigned a local network IP address. Networking software will automatically direct all TCP packets with the IP addresses not matching the local network address through this default gateway.It is not necessary to provide a host name for this submodule, unless a remote user will try to

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1190 Setup&Installation