MeasureIT Scanning Platform Troubleshooting Procedures Manual

Measure IT
Scanning Platform
Troubleshooting Procedures 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.
Produced by QCS Product Development.
Writers: Bill Houston, Pamela Murray
Illustrators: Melinda Hoyle, Todd Theodore
Technical Contributor: Mort Jensen
© 1992, 1994-1999, 2002-2003 by ABB Inc. All rights reserved.
1180 MICRO, 1190, Smart Platform, and ACE are trademarks of ABB Inc.
UNIX® is a registered trademark of AT&T.
DESQview is a registered trademark of Quarter Deck Office Systems.
® AccuRay is a registered trademark and service mark of ABB Inc.
March 2003
3BUS 208 055 R1101
(formerly 101761-001)

PROPRIETARY DATA: This document contains proprietary data of ABB Inc. No disclosure, distribution (electronic or otherwise),
reproduction, or other means of dissemination may be made without written permission.
Document Version History
Measure IT
Scanning Platform
Troubleshooting Procedures Manual
Version
Level
Effective
Date
Sections Changed
by Revision
Sections Added
by Revision
Sections Deleted
by Revision
A April 1992 Original Release
B March 1994 Entire Manual
C December 1995 Entire Manual
D April 1996 Profile Development in the
Scanning Platform, 24
ABB 1190
Measurement Analysis
Using On-Line Utilities,
28-36
Startup Messages, 75-76
AEOS Setup Problems, 94
E October 1996 Entire Manual
F March 1997 Servo and Scanner Diagnostic
Instance Variables, 87
Troubleshooting Flow Charts,
61, 69
G
September
1997
Entire Manual
H August 1998 Entire Manual
I August 1999 “Power Down and DC Power
Analysis” on page 149
“Micro-Controller DC Power
Log” on page 152
J January 2002 cover art, header, product
names
K February 2002 Exercising the Reflection IR
Flag, 237
11 March 2003 Manual Part Numbers
3BUS 208 055 R1101
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.
Preface
The Measure IT Scanning Platform Troubleshooting Procedures Manual, 3BUS 208 055 R1101, is
a reference guide to troubleshooting the SP 1200 and the SP 700. This manual contains information
for the trained diagnostician on the theory of Scanning Platform operation and advanced
troubleshooting tools.
3BUS 208 055 R1101
Preface
i

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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.
Table of Contents
Preface ........................................................................................... i
List of Figures ............................................................................. xi
1 Selected Theories of Operation.............................................. 1
Positioning System Overview......................................................................2
Head Package Dimensions Setup ...............................................................3
Definition of Head Package Dimensions ..............................................................4
How Head Position is Determined...............................................................5
Motion Theory ...............................................................................................7
Servo Theory of Operation....................................................................................7
ACCELERATION Phase Operation..............................................................9
CRUISING Phase Operation..........................................................................9
DECELERATION Phase Operation ............................................................10
HOMING Phase Operation ..........................................................................11
Motion Control Theory .......................................................................................12
System Response to Some Position Parameters..................................................13
Moving from Off–Sheet to On–Sheet ..........................................................17
Detecting Edges While Scanning.................................................................18
Profile Development for 1190 Systems.....................................................19
Time Based Measurement ...................................................................................19
Profile Development in the Scanning Platform...................................................21
Profile Transmission to the Host Computer ........................................................25
Profile Development in the 1190 Host Computer ...............................................26
1190 Measurement Analysis using On-Line Utilities ...............................27
Introductory Comments.......................................................................................27
ABB Measurement Analysis Using the tbmcu Utility ........................................27
Using tbmcu Utility in Stand-alone.....................................................................31
Converting tbmcu Files for Spreadsheet Analysis ..............................................32
Examining Floating Point TBM Arrays ..............................................................34
1190 Measurement Analysis Using sentest Utility .............................................35
Profile Data ..................................................................................................36
Single Point Drift Data.................................................................................37
Profile Development for 1180 Systems.....................................................38
Profile Transmission and Development ..............................................................38
Profile Development in the Scanning Platform...................................................39
Accessing 1180 MICRO Profile Data Inside the Scanning Platform..................42
Displaying the Mini-Access Profile Array...................................................44
Profile Transmission to a Host Computer ...........................................................45
Profile Development within the Host Computer..........................................46
Data Box Collection Calculation..................................................................47
Logical Zone Calculations...................................................................................48
3BUS 208 055 R1101
Table of Contents
iii

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.
Sensor Theory .............................................................................................49
Sensor Processing Overview ...............................................................................49
Filtering ........................................................................................................49
Normalization...............................................................................................49
Linearization.................................................................................................50
Correction.....................................................................................................50
Conversion ...................................................................................................50
Compensation...............................................................................................50
Fine Tuning ..................................................................................................50
Sensor Input Signal Processing ...........................................................................51
Sensor Output Signal Processing ........................................................................55
2 General Troubleshooting Instructions................................. 59
Data Required for Problem Escalation......................................................60
Troubleshooting Flow Charts ....................................................................63
Host Computer Coldstart Data File Overview ..........................................76
Startup Messages .......................................................................................77
Changing the Host/SP BAUD Rate and the Station ID.............................85
Radiological Safety Features and Alarms ................................................86
Broken Grid Alarm..............................................................................................86
Inherent Sheet Break (ISB) Alarm ......................................................................86
Head Tracking Error............................................................................................87
Shutter Closed During Prepare to Move .............................................................87
Shutter Closed When Host Computer is Down...................................................87
Invalid Shutter Open Alarm ................................................................................87
3 Position and Motion Problems ............................................. 89
Preliminary Troubleshooting Activity .......................................................90
Positioning Events Historical Diagnostic .................................................91
Mechanical Influence on Motion Problems ..............................................94
Comments About the Motor Controller.....................................................95
Diagnosis of Platform and Servo Problems .............................................96
Hang Up Problems ..............................................................................................96
vmin Too Small............................................................................................96
Motor Controller Slope Too Small...............................................................97
servo01 Request Complete...........................................................................97
Overcontrol Problems..........................................................................................97
vmin Too Large (or activeVmin) .................................................................97
Motor Controller Slope and Offset Too Large.............................................98
xdb Too Small ..............................................................................................98
Miscellaneous...............................................................................................98
Servo & Scanner Diagnostic Instance Variables .....................................99
servo01 object......................................................................................................99
xdb................................................................................................................99
iv
Table of Contents
3BUS 208 055 R1101

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.
vdb................................................................................................................99
avdb ..............................................................................................................99
advdb ............................................................................................................99
vmin/activeVmin..........................................................................................99
vmax...........................................................................................................100
vminFilterFactor.........................................................................................100
ddcExcessiveErrorPercent..........................................................................100
ddcRestrictedMotionPercent ......................................................................100
Accel...........................................................................................................100
Kp...............................................................................................................100
Ki................................................................................................................101
slopep .........................................................................................................101
slopen .........................................................................................................101
biasp ...........................................................................................................101
biasn ...........................................................................................................101
vminTune ...................................................................................................101
sampleInterval ............................................................................................101
xfinal[3]......................................................................................................101
vfinal[3]......................................................................................................101
increment[3] ...............................................................................................101
duration[3]..................................................................................................102
homingError ...............................................................................................102
farEdge .......................................................................................................102
homeEdge...................................................................................................102
scanner01 object ................................................................................................102
maxEdgeChange.........................................................................................102
dbWidth......................................................................................................102
dbAvgTime.................................................................................................102
healthRequest .............................................................................................103
maxSpeed ...................................................................................................103
positioningSafetyMargin............................................................................103
target...........................................................................................................103
autoEOS .....................................................................................................103
farEOSUnknown/homeEOSUnknown.......................................................103
inTransit .....................................................................................................103
scanning......................................................................................................103
sheetBreakPresent ......................................................................................104
stdzPending ................................................................................................104
offSheetTimer.............................................................................................104
onSheetTimer .............................................................................................104
Servo Diagnostic Troubleshooting Utility ........................................................104
Selected Servo Diagnostics Definition of Terms: .............................................105
delx.............................................................................................................105
STOP_PAST ..............................................................................................105
CONTINUE HOMING..............................................................................105
FINISHED HOMING ................................................................................105
3BUS 208 055 R1101
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v

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.
AEOS Setup Problems..............................................................................107
Frame Tuning and Diagnostic Tool, ft.....................................................110
Enter ft Utility ............................................................................................112
4 ABB Smart Processing Center (ASPC) Hardware............. 113
Host/Workstation Interface to the ASPC.................................................114
Inspecting and Repairing BRAM .............................................................116
Digital I/O Utility ........................................................................................118
dim Main Menu .................................................................................................118
Procedure for Using the dim Utility ..................................................................118
dim Reports .......................................................................................................119
I/O Selection..............................................................................................119
Printout of I/O Configuration.....................................................................119
Digital Input/Output Signal Verification and Tracing.............................120
Analog Input Monitor Utility .....................................................................121
aim Main Menu .................................................................................................121
Procedure for Using the aim Utility ..................................................................121
aim Reports........................................................................................................122
I/O Device Selection Report ......................................................................122
AI Signal Report (Statistics) ......................................................................123
AI Channel Gains Report ...........................................................................124
AI Channel Slopes and Offsets Report ......................................................124
Analog Input Signal Verification and Tracing ........................................125
Using the Diagnostic Card Adapter.........................................................126
Diagnostic Cards ...............................................................................................130
Replacement Parts .............................................................................................138
LED Interpretation.....................................................................................139
Power Supply LEDs ..........................................................................................139
ECF, ECS, and ECC LEDs ...............................................................................140
ECF and ECC Boards (Only).....................................................................140
MPRC LEDs......................................................................................................141
Analog and Digital I/O Documentation....................................................146
Power Down Analysis...............................................................................147
Safety Interrupt Alert.........................................................................................147
Power Down and DC Power Analysis...............................................................149
Micro-Controller DC Power Log...............................................................152
5 Software Diagnostic Tools.................................................. 155
Software Diagnosis...................................................................................156
General Software Troubleshooting Techniques ................................................156
Resource ............................................................................................................156
Operating System ..............................................................................................157
Application ........................................................................................................157
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3BUS 208 055 R1101

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.
AVOS and Application Utilities........................................................................158
General AVOS Utilities .............................................................................158
The inspect Utility .............................................................................................160
The gstore Utility...............................................................................................162
Identifying Sensor Configuration ............................................................164
Identifying Software Release Levels .......................................................165
Finding System Release Levels.........................................................................165
Finding Subsystem Release Levels ...................................................................165
Release Level Check of Diskettes .....................................................................166
Signal/Measurement Processing Analysis and Reporting (smr)..........168
Summary of smr Capabilities ............................................................................168
Operation Overview ..........................................................................................169
Triggers..............................................................................................................171
Outputs ..............................................................................................................173
Automatic Reporting and Retriggering .............................................................175
Global Access....................................................................................................176
Starting and Stopping Data Collection..............................................................176
Overview of Menu Selection.............................................................................176
General Procedure......................................................................................176
Practical Application..................................................................................177
Example......................................................................................................177
Trigger Setup..............................................................................................177
Collect Data On:.........................................................................................178
smr Work Sheet .................................................................................................178
Resource Checks ......................................................................................180
Obtaining the monitor Report............................................................................180
Obtaining derr, bfchk, and dfree Data...............................................................183
How to Start the Scanning Platform........................................................185
Displaying Reports within inspect ..........................................................187
Standardize Report ............................................................................................187
Sample Check Report........................................................................................188
Calibrate Sample Report....................................................................................189
Preparing On–Site Documentation..........................................................190
Operation of the Sensor Health Pages....................................................191
Off-Line Debug ..........................................................................................195
6 Sensor Troubleshooting...................................................... 197
Sensor Compensation - Operation and Setup .......................................198
Definition of Terms ...........................................................................................198
Operation ...........................................................................................................199
Compensation Flag Setup..................................................................................201
Air Column Compensation for Smart Sensors.......................................202
Procedure to Disable Gap Compensation..........................................................202
3BUS 208 055 R1101
Table of Contents
vii

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.
Changing the Measurement Resolution .................................................203
Sensor Measurement Validity Codes ......................................................205
Sensor Local Modes of Operation...........................................................206
Basis Weight Sensor (TLK, TLP, and TLS) .............................................209
Troubleshooting Flow Chart .............................................................................209
Basis Weight Hardware Diagnostics.................................................................211
To Open or Close Shutter:..........................................................................211
To Unclamp or Clamp Electrometer ..........................................................211
Infrared Moisture Sensor..........................................................................213
Sensor Alarm Codes..........................................................................................213
Alarms 4619/4719 and 4624/4724 .............................................................214
Alarms 4615/4715, 4616/4716, 4617/4717, 4618/4718, & 4622/4722 .....215
Alarm 4603/4703........................................................................................216
Alarm 4608/4708........................................................................................217
Alarm 4602/4702........................................................................................217
Alarm 4621/4721........................................................................................217
Alarms 4609/4709, 4611/4711, 4612/4712, 4613/4713, 4614/4714, and
4679/4779............................................................................................217
Correlation Problems.........................................................................................218
General Correlation Scatter........................................................................218
Rewet..........................................................................................................218
Dirt Buildup on the Sensor Window..........................................................218
Step-Outs in the Trend ...............................................................................219
Composition Effects on Infrared Sensors...................................................219
Operation at Design Limits ........................................................................219
Insufficient Cooling....................................................................................220
Troubleshooting Flow Charts............................................................................220
Exercising the Gain Using Software Commands ..............................................237
Using inspect..............................................................................................237
Using the Health Page Pulse Monitor ........................................................237
Exercising the Reflection IR Flag .....................................................................237
Discontinuity Counter .......................................................................................238
Ash Sensors (TLXR) .................................................................................239
Ash Sensor Standardize Results ........................................................................240
Ash Sensor Hardware Diagnostics ....................................................................242
To Open or Close Shutter...........................................................................242
To Unclamp or Clamp the Electrometer ....................................................242
Ash Correlation Problems ...............................................................................244
Air Bearing, Contacting, and Non-Contacting Caliper Sensors ...........246
Exercising the Caliper Sensor ...........................................................................246
Troubleshooting Alarms....................................................................................247
Alarm Code Classification ................................................................................249
Sensor Validity Codes .......................................................................................250
viii
Table of Contents
3BUS 208 055 R1101

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.
Appendix A: Quick Reference Guide ..................................... 251
Scanning Platform Utilities ......................................................................252
Line Prompts .....................................................................................................252
Special Functions ..............................................................................................252
Utility Command Response to a File ................................................................252
Utility Commands......................................................................................253
File Commands..................................................................................................253
Maintenance and Debugging.............................................................................253
Performing a gstore ..................................................................................254
Object Inspector........................................................................................255
Display Object...................................................................................................255
Modify Object ...................................................................................................256
Special Characters .............................................................................................257
Inspect Messages...............................................................................................257
Command Format.......................................................................................257
Examples:...................................................................................................258
Using the Editor.................................................................................................258
Enter Editor ................................................................................................258
Editor Commands.......................................................................................258
Editor Example...........................................................................................258
Function Keys ...........................................................................................259
DESQview Operations ..............................................................................260
Open Window....................................................................................................260
Close Window ...................................................................................................260
Switch Window .................................................................................................260
Rearrange...........................................................................................................260
Move..................................................................................................................261
Resize ................................................................................................................261
Creating a Hot Key............................................................................................261
Display Scripts ..................................................................................................262
Off-Line Debug ..........................................................................................263
Inspect Messages .....................................................................................264
Application Tools ......................................................................................265
Index ......................................................................................... 267
3BUS 208 055 R1101
Table of Contents
ix

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reproduction, or other means of dissemination may be made without written permission.
List of Figures
Figure .............................................................................................................Page
Figure 1-1 Diagram of Positioning Subsystem ..................................................... 2
Figure 1-2 Sensor Head Positions & their Relationship to the Scanner ............... 14
Figure 1-3 Frame Scan Limits Aligned about the Center of the Process ............. 15
Figure 1-4 Position Relationships of Various Sheet Width Parameters ............... 20
Figure 1-5 TBM Profiling Parameters (Sensor Measurement Using LO RES 1) 23
Figure 1-6 Data Box Relationships for Different Resolutions ............................. 24
Figure 1-7 Sheet Width and Profile Relationships ............................................... 40
Figure 1-8 profiler object display ......................................................................... 43
Figure 1-9 Scanning Platform Algorithm Processing ........................................... 49
Figure 1-10 Sensor Input/Output Signal Relationship ........................................... 51
Figure 1-11 Example Printout of Input Signal Array ............................................. 52
Figure 1-12 Locating A2D Data in a Logical Channel .......................................... 54
Figure 1-13 outputSignals as Inputs to Other Sensors ........................................... 56
Figure 1-14 Example Printout of Output Signal Array .......................................... 57
Figure 2-1 Troubleshooting Flow Chart A ........................................................... 64
Figure 2-2 Troubleshooting Flow Chart B ........................................................... 65
Figure 2-3 Troubleshooting Flow Chart C ........................................................... 66
Figure 2-4 Troubleshooting Flow Chart D ........................................................... 67
Figure 2-5 Troubleshooting Flow Chart E ........................................................... 68
Figure 2-6 Troubleshooting Flow Chart F ............................................................ 69
Figure 2-7 Troubleshooting Flow Chart G ........................................................... 70
Figure 2-8 Troubleshooting Flow Chart H ........................................................... 71
Figure 2-9 Troubleshooting Flow Chart I ............................................................. 72
Figure 2-10 Troubleshooting Flow Chart J ............................................................ 73
Figure 2-11 Troubleshooting Flow Chart K ........................................................... 74
Figure 2-12 Troubleshooting Flow Chart L ........................................................... 75
Figure 3-1 Servo Diagnostics Report ................................................................... 105
Figure 3-2 Frame Tuning Utility Menu Tree ........................................................ 111
Figure 3-3 Description of ft Menu Options .......................................................... 112
Figure 4-1 Debug Port on the Scanning Platform ................................................ 115
Figure 4-2 Example of Diskette Repair Activity .................................................. 116
Figure 4-3 Main Menu for the Digital I/O Utility ................................................ 118
Figure 4-4 I/O Selection Menu ............................................................................. 119
Figure 4-5 Digital I/O Monitor ............................................................................. 119
Figure 4-6 Partial Example of an I/O Configuration Printout .............................. 119
Figure 4-7 aim Main Menu ................................................................................... 121
3BUS 208 055 R1101
List of Figures
xi

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.
Figure 4-8 I/O Selections from the aim Report .................................................... 122
Figure 4-9 Device Selected ................................................................................... 122
Figure 4-10 aim Input Values ................................................................................. 123
Figure 4-11 aim Statistics Display Page ................................................................. 123
Figure 4-12 aim Software Gains Report ................................................................. 124
Figure 4-13 aim Slopes and Offsets Report ........................................................... 124
Figure 4-14 Example of aim Analog Input Display ............................................... 125
Figure 4-15 ASPC Backplane (-003 Version Shown) ............................................ 127
Figure 4-16 Test Board Hookup ............................................................................. 128
Figure 4-17 Carriage Assembly .............................................................................. 129
Figure 4-18 Diagnostic Card: Top Power .............................................................. 130
Figure 4-19 Diagnostic Card: Bottom Power ......................................................... 131
Figure 4-20 Diagnostic Card: Top Signal ............................................................. 132
Figure 4-21 Diagnostic Card: Bottom Signal Sensor ............................................ 133
Figure 4-22 Diagnostic Card: Backplane Power ................................................... 134
Figure 4-23 Diagnostic Card: Bottom Auxiliary Power ......................................... 135
Figure 4-24 Detector Module Diagnostics Card .................................................... 136
Figure 4-25 Source Module Diagnostics Card ....................................................... 137
Figure 4-26 Smart Plarform Electronics Cabinet (-003 Backplane) ...................... 143
Figure 4-27 Location of SMI and BRAM Boards .................................................. 144
Figure 4-28 Location of OSPS2 and EC24V (SP1200) ......................................... 145
Figure 4-29 Example of Analog I/O Documentation ............................................. 146
Figure 4-30 Historical Trend for Microcontroller DC Voltages ............................ 153
Figure 5-1 gstore Menu Screen ............................................................................ 162
Figure 5-2 Hierarchical View of the smr Utility .................................................. 169
Figure 5-3 smr Menu Selection Tree .................................................................... 170
Figure 5-4 Analog and Measurement Historical Data Display ............................ 174
Figure 5-5 Digital Historical Data Display ........................................................... 174
Figure 5-6 Statistical Data Display ....................................................................... 175
Figure 5-7 Monitor Command Menu ................................................................... 180
Figure 5-8 Monitor General Time Display ........................................................... 181
Figure 5-9 monitor Resource Activity Display .................................................... 182
Figure 5-10 Example of the Use of derr, bfchk, and dfree ..................................... 183
Figure 5-11 Standardize Report .............................................................................. 187
Figure 5-12 Check Sample Report ......................................................................... 188
Figure 5-13 Check Sample Report ......................................................................... 189
Figure 5-14 Health Overview Page ........................................................................ 191
Figure 5-15 Basis Weight Health Report Showing Sample Check ........................ 193
Figure 5-16 Basis Weight Health Page Showing Calibrate Sample ....................... 194
Figure 6-1 Flow Diagram of Compensation Selection Logic ............................... 200
xii List of Figures 3BUS 208 055 R1101

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.
Figure 6-2 Basis Weight Troubleshooting Flow Chart ........................................ 210
Figure 6-3 Sensor Head Signals ........................................................................... 216
Figure 6-4 Troubleshooting Flow Chart 1 ........................................................... 221
Figure 6-5 Troubleshooting Flow Chart 2 ........................................................... 222
Figure 6-6 Troubleshooting Flow Chart 3 ........................................................... 223
Figure 6-7 Troubleshooting Flow Chart 4 ........................................................... 224
Figure 6-8 Troubleshooting Flow Chart 5 ........................................................... 225
Figure 6-9 Troubleshooting Flow Chart 6 ........................................................... 226
Figure 6-10 Troubleshooting Flow Chart 7 ........................................................... 227
Figure 6-11 Troubleshooting Flow Chart 8 ........................................................... 228
Figure 6-12 Troubleshooting Flow Chart 9 ........................................................... 229
Figure 6-13 Troubleshooting Flow Chart 10 ......................................................... 230
Figure 6-14 Troubleshooting Flow Chart 11 ......................................................... 231
Figure 6-15 Troubleshooting Flow Chart 12 ......................................................... 232
Figure 6-16 Troubleshooting Flow Chart 13 ......................................................... 233
Figure 6-17 Troubleshooting Flow Chart 14 ......................................................... 234
Figure 6-18 Troubleshooting Flow Chart 15 ......................................................... 235
Figure 6-19 Troubleshooting Flow Chart 16 ......................................................... 236
Figure 6-20 Ash Sensor Troubleshooting Flow Chart ........................................... 239
Figure 6-21 Ash Correlation Troubleshooting Flow Chart .................................... 245
3BUS 208 055 R1101
List of Figures
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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.
1
Selected Theories of Operation
This section presents an overview of profile and motion theory for both
ABB 1190 and ABB 1180 systems.
This chapter contains the following major sections:
Section ...............................................................................................Page
Positioning System Overview ........................................................................ 2
Head Package Dimensions Setup ................................................................... 3
How Head Position is Determined ................................................................. 5
Motion Theory ............................................................................................... 7
Profile Development for 1190 Systems ......................................................... 19
1190 Measurement Analysis using On-Line Utilities .................................... 27
Profile Development for 1180 Systems ......................................................... 38
Sensor Theory ................................................................................................ 49
3BUS 208 055 R1101
Selected Theories of Operation
1

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.
Positioning System Overview
The positioning subsystem is made up of several components encompassing both
software and hardware elements. See Figure 1-1. In simplified terms, scanner01
determines what is to be done, getting needs from other parts of the system and
determining priorities. servo01, upon a request from the scanner01, decides how
to do it by establishing the needed acceleration, cruise, deceleration, and homing
instructions. The ECF portion of the servo software translates these instructions
for the Motor Controller which delivers the required energy to the motor. It is
here that the motor controller slope and offset (MCslope & MCcoffset) are applied
to the voltage being sent to the Motor Controller. The action of the motor rotates
the encoder whose output is interpreted by the ECF who, in turn, converts it into
position complete information. This is sent to the servo01 who determines
completion of the task and notifies the scanner01 that it is done.
MPRC
scanner01
ECF
Micro–controller
(servo execution)
Motor
Controller
motor
trajectory
servo01
(trajectory)
position
complete
encoder
Figure 1-1 Diagram of Positioning Subsystem
2 Selected Theories of Operation
3BUS 208 055 R1101

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.
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 purpose 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. Two basic equations deal with bringing the head on sheet, depending on
whether auto edge-of-sheet is turned on or not:
Auto Edge-of-Sheet Turned Off:
Prepare to measure position=homeScanLimit + homeHeadClearance - homeWindowClearance
+ curlDist + positioningSafetyFactor
Auto Edge-of-Sheet Turned On:
Prepare to measure position = homeEOS + homeHeadClearance + curlDist + positioningSafetyFactor
3BUS 208 055 R1101
Selected Theories of Operation
3

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.
Definition of Head Package Dimensions
homeHeadClearance This variable represents the distance between the home–side
edge of the sensor head package and the measurement center
line. Its value will depend on how far beyond the home edge of
the sheet the head must come before starting the Prepare To
Measure activity. In any event, it must always be larger than the
homeWindowClearance.
farHeadClearance This variable represents the distance between the far–side edge
of the sensor head package and the measurement center line.
This variable only comes into play when the head must enter the
prepare to measure position from the far side of the scanner. In
that case, it will have the same function as the
homeHeadClearance. When it is to be used, it must be larger
than the farWindowClearance.
homeWindowClearance 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 0.3 inches for an STLXR
Ash sensor, to 2.5 inches for a HemiPlus IR sensor.
farWindowClearance 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 package. The window radii
will range from approximately 0.3 inches for an STLXR Ash
sensor, to 2.5 inches for a HemiPlus IR sensor.
curlDist
This variable represents the additional distance that the heads
will travel when first coming on–sheet to the prepare-tomeasure
position to assure that sheet contacting sensors, such as
caliper, are fully on-sheet before making contact. The head will
then back up to the current homeScanLimit to start scanning. If
desired, the entire prepare-to-measure positioning can be
accomplished with the homeHeadClearance dimension, leaving
the curlDist at its default value of 0.1 units.
positioningSafetyFactor This is a small amount of distance (default of approximately 0.5
inches) which is included in the various positioning algorithms
to assure that errors made in determining the dimensional
characteristics of the head and the sheet positions, will result in
a minimal exposure of the window being off the sheet during a
measure operation.
The locations of these positions on a Scanning Platform sensor head package are
shown in Figure 1-2 on page 14.
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How Head Position is Determined
This section will trace the operational steps and calculations being made along the
way as head position calibration is established within the Scanning Platform.
Several components and software programs come into play as calibration takes
place. These are:
Table 1-1 Head Position Calibration Components and Programs
The Digital Encoder
ECF Micro–controller
ft. utility
home limit switch
home mechanical stop
home reference plane
A electro-mechanical device which outputs a
stream of pulses. Based on the gear ratios used,
each pulse represents 0.010 in. of linear motion.
Each rotation of the shaft generates an index pulse
which computes out to once every 20 in.
Contains hardware devices to collect and process
the pulses coming from the encoder. Resident
software then converts the information into
engineering units for the rest of the system to use.
A diagnostic utility which is used to establish the
relationships between the encoder and the physical
dimensions of the frame.
A device which will interrupt the motor drive
power when activated by the head carriage
assembly as it drives toward the home end column.
It serves to prevent a mechanical collision with the
end column as well as identifying a point where the
encoder signals can become synchronized.
A bump block several inches past the limit switch
(about 4 in.), which defines the absolute farthest the
head can go in the home direction.
The point in space where position of the head
package on the frame are referenced to. This is
typically the inside surface of the home end
column. It could be any structural point that has a
fixed positional relationship with the frame as long
as it is past the head carriage position.
With these definitions in mind, the steps to head position calibration can be
explained as follows. In order to perform the head position calibration, the encoder
must be synchronized. This happens when the system is started up and the Frame
Control Panel (FCP) is placed in remote. At this point in time, the head is driven
in search of the home limit switch. When the switch is tripped, the head stops and
immediately the direction of motion is reversed and the head is moved very slowly
until the system senses that the limit switch has disengaged. At this point, the A2D
value becomes arbitrarily defined as 2001. This A2D value has the default engSlope
and engOffset for headPosition01_ai applied to it to establish a default head
position. The ft utility can now be activated to do the head position calibration.
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The ft utility does several things during the course of calibration. First, it modifies
the engSlope and engOffset of headPosition01_ai so that all reported positions
will be relative to the home reference plane. Then it divides up the maximum travel
available (farTravelLimit - homeTravelLimit) into an A2D range of 1000 to 31767
units. It also establishes an a2dConversionSlope and a2dConversionOffset which
is used to convert the reported head positions into pseudo-A2D units for transmittal
to a host. This slope and offset is stored in the pmmFrame01 object.
The sequence of steps is as follows. The operator places the head at the home
mechanical stop as directed by the utility. The distance from the home reference
plane and the head carriage support surface is then measured and the value entered
into the utility. The utility then adds a fixed amount to this value so that the value
becomes the distance from the home reference plane to the measure window center
line. A different add-on dimension is used for SP1200 and SP700 due to slight
differences in their head sizes.
It should be noted here that it really does not matter what the entered value is. It
only becomes important if someone decides to take a tape measure and check the
distance from the measure window centerline to the home reference plane. CMC
does use the value in its setup, however, it does not care what it is in reference to,
only that it be consistent over time.
Here are some of the equations the calibration goes through:
Hpslope = engSlope = 0.0254/units (where units = 1.0 for cm, and 2.54 for in.)
Hpoffset = engOffset = homePosition - (homePosCounts * engSlope)
a2dConversionSlope = (farTravelLimit - homeTravelLimit)/30767
a2dConversionOffset = homeTravelLimit - (1000 * a2dConversionSlope)
Here is a summary of what happens to an actual head position as it gets processed
and sent up to a host. The ECF micro–controller software has kept track of encoder
pulses with respect to the point at which it was synchronized. The current position,
therefore, has a specific count associated with it. This count is converted to customer
units by applying the engSlope and engOffset. Along with being used by other
parts of the Scanning Platform, the position is also converted to pseudo-a2d units
for availability to the host. This is done by taking the head position in customer
units, and applying the a2dConversionSlope and a2dConversionOffset factors to
it. The exception to this are AccuRay Direct applications which present the host
with data in terms of customer units.
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Motion Theory
Servo Theory of Operation
The scanner sends trajectories to the servo asynchronously and without regard to
the servo’s current duties. The previously requested trajectory may be overridden
at any time by the scanner, even if the servo has not yet responded to that previously
received trajectory.
A trajectory consists of the following information. Refer to Table 1-2.
Type:
FIXED_POINT
STOP_PAST
MOVING
HOLD_POSITION
STOP
POSITION
VELOCITY
MESSAGE
Table 1-2 Trajectory Type and Definition
One of the following:
Go to position and stop (single point, stdz position, etc.)
Go slightly beyond position and stop (scanning)
Go to position and remain moving at speed
Stop and return to current position
Stop and remain at resulting position
Desired final position in units of head position
Desired average velocity to position
Response to the scanner upon satisfaction of this trajectory
Most trajectory requests from the scanner are of the type STOP_PAST; this insures
that the requested positions are attained plus a small dead band. Using STOP_PAST
trajectory requests insures that data is filled in all assigned profile boxes.
Occasionally, the scanner will request a STOP type trajectory in order to guarantee
that it has an unchanging position before making motion decisions. MOVING and
HOLDING_POSITION are rarely used. FIXED_POINT is used to achieve Off–
Sheet, Standardize, and Single Point positions.
The servo attempts to satisfy the requested trajectory by applying four control
phases in sequential order. These phases are defined in Table 1-3.
Table 1-3 Control Phases and Definitions
Control Phase
ACCELERATION
CRUISING
DECELERATION
HOMING
Definition
Increments the velocity from the current output value
Maintains the requested velocity via Direct Digital Control
(DDC)
Decrements the velocity to the final value
Closes on the final position at the minimum velocity
These four phases are unconditionally performed, regardless of the trajectory.
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When the trajectory is first received from the scanner, the servo computes a vector
for each of the first three phases: ACCELERATION, CRUISING, and
DECELERATION based on the tuning parameters provided to it, such as vmin,
vmax, Accel, xdb, vdb, and so forth. These vectors define the predicted endpoint
for each phase in space and time. The fourth phase HOMING, infers its end point
from the original trajectory and therefore does not need a vector to define it, for
example, the final position at zero velocity. The run task of servo will make every
effort to match these predicted end points.
Each of the three vectors contain the following information. Refer to Table 1-4.
Table 1-4 Information Type and Description
Information Type
POSITION
VELOCITY
INCREMENT
DURATION
Description
Predicted final position for this phase
Desired termination velocity for this phase
Per execution VELOCITY or POSITION
increment for this phase
Predicted total time of execution for this phase
The Servo run task determines when each phase is finished by performing the
following comparisons (referred to as the “done check”). Refer to Table 1-5.
Table 1-5 Motion Phases and Descriptions
Comparison
ACCELERATION
CRUISING
DECELERATION
HOMING
Definition
Finished when current output velocity exceeds the
requested speed for this phase or when the requested
acceleration is close to zero.
Finished when the position is close to the estimated
end point
OR
Finished when the elapsed time is greater than the
predicted duration
OR
Finished when the trajectory type is STOP
Finished when the position is close to the predicted end
point
OR
Finished when the elapsed time is greater than the
predicted duration
OR
Finished when the velocity is within vmin of the
desired speed
Finished when the position is close to the trajectory
end point
OR
Finished when the trajectory is STOP
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When the final phase, HOMING, is complete, the required message is returned to
the scanner object to indicate that this trajectory has been achieved.
The following phase logic is executed by the Servo’s run task every 200
milliseconds. Each phase executes its “done check” prior to continuing. When the
“done check” is complete, then the next phase begins.
ACCELERATION Phase Operation
During the ACCELERATION phase, Servo increments its velocity output by adding
the predicted velocity increments during each sampleInterval. The predicted
velocity increment is derived from the following equation:
inc [this phase] = Accel * sampleInterval
CRUISING Phase Operation
During the HOMING phase, the positioning is handled in two different ways. One
way is used when the trajectory mode is scanning and the other is used for all other
trajectory modes.
For the normal scanning mode (called STOP_PAST in the program), the head is
driven toward the target until it reaches a location close to the target and then the
output to the motor controller is set to zero and the head comes to a stop slightly
past the target. The servo logic monitors the distance the head travels after
outputting the zero output (the stopping distance) in order to determine how far in
advance of the target to start stopping the head. A separate distance is kept
depending on the direction the head is moving. Initially, the servo logic has no
history of the stopping distance so it defaults to using the actual target for when to
start stopping. But after scanning in both directions the operation of the servo will
get much better. This is a key point to keep in mind, because after every restart the
system must go through this learning process. That means that the initial scans
after a restart will not be as accurate in terms of achieving the correct EOS position
as will later scans. The learning curve is, however, fairly short with only two to
four scans needed to establish reasonable results.
The other trajectory modes; i.e., single point, standardize, etc., are handled in the
traditional positioning (called NON_STOP_PAST in the program) way. The head
is driven toward the target until it gets to a location close to the target and then the
output to the motor controller is set to zero and the head should come to a stop
slightly past the target. The determination of how far in advance of the target to
start stopping is the same as for the scanning mode. After once trying to stop, the
logic reverts back to keeping the head inside the deadband of xdb around the target.
The stopping distance is not monitored for the positioning cases. In this way, the
stopping distance is more accurately kept for the scanning logic (scanning is the
mode desired to optimize).
During the CRUISING phase, Servo performs a DDC-PI (proportional and integral
direct digital control) algorithm on the desired scan position which insures that the
position error is kept to a minimum.
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A motion restriction detector has been built into this phase which senses the
increased effort required to overcome an obstacle. Its sensitivity may be adjusted
infinitely from zero. If an obstacle has been detected, then the head is immediately
stopped and the platform is put in local. To recover, the platform must be cycled
through local using the pushbuttons at the platform control panel. A console
message notes this local condition.
The algorithm used for the obstacle detection is:
IF: ddc speed is more than ddcExcessiveErrorPercent greater than
requested speed
AND IF: measured motion is less than ddcRestrictedMotionPercent of
expected motion
OR IF: measured motion is close to zero
THEN: motion is restricted.
DECELERATION Phase Operation
During the DECELERATION phase, Servo decrements the velocity output by
subtracting the predicted velocity increment each sampleInterval. The predicted
velocity increment is derived from the following equation:
inc [ACCELERATION] = Accel * sampleInterval
The terminal velocity for this phase is assumed to be vmin for most trajectories
since the HOMING phase is next and will zero the output immediately if the position
dead band, xdb, has been satisfied. This velocity assures that “stiction” (an
impedance to free movement either by friction or stickiness) does not occur between
deceleration and homing.
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HOMING Phase Operation
For both modes of HOMING when trying to drive the head (non-zero output to the
motor controller), the initial output to the motor controller will be the activeVmin
speed. If the head stalls (no movement when trying to drive the head), the output
is increased by a small amount velInc (velInc = vminFilterFactor * activeVmin).
After two time iterations, the movement is checked again. If there is still no
movement, the output is again increased by velInc. This procedure is repeated until
the head shows movement.
After driving the head close enough to the target, the output to the motor controller
is set to zero (as previously mentioned). At that time a check is made to determine
if the previous output was more than two times velInc larger than activeVmin and
if the flag vminTune is TRUE. If that is the case, the activeVmin is increased by
velInc. By operating with the flag vminTune TRUE, activeVmin would eventually
reach a value that will assure movement of the head. If the flag vminTune is FALSE,
the output to the motor controller will be incrementally increased. But, the
activeVmin will not be modified so that the starting activeVmin for the next
trajectory would revert back to the same value each time.
If the communication to the ECF is lost, then restored, the activeVmin will get
initialized to the value of vmin even if the activeVmin value had been changed
because of the flag vminTune being set to TRUE. So the proper way to tune the
frame is to set vmin to a relatively small value and then set vminTuning FALSE
and then back to TRUE with either the ft utility or the Frame Health Page. Let the
system scan until activeVmin reaches a stable value, then set vmin equal to the
stable value and turn vminTuning FALSE.
For FIXED_POINT positioning during the HOMING phase, the head position is
compared to the end point of the requested trajectory. The Servo will remain in this
phase until it is sent a new trajectory. The two possibilities for control are:
Acceptable:
The current head position is close enough to the target. The output velocity is set
to zero. The actual current velocity of the head is not necessarily zero at this instant.
Assuming that the velocity remaining from the DECELERATION control phase is
usually equal to vmin, the actual velocity should be zero within the next 100
milliseconds.
Unacceptable:
The current head position is too far from the target. The minimum velocity vmin
is requested. A DDC proportional and integral algorithm is performed to insure
that minimum velocity is achieved. Additionally, if the flag vminTune is set, then
vmin may be modified in the following way prior to use:
If the DDC algorithm is detecting excessive homing errors (that is, total correction
is greater than vmin) and if there has been no detected motion in the last 0.1 seconds,
then vmin is increased using the following formula:
new vmin = (old vmin * vminFilterFactor) + old vmin
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This increase insures that vmin reaches a value which is correctable by the DDC,
but is not too large. Positioning delays may still occur, however DDC will eventually
overcome platform resistance. vmin is limited in this algorithm to no more than
one third of vmax.
In a poorly tuned platform, the required minimum velocity may approach or exceed
the desired scanSpeed or onSheetSpeed of the scanner. If the platform is poorly
tuned, the head may “hang up” or “hunt” when trying to achieve a position.
Motion Control Theory
Proper setup of the Scanning Platform is very important to trouble free operation.
There are critical factors in both the hardware and the Scanning Platform software.
A brief description of the motion algorithm may be of help in case of problems.
The Scanning Platform software controls the motion of the head package with an
object called Servo. The servo object is told to wait for the next input value of its
head position (called servoHeadPosition0x). This head position is expected every
100 milliseconds. If it does not arrive within 500 milliseconds, an error will be
generated in the error log (pe) and the previous velocity will be used.
Upon receipt of the head position, the servo executes its position algorithm. This
algorithm uses a DDC loop with both integral and proportional control. The
components of the output velocity in customer units from the servo are:
command
pcommand
icommand
lcommand
= total output cu/sec
= proportional error cu/sec
= integral error cu/sec
= desired velocity cu/sec
The position tolerance xdb is used to determine position complete of the head.
The scan speed used by the servo is computed by the pmmFrame0x object from
information it receives from the Host Computer. The scan speed is used for several
modes besides scanning; for instance, to move between single point positions which
are close together, and for moving from off–sheet to near the sheet edge position.
The new velocity command is sent to a signal object called servoVelocity0x. All
objects which are waiting for this signal will be awaken for processing.
The servo drive program in the frame SMI has been told to wait for the next update
of the velocity command signal from the MPRC servo object.
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System Response to Some Position Parameters
The Scanning Platform subsystem uses the following rules and equations to safely
position the measure window over the process. While the entries refer to actual
physical dimensions on the head and frame, the values used may be modified to
accomplish desired results. For example, a process with little or no curl and no
edge flutter need not take into account the full homeHeadClearance or curlDist
when bringing the head on–sheet for the prepare–to–measure function.
Read the following six comments to assist your understanding of the parameters
used. See Figure 1-2 on page 14 and Figure 1-3 on page 15.
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Home
End
Column
homeTravelLimit
Far
End
Column
Home Limit Switch
garagePosition
stdzPosition
homeTrimLimit
homeMeasureLimit(LHEOS)
homeEOS (auto EOS only)
homeScanLimit (KHEOS)
homeDetector
curlDist
farTravelLimit
frameWidth
Measurement
Reference Line
farScanLimit (KFEOS)
farEOS (auto EOS only)
farMeasurementLimit (LFEOS)
farTrimLimit
Process Sheet
Figure 1-2 Sensor Head Positions & their Relationship to the Scanner
Far Limit Switch
farDetector
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D1
HomeEdge
Detector
homeHeadClearance
Measurement
Reference Line
HEOS
Process Sheet
farDetectorOffset
and D2
Figure 1-3 Frame Scan Limits Aligned about the Center of the Process
farHeadClearance
FEOS
FarEdgeTrackingDistance
Far Edge
Detector
D2
EOS
DB
homeEdgeTrackingDistance
homeEdgeWindowClearance
farEdgeWindowClearance
homeDetectorOffset
and D1
EOS
DB
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1. The homeHeadClearance and farHeadClearance variables are cross–
machine distances with respect to the head position reference point
(measurement window center line). They establish a cross–machine area called
the head. These values define a boundary along each home edge of the process
sheet when the head is going on–sheet.
The head will not move past the homeHeadClearance if any portion of the
head is already determined to be on the sheet. This is particularly significant
for auto edge–of–sheet measurements.
Note:
The instance variable curlDist can be used in place of
homeHeadClearance. Whichever one is used, the other should be
set to a very small value such as 0.1. However,
homeHeadClearance must always be larger than
homeWindowClearance.
2. The homeWindowClearance and farWindowClearance variables are cross–
machine distances with respect to the head position reference point
(measurement window centerline). They establish a cross–machine area called
the head window. The purpose for these special areas is to restrict measurement
operations which would have any part of the window area to be off–sheet.
3. When auto edge–of–sheet is enabled, the edge detectors will be used to find the
actual edge–of–sheet. With auto edge–of–sheet disabled, the envelope
dimensions of the head and measure limits will be used to compute and
anticipate the sheet edge position.
4. Three speeds are defined in the Scanner community file in the Scanning
Platform. maxSpeed is the high velocity used for moving the head distances
which are greater than one fourth the platform width and which do not cause
the sheet boundary to be crossed. scanSpeed is determined by the desired scan
time and the current scan limits. It is computed by the Scanning Platform based
on data sent to it by the Host. The third speed, onSheetSpeed, is invoked any
time the head is given a command to cross the sheet edge boundary area from
the off–sheet position.
5. On platforms significantly longer or shorter than 6–7 meters, the variable xdb
in the servo0x object file may need adjustment. xdb is the position dead band.
Adjust it smaller on short platforms and wider on long platforms. The criteria
is attainment of position, complete without hunting.
6. The acceleration variable “Accel”, has a large impact on stability at the scan
edges. A typical value should be about one-half of the scan speed. Too high
of a value will cause the head to start abruptly and shoot past the target at the
end. Too low of a value will cause the head to struggle in getting to its cruising
velocity.
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The heads will appear to move at different rates to get to a particular target position.
This is because the system keeps a constant monitor of the positional relationship
between the sheet edge and the current head position. Moving the head, then,
becomes a complex process involving several computations to determine how fast
the heads may be moved. An example of moving the head from off–sheet at the
home end to a scanning position inside the curl area is as follows:
Example:
ACTION
How It Happened
The head package moves
to a position just off
the homeTrimLimit
at maxSpeed. position target = (homeTrimLimit - farHeadClearance
- positionSafetyMargin)
The head package moves
to a position just beyond
the curl area at
the onSheetSpeed. position target = (homeScanLimit -
homeWindowClearance +
homeHeadClearance +
curlDist + positionSafetyMargin)
The head package moves
to the starting scan
position at maxSpeed. position target = (homeScanLimit)
Moving from Off–Sheet to On–Sheet
When you move the head from the off–sheet position, either garagePosition or
stdzPosition, the initial request to scan causes the head to move towards the sheet
edge at maximum speed. When the far edge detector sees the home edge, the head
halts momentarily, checks that all the sensors are prepared to cross the sheet edge,
then proceeds at onSheetSpeed to the prepare to measure position. The system
then knows where the home edge is located. This knowledge causes the head to
proceed to the calculated homeScanLimit to start the scanning operation, just as
it would under non–AEOS conditions.
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Detecting Edges While Scanning
During the scanning process, the leading edge detector is constantly monitored to
determine the location of the edge–of–sheet. When the edge is detected, the detector
computes a new ideal scan limit for that edge. The difference between this new
ideal scan limit and the current scan limit is compared to the EOSDeadband. If
the difference is greater than the EOSDeadband, the scan limit is changed to the
new ideal scan limit. The head then pauses and moves to the new scan limit. If the
scan limit is not changed, the head continues to use the current scan limit.
If the edge is not detected before the sensor window reaches the current scan limit,
the system causes the head to proceed to the corresponding MeasureLimit as a
target. The edge–of–sheet should be detected before the sensor window reaches
the MeasureLimit target. A new ideal scan limit is then computed and the head
moves to this new location. As of SCN release SP210.2, any further edge detections
by the farDetector are ignored (for example ropes). If the sensor window reaches
the MeasureLimit before the edge is detected, then the MeasureLimit is used as
the scan limit.
Whenever the system determines that the EOSDeadband has been exceeded and
a new ideal scan limit is to be used, the Host is notified and it in turn will compute
a new scan speed if necessary. The Host will delay the next scan enable until it has
completed its analysis and sent the new information to the Scanning Platform.
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Profile Development for 1190 Systems
Time Based Measurement
This section contains information on how the Scanning Platform software produces
time based measurement profiles, how these profiles are transmitted to the Host
computer, and how the Host computer displays the time based profiles.
In the TBM (Time Based Measurement) system, there is only one type of profile
generated within the Scanning Platform for each sensor. It is an uncomposited
profile which the Host computer can then composite if desired. All profiling takes
place within the pmmSensor objects (for example: pmmBeta01, pmmIR01) rather
than in the sensor objects (for example: betaSensor01, IRSensor01). By having the
profiling occur in the pmmSensor objects, the Scanning Platform software can
interface with a variety of Host computers, each of which might have unique profile
generation requirements.
The Scanning Platform software supports any number of data boxes for its profiles.
The number of data boxes is determined by the variable fsdi->ibxw, which is in the
pmmFrame’s static data area from the Host. This variable specifies the width of
the data box for the highest resolution profile that the system will support. Data
box numbers start at 0 at the location defined by LHEOS (the pmmFrame’s
homeTrimLimit), and increase by 1 each data box width (fsdi stands for frame static
data input from the Host.)
The width of the data boxes in the Scanning Platform and the host computer are the
same with a value calculated and provided by the host. A maximum number of
data boxes can be displayed if the current scan limits are made equal to the maximum
measure limits. Due to round off errors in converting from integer to floating point
of the box width variation. The maximum number of boxes for display may be less
than the system defined number of boxes. It is important that the maximum scan
limits (LFEOS and LHEOS) be set to the maximum trim of the machine. If this is
not done, the operator will lose the perspective of which slice screw represents
which area of the profile. As the current scan limits are moved inward (KFEOS
and KHEOS), the number of profile boxes displayed will be reduced proportionally
to the decrease in sheet width. See Figure 1-4.
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HEADBOX
Maximum Slice
Maximum Head Position Range of Encoder
1 count 65535 counts
homeTravelLimit
at homeLimitSwitch
(2001 counts)
Maximum Head Position Readings
farTravelLimit
at farLimitSwitch
(2001 + [farLS - homeLS] / .01 inch per count)
homeMeasureLimit
(minhl/LHEOS)
Maximum Trim
farMeasureLimit
(maxfl/LFEOS)
homeScanLimit
(heos/KHEOS)
Scan Limits
farScanLimit
(feos/KFEOS)
homeEOS
EOS Positions
(same as above if no AEOS)
farEOS
Figure 1-4 Position Relationships of Various Sheet Width Parameters
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Profile Development in the Scanning Platform
Placing the measurement data received from the various sensor objects in profile
arrays requires first that appropriate array objects be built to contain the data. This
is only done once when the Scanning Platform starts up. These array objects are
circular buffers of 500 entries. The data stored in these array objects are from the
static and dynamic data input areas of pmmFrame (fsdi/fddi) and from the dynamic
data input areas of pmmSensor (ddi). The information format for the circular buffer
arrays is normally scaled, customer unit data, in integer format. For chemical and
AccuRay Direct applications, it is the floating point format. This information is
shown in Table 1-6 on page 22.
The Scanning Platform software identifies which data box a measurement belongs
in, based on its head position (which was calibrated using the frame tuning utility
ft) and on data box specification information sent down from the Host in the
Scanning Platform’s static and dynamic input data areas. As each measurement
data point is received, the microcontroller routine stuffs that data into the correct
data box, averaging it with the previous data points in that data box. The boxes of
averaged signals are then delivered to the MPRC board processing where the boxes
are converted into sensor measurements. Each time that the data box number
changes, a new cell in the circular buffer is updated. The number of data points
included in each data box is determined by:
• the sensor sampling rate (which is 50 or 60 smples/second based on power
frequency),
• the scan speed, and
• the number of data boxes per scan (which is a function of data box width and
scan limits).
For all sensors except IR, use the following equation:
z samples -------------------- = 1000 samples
databox seconds
Equation 1-1
For IR sensors, use the following equation:
-------------------- x--------------------
seconds 1
× × -----------------------------
scan
z samples -------------------- = hHz × x--------------------
seconds
databox
scan
Equation 1-2
y databoxes --------------------------
scan
1
× -----------------------------
y databoxes --------------------------
scan
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Example: The number of IR data points in each of 600 data boxes for a 30
second scan on a 60 Hz system would be:
----------------------------------------------
Number of Samples
data box
60
--------------------------
samples 30
-------------------------
seconds 1 scan
= × × ----------------------------------- =
second scan 600 data boxes
3
-----------------------
samples
data box
Table 1-6 Scan and Data Box Width Elements
Function Structure Element Scanning Platform
Variable Name
Current home scan limit
KHEOS
Current far scan limit
KFEOS
Hi res profile box width
Minimum home edge-of-sheet
LHEOS
Max far edge-of-sheet
LFEOS
Box width multiplication
factor
Resolution selector
Indexes into circular TBM
buffers
fsdi->heos
(in A/D units)
fsdi->feos
(in A/D units)
fsdi->ibxw
(in A/D units scaled by 64)
fsdi->minhl
(in A/D units)
fsdi->maxfl
(in A/D units)
fsdi->bxwmf[0-3]
One factor for each of the 4
resolutions:
HI RES factor = 1
each of the LO RES factors is
a power of 2 (e.g. 2,4,8,16)
ddi->ressel
(Selects either the HI RES or
one of the 3 LO RES)
fddo->index[0-3]
One index for each of the 4
resolutions
scanner->homeScanLimit
(in customer units)
scanner->farScanLimit
(in customer units)
scanner->dbWidth
(in customer units)
scanner->homeMeasureLimit
pmmFrame->homeTrimLimit
(in customer units)
scanner->farMeasureLimit
pmmFrame->farTrimLimit
(in customer units)
pmmSensor->resolution
(resolution = ddi->ressel - 1)
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Time based measurement profile development in the Scanning Platform involves
the following sequence of events:
1. The pmmFrame object waits on the head position signal to be updated. This
signal is updated with data from the ECF board every second (and contains 50
or 60 data points).
2. When the system is scanning, the logic sequences over each data point in the
head position object determines which data box that head position value falls
into. Whenever the calculated data box number changes, an entry
corresponding to that data box number is put into the next consecutive cell of
the box TBM circular buffer. Each consecutive head position signal that falls
into the same data box is averaged together so that the average head position
(for that data box) can be put into a corresponding cell of the position TBM
circular buffer. The amount of time that was spent scanning each data box is
put into a corresponding cell of the time TBM circular buffer. After processing
the entire head position signal, the three circular buffers will all have been
updated based upon the high resolution data box width. An index is kept that
always indicates where data is being placed in the high resolution buffers. See
Figure 1-5.
FRAME:
CIRCULAR BUFFERS (500 CELLS)
Box 1 2 3 500
Time
Position
SENSOR :
Measurement
indexes (points to current position in circular buffers)
index [HI RES]
x
H
index [LO RES 1]
index [LO RES 2]
index [LO RES 3]
a
b
c
H
Note that the different resolution indexes point
to different cell positions in the circular buffers.
There is no relationship between these with
respect to where they point.
Figure 1-5 TBM Profiling Parameters (Sensor Measurement Using LO RES 1)
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3. After the high resolution box buffer has been updated, calculations are made to
determine the number of consecutive samples (in a data signal packet) that fall
into each data box for each of the three lower data box width resolutions. Indexes
for each of the lower resolution buffers are updated. This information is made
available to each of the pmmSensor objects so that they can quickly process
their measurement signals when they become available, and not have to
recalculate which data box each sample falls into. Lower resolution data box
widths are all a multiple of the high resolution data box width. A lower
resolution box width can be calculated by multiplying the high resolution box
width by the appropriate low resolution box width multiplication factor. A
lower resolution data box will contain an even, integral number of high
resolution data boxes, the number of which is equal to the box width
multiplication factor (BXWMF). Box width multiplication factors are
restricted to being powers of 2 (for example: 2, 4, 8, 16, 32). See Figure 1-6.
RESOLUTION BXWMF
DATA BOX NUMBERS
a
b
HI RES
LO RES (1)
1
2
1 2 3 4 5 6 7 8 9 10 11 12 . . . . 599 600
1 2 3 4 5 6 . . . . 300
LO RES (2)
4
1
2 3
.
.
.
150
LO RES (3)
8
1
2 . 75
There is only one circular buffer for data box numbers, that of the HI RES. These data box numbers
line up exactly with entries in the HI RES measurement arrays. To determine corresponding data box
numbers for LOW RES measurement arrays, it is necessary to base these numbers upon the HI RES
values. One must divide the HI RES data box number by the box width multiplication factor (BXWMF),
realizing that a LOW RES data box will not be filled in until the completion of the data box.
From the picture above:
a The HI RES data box number would be 8;
LOW RES (1) would be 4, LOW RES (2) would be 2, LOW RES (3) would be 1.
b The HI RES data box number would be 10;
LOW RES (1) would be 5, LOW RES (2) would be 2, LOW RES (3) would be 1.
Figure 1-6 Data Box Relationships for Different Resolutions
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4. When the system is not scanning (for example, single point, dwelling at edgeof-sheet,
standardizing, off-sheet) all measurement data points in a one second
data packet are averaged together and put into a single cell of the TBM circular
buffers. The time buffer would contain 1000 milliseconds, the box buffer would
contain the negated data box number corresponding to the data box of the last
piece of data in the data packet, and the position buffer would contain the
average head position for the data packet. The system is operating in what is
termed the TIME mode. When the system is scanning and comes to the edge
of the sheet, zeros are put into a cell of every circular buffer (regardless of
resolution). The system switches into the TIME mode at that time.
5. There are two modes of operation with regards to how data is calculated and
stored in the circular buffers: TIME mode and SPACE mode. When the system
is actually scanning, the system is in the SPACE mode. At all other times, it is
in the TIME mode.
6. When in the SPACE mode, a unique cell is updated every time that the system
scans over a different data box. Data box numbers are determined based upon
the actual position of the head. When in the TIME mode, only one cell is
updated each second. Data box numbers are either zero (if off-sheet), or the
negative of the actual data box number. Transitions can occur in the middle of
a data packet, for example: at edge-of-sheet, or at the beginning of a scan.
Transitions that occur in the middle of a packet are processed in one mode until
the transition and in the other mode after the transition.
Profile Transmission to the Host Computer
Transmission of the sensor profiles to the Host computer is done over a serial link
operating normally at a 9600 baud rate. Where real time permits, this can be
increased to 19200 baud. The actual transmission of the data involves the Host
reading the fddo->index[0-3] variables every five seconds to determine the number
of additional entries in the circular buffers (for each resolution) since the last time
that the buffers were read. All new entries are then read for time, position, box
number, and for each sensor’s measurement data. The time, position, and box
number arrays are all high resolution buffers. The resolution of each of the sensors’
measurement data arrays will be determined by the sensor’s ddi->ressel variable,
which is sent down from the Host for each sensor. This variable selects the desired
data box resolution for the sensor and is used in conjunction with the system’s box
width multiplication factor that is sent down from the Host in the fsdi->bxwmf
variable.
fddo stands for frame dynamic data output to the Host. fsdi stands for frame static
data input from the Host. ddi stands for (sensor) dynamic data input from the Host.
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Profile Development in the 1190 Host Computer
In the Host computer maximum scan limits are maintained which indicate the limits
of displayed profiles. The closer these limits are to the actual scan limits means
that more data is displayed. The number of data boxes included in a profile is
determined by the box width variable that the Host sends down to the Scanning
Platform in its Frame Static Data area.
Every five seconds, the Host reads a Frame Dynamic Data area from the Scanning
Platform to check four index counters (one for each of the possible data box
resolutions). These index counters indicate where in the circular data buffers the
last data has been entered by the Scanning Platform. The Host then reads all data
from the circular buffer that has been updated since its last data read five seconds
previously. This data includes platform data (box, position, and time) and
measurement data from all of the sensors. Since the circular buffers contain data
already averaged over the data box regions (one data box value per circular buffer
cell) it is already in the form needed for display. Now, the Host has the capability
to composite its profiles, if desired, before they are displayed. Compositing is based
on an exponential averaging technique, which can place more or less importance
upon the last scan (based upon selected filter factors).
When the Host builds a profile for the previous scan, it looks at every data box in
the scan checking for valid data. As long as every data box is valid, the scan can
be composited with the previous composite scan and displayed. For those boxes
which do not have valid data, the previous scan’s value for that data box is used as
long as the previous value was valid. If the previous value was not valid, then that
data box is marked invalid, which invalidates the entire scan. Invalid scans are not
displayed.
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1190 Measurement Analysis using On-Line
Utilities
Introductory Comments
Analysis of 1190 measurements at the Scanning Platform level involves
examination of the TBM arrays which contain the data as it is delivered to an 1190
host. There are two utilities available to examine this TBM data when it is in scaled
integer format. Systems with an AccuRay Direct host interface will have the data
in floating point format and cannot use these utilities. They must use the procedure
found under the topic “Examining Floating Point TBM Arrays” on page 34.
The tbmcu utility offers a way of seeing detailed data box values for each
measurement selected. It will display measurement data in a side by side, parallel
fashion, to facilitate the presence of spikes or other noise in specific data boxes.
The sentest is another utility which provides a means of doing a quick quality
assessment of the statistical content of both scan profiles and long-term stability.
Both utilities are suitable for doing single point as well as scanning performance
analysis.
ABB Measurement Analysis Using the tbmcu Utility
With release SP270.3, there is a utility to examine the TBM arrays on 1190 systems.
In the past, examination of the TBM arrays required multiple steps to obtain the
needed data. This utility simplifies the data extracting process, permitting quicker
analysis of the arrays. The utility tbmcu is an interactive menu driven program. It
provides access to the following TBM data:
• All configured sensor measurements except for color
• Data box numbers
• Dwell time
• Head position
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There are separate start/stop commands so the user can manually control the
collection period. The data collection buffer is able to hold up to 12 scans of data.
When the display mode is selected, the initial selection menu is displayed showing
what data has been collected. Note that there are two columns in front of each item,
one for collection and one for display. After making the display selections, the
utility then asks if you want to display one item at a time, or all together (side by
side). If side by side is chosen, the display then presents a header, or index to the
columnized data. The naming convention is “cu.xxxxx” where “xxxxx” is the item
name. After each page of display (23 lines), type a carriage return to get the next
page. All data is displayed in hex format. Zero data will indicate an edge of sheet
occurrence. A value of “0x8000” in a measurement indicates invalid data. Edge
of sheet measurements will always be shown as invalid. This SP270.3 version of
the utility can only be used for integer TBM arrays. Use by the Chemical and
Accuray Direct systems, which have floating point arrays, will have to wait for a
later release. Those floating point arrays can be viewed using the Examine Floating
Point TBM Arrays procedure. It should be noted that the procedural description
given here is for a Scanning Platform connected to an 1190 host system. To use
this utility in stand-alone, see the supplemental instructions in the Using tbmcu
Utility in Stand-alone.
When the utility is activated there are five commands presented in a menu:
1. Select Arrays to Capture
2. Start Data Capture
3. Stop Data Capture
4. Display Captured Arrays
5. Quit
The general sequence of operation is to first select the desired profile arrays along
with support data such as head position, time in the data box, and/or data box number.
An example of this menu is shown in Table 1-7.
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Table 1-7 Example of “Select Arrays to Capture”
Item
Selected for
Capture Display
Array Description
00 END SELECTION
01 * Databox Number
02 * Time in Databox
03 Head Position
04 * pmmBeta01
05 pmmCaliper01
06 pmmIR01
07 * pmmAsh01
* The asterisk is replaced by a smiling face on the profile display. The
selection notation appears under the Capture column with the Display column
being left blank. It will be filled out when the display function is selected later.
In the above example, Basis Weight and Ash profiles were selected along with the
data box number and the amount of dwell time in each box.
After all the desired selections have been made and the select command function
exited (by entering item “0”), start the data collection by selecting Start Data
Capture. If the system is under host control, each edge of sheet will be noted by
an incremental counter called Edges-of-Sheet Detected=. The utility will collect
up to 12 scans of data, after which a wraparound message will appear at each
subsequent edge of sheet indicating that the buffer is full.
The decision to stop data collection can be issued at any time. At this point, the
data can then either be viewed immediately, or the utility exited and re-entered at
a later time. The profile array data and box position/number data is stored as
individual cu.xxxx binary files in the /ss01 directory so that collected data from the
most recent activity is always available. It should be noted that the files are not
readily useable in a spread sheet. If a spread sheet analysis is desired, it is
recommended that while the display is being brought to the screen, the disk logging
function (F3) be activated so that an ASCII file can be created on the workstation
hard disk.
The display function has two options. The data can be brought to the screen in a
serial fashion, displaying each cu.xxxx file separately, or the presentation can be a
parallel one in which all the files are arranged side by side. This is particularly
useful if looking for common points of interest in the profiles. The first step in
getting the data displayed is to select the desired files. This is done through a similar
menu as was used to set up the collection in the first place. The menu is displayed
identifying the selections made initially. Any combination of collected data may
be selected for display. As each item is selected, a second selection notation (*) is
shown under the Display column. Table 1-8 is an example.
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Table 1-8 Example of “Display Captured Arrays”
Item
Selected for
Capture Display
Array Description
00 END SELECTION
01 ** Databox Number
02 * Time in Databox
03 Head Position
04 * * pmmBeta01
05 pmmCaliper01
06 pmmIR01
07 * pmmAsh01
* The asterisk is replaced by a smiling face on the profile display.
After exiting the display selection menu, an interactive sequence continues as the
display format is being defined.
1. Print arrays one at a time
2. Print arrays together
Enter: 2
TBM Display
TBM Synchronized Display
Column File Name
1 /ss01/cu.boxnum
2 /ss01/cu.Beta01
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The utility will ask if data is to be paged. Answer yes (y) if you want to see the
data a screen full at a time. Answer no (n) to have the display continuously scroll
until the end of available data.
Enter: c to continue; q to stop display: c
01f3 0288
01f2 0287
01f1 0289
01f0 0289
01ef 028a
•
•
•
01db 0287
01da 0287
01d9 0285
01d8 0288
01d7 0287
The data is displayed in hex format. If paging was requested, a carriage return must
be pressed to bring up the next page of data. After all the data has been displayed,
the utility may be exited by selecting Quit from the main menu.
Using tbmcu Utility in Stand-alone
In a stand-alone situation, where there is no host connected, the tbm buffers will
not update on their own. It is possible to use the utility under these conditions,
where the scanner is operating under either Health Page Control, or in the noMini
mode. To activate the TBM arrays, proceed as follows:
1. In the avos shell, change the forceMode.s flag to a 1:
mm forceMode.s /X
2. In the inspect utility, change the compositeScaleFactor value in each desired
pmm sensor object from a 0 to a 10. For example:
pmmBeta01->compositeScaleFactor=10
3. Start scanning activity.
Activate the tbmcu utility following the instructions given earlier in this section.
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Converting tbmcu Files for Spreadsheet Analysis
The tbmcu utility creates one binary file in the /ss01/clm directory for each selected
parameter. Each file is sized at 12,288 bytes. These files are identified by the root
name cu. with extensions showing the particular parameter. In their binary state,
these files can only be used by the utility in its display function. In order to have
these files be available for spreadsheet analysis, it is necessary to move them into
a PC environment and convert them into ASCII files. This can be done using a DOS
utility call cvtbm.exe found in the \ACE2 directory of the workstation (release
SP280.3 and later). For convenience, it might be helpful to place this utility in the
workstation’s \DOS directory so that the conversion activity can take place in any
desired directory.
Since the cu. file extensions are more than three characters, it will be necessary to
rename the files before the gonzo transfer takes place. A convenient way to do this
is to reverse the extension and root so that, as an example, cu.boxnum becomes
boxnum.cu. On some sensors, where the extension is greater than eight characters,
it may be necessary to abbreviate the sensor name. Having all the files with a
common extension; i.e. .cu, makes the file transfer to the workstation a little easier.
Use the gonzo utility to transfer the files as follows:
1. Make the file directory active; type:
cd /ss01/clm
2. Activate gonzo by pressing F6.
3. Select directory where files are to reside:
w (directory path)
4. Transfer the files:
r cu.*
The conversion utility can now be used to change each binary file into a column of
ASCII floating point numbers. The operation of the conversion utility takes the
following format:
cvtbm srcFile destFile scaleFactor
Where:
srcFile = the binary .cu source file
destFile = the new ASCII file to be created
scaleFactor = the measurement scale factor of the data that was collected.
See Table 1-9 on page 33 for values to use.
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Table 1-9
Variable
Value
cu.boxnum 1
cu.time 1
cu.hp 100
cu.sensor Use measurementScaleFactor found in the pmm interface object.
The format shown above assumes that the cvtbm.exe utility has already been placed
in the \DOS directory. If not, the complete path name of the utility will have to be
included unless the data files are in the same location.
The ASCII file for each parameter can be ported into a spreadsheet, taking care to
maintain the start of each file in the same row. This is because the data in the files
was collected at the same time in parallel, so that, for example, the first element in
cu.boxnum, matches the first element in cu.Beta01 with regard to time collected.
Starting the data for each parameter in the same row will properly line up and relate
measured data to a box number or head position or any of the other collected data.
The following will assist in interpreting the floating point data. ALL analysis should
be done using the databox number as a referee to determine where scans start and
end, and where the edge of sheet dwell times are. The data box column being the
key then, here is what will be found in there:
Table 1-10
sequential numbers These are the data box numbers, ascending for a
forward scan and descending for a reverse scan.
zero
The notification that edge-of-sheet has been reached.
There should only be one at the end of each scan. More
than one indicates instability at the edge position.
negative numbers These occur in conjunction with the edge-of-sheet and
are actually considered a single point positions with
valid measurement data associated with each number.
They will occur after each zero value. The more there
are, the longer the dwell time is.
-32768 This is invalid data. It appears for all measurements
when the head goes off-sheet for any reason. It also
appears in the measured data when the edge-of-sheet
notification is received. At that point in time, the
measurement data is invalid.
Use of a spreadsheet to analyze the tbmcu data is left to the expertise and creativity
of the user.
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Examining Floating Point TBM Arrays
This procedure is designed to examine the raw data being sent to the AccuRay Direct
DCS system from a Scanning Platform. The general approach will be to establish
a shell script which will take a snapshot of the fbox and tbmf arrays in the Scanning
Platform when the script is activated. The captured arrays can then be printed out
and examined. fbox reports the data box activity, and tbmf contains the
corresponding sensor data. There is a separate tbmf array for each sensor. Each
tbmf array contains 500 floating point elements in a rotating buffer. That means
that with a 600 data box profile, the buffer will contain 500 data boxes of
information. With a 30 second scan, it will take about 25 seconds for the buffer to
rotate.
1. Locate the 0xaddress for the tbmf and fbox arrays using the inspect utility as
follows:
pmmFrame->fbox
pmmCaliper01->tbmf
pmmIR01->tbmf
pmmBeta01->tbmf
etc. for each sensor in the configuration
The response to each of the above commands will be a 0xaddress. Note the
address part, leaving off the 0x. For other sensors, use the :glob command to
find their global names.
2. Change the working directory to /ss01, and create the following script using the
edit utility:
ed
a
md (address of fbox) 50(10x) > /ss01/fbox
md (address of caliper tbmf) 50(10f) > /ss01/ctbmf
md (address of IR tbmf) 50(10f) > /ss01/itbmf
md (address of beta tbmf) 50(10f) > /ss01/btbmf
etc. for each additional sensor.
w t
q
This will create a script file called “t” in the /ss01 directory.
3. As the frame is scanning, execute the script. To execute the script, make sure
the working directory is /ss01, then type:
. t
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4. Print out the arrays as follows:
cat fbox
cat ctbmf
cat itbmf
cat btbmf
etc..
5. Examine the arrays as follows:
The fbox array will show the position of the first data box after the scan starts.
This will generally be the first location after a series of FFFF and Fxxx data
values. The FFFF indicates off sheet and prepare to measure times. The Fxxx
identifies valid data made available while the head is waiting for a scan enable
command. The actual box numbers will be in hex notation. All fbox and tbmf
arrays captured by the shell script will have their data in the same index position
within the array.
Invalid data within the tbmf arrays will have a very large negative number.
Edge of sheet dwell times will mark the data value as zero for one box. Then,
until the head starts to scan again, the data will be invalid and should be the
same as the values shown in the fbox array. These will not be data boxes but
will represent a single point value. Other times invalid data will appear, are
those times when the head is in prepare-to-measure mode (coming on sheet),
or one second after receiving a prepare to go off sheet command.
1190 Measurement Analysis Using sentest Utility
With Software Release 280.2, there is a utility available to provide a quality analysis
of profile or single point data using the reporting of statistical parameters. The
utility has two modes of operation. One is to report on profile quality, and the other
is to report on single point drift. Each mode has a unique report presentation. In
both cases, however, the statistical parameters of mean, hi, lo, p-p, and 2-sigma,
are provided.
Perform the following steps to get a report:
1. Activate the utility by typing sentest at the AVOS prompt.
2. Select command 1, Select Sensors to Test, from the main menu.
3. The display will show all the available measurements which may be tested in
the form of pmmSensor. Select the desired assortment of measurements to be
tested by entering the associated number.
4. When all desired measurements have been selected, terminate the selection
process by entering a 0.
Note:
At this time (Software Release 280.2), the Change Peak-to-Peak
Limits selection is not functional. This will be addressed in a later
release.
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reproduction, or other means of dissemination may be made without written permission.
5. Set the scanner in the mode desired, either scanning or in single point.
6. Select either Start Drift Test, or Start Profile Test as desired. If Start Profile
Test was selected, the reports will print out automatically after each scan and
a summary after 10 scans. If Start Drift Test was selected, a report will be
issued after each minute of operation.
7. When the Drift test has run for as much time as desired, select Print Drift Test
Summary. This willl terminate the collection process and cause the report to
be printed.
8. Select Quit to exit the utility.
The following are examples of the two reports available.
Profile Data
As the sentest utility collects profile data, it will display an individual report as each
scan is accomplished. When the 10 scans have been completed, a summary report
will be displayed showing the individual scan values of all sensors selected. Make
sure that the Disk Logging function is turned and that the destination file is unique
(i.e., profile.log) and empty initially, so that when the summary report is requested
it can be saved in a file. The summary data is displayed on a per sensor basis in the
following format:
Scan * 1 2 ----- 9 10
High ...... ...... ...... ...... ......
Low ...... ...... ...... ...... ......
Mean ...... ...... ...... ...... ......
p-p ...... ...... ...... ...... ......
2SIGMA ...... ...... ...... ...... ......
%Inv ...... ...... ...... ...... ......
High Low Avg P-P
Trend ...... ...... ...... ......
Composit
e
...... ...... ...... ......
Trend is the variation seen in the Mean which is calculated for each scan.
Composite is a 10-scan filtering of the profile data for all the scans. Compare each
sensor’s limits to the collected data.
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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.
Single Point Drift Data
The sentest utility drift test summary report for all selected sensors will be presented
in the following format:
Drift Test Summary
Run Time: xx Minutes
P-P 2SigmaMax 2SigmaMean MeanVarn Sensor
p-p gives the peak-to-peak variation of one-minute averages during the test;
mean var gives a 2-sigma calculation on the one-minute averages.
2SigmaMax is the maximum noise value during any one-minute interval;
2SigmaMean is the average of the noise during the collection period.
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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.
Profile Development for 1180 Systems
Profile Transmission and Development
This section contains information on how the Scanning Platform software produces
profiles, how they are transmitted to the minicomputer, and how the Host computer
displays the data.
The Scanning Platform software provides for a maximum of 480 single scan (no
composite) data boxes. The number is determined by the variable MBOXES in the
Host Computer. An initialization task at startup calculates the starting, ending, and
box width in both computers.
The width of the data boxes in the Scanning Platform and the host computer are the
same, with a value calculated and provided by the host. A maximum number of
data boxes can be displayed if the current scan limits are made equal to the maximum
measure limits. Due to round off errors in converting from integer to floating point
of the box width variation, the maximum number of boxes for display may be less
than the system defined number of boxes. It is important that the maximum scan
limits (LFEOS and LHEOS) be set to the maximum trim of the machine. If this
is not done, the operator will lose the perspective on which slice screw represents
which area of the profile. As the current scan limits are moved inward (KFEOS
and KHEOS), the number of profile boxes displayed will be reduced proportionally
to the decrease in sheet width. Whenever the number of defined data boxes is an
integer multiple of 60, the host display will resize to fill the allotted profile space.
38 Selected Theories of Operation
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Profile Development in the Scanning Platform
Placing the measurement data received from the various sensor objects in a profile
array requires first that an appropriate array receptacle be built to contain the data.
This is done each time a PMMRLD command is issued and the frame static data
input fields get updated from the Host Computer. Information shown in Table 1-7
is received in the static data input specification table (fsdi) in the pmmFrame01
object, and is used to construct the profile array in customer units.
Table 1-11 Box and Zone Relationships to the Process
Scanning Platform
Function
fsdi Variable Name Variable Name
Current home scan limit heos homeScanLimit
Current far scan limit feos farScanLimit
Std. profile box width
ibxw
First zone box boundary fznb
Zone width in boxes
znwd
Minimum home edge-of-sheet minhl homeMeasureLimit
Maximum far edge-of-sheet maxfl farMeasureLimit
Number of logical zones nlogz
Number of std. boxes
stdProfDataPts
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reproduction, or other means of dissemination may be made without written permission.
Figure 1-7 shows the headbox to profile relationships in a graphic format.
Headbox
Maximum Slice
0 vdc
approx
1000 A/D
homeTravelLimit
homeMeasureLimit
(minhl)
Maximum Head Position Range
Maximum Head Position Readings
Maximum Trim
10.0 vdc
approx
31267 A/D
farTravelLimit
farMeasureLimit
(maxfl)
homeScanLimit
(heos)
Scan Limits
farScanLimit
(feos)
homeEOS
EOS Positions
(same as above if no AEOS)
farEOS
POBOX (firstMiniBox)
PLBOX (lastMiniBox)
1 2 3 - - - - - - - - - - - - - - 477 478 479 480
_Profile
Scanning Platform
Mini Profile Ptr.
1 2 3 - - - - - - - - - - - - - - 477 478 479 480
Mini-Access Profile
Updated
at zone
boundaries
MOBOX
MLBOX
1 2 3 - - - - - - - - - - - - - - 477 478 479 480
Actual Minicomputer Profile
BXFOF
BXLOF
1 2 - - 120
1 2 - - 120 1 2 - - 120 1 2 - - 120
Log Zone #1
Log Zone #2 Log Zone #3 Log Zone #4
Figure 1-7 Sheet Width and Profile Relationships
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reproduction, or other means of dissemination may be made without written permission.
As a part of the edge change or scan width adjustment activities, the Scanning
Platform software identifies the head position boundaries of each data box in
customer units. This is based on the head position calibration done using the frame
tuning utility ft. Then, as each measurement data point is received with its
associated head position, the profile routine stuffs the data into the correct box,
averaging it in with the previous data points in the box. The boxes of averaged
signals are then delivered to the MPRC board processing where the boxes are
converted into sensor measurements. To provide standard profiles free from data
aliases for use in both display and process control, it is important that each data box
contain at least three or four samples or data points. This can be controlled by
proper setup of scan speed in conjunction with the sensor sample rate and the number
of data boxes. Sampling rates for all sensors except for IR are 1000 samples per
second. For IR, the rate is dependent on the line frequency.
For all sensors except IR and Color, use the following equation:
z samples -------------------- 1000 samples -------------------- x--------------------
seconds 1
=
× × -----------------------------
databox seconds scan
y databoxes --------------------------
scan
Equation 1-3
For IR and Color sensors, use the following equation:
z samples -------------------- = hHz × x--------------------
seconds
databox
scan
Equation 1-4
1
× -----------------------------
y databoxes --------------------------
scan
Example: The number of IR data points in each of 600 data boxes for a 30
second scan on a 60 Hz system would be:
Number
----------------------------------------------
of Samples
data box
60
--------------------------
samples 30
-------------------------
seconds 1 scan
= × × ----------------------------------- =
second scan 600 data boxes
3
-----------------------
samples
data box
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reproduction, or other means of dissemination may be made without written permission.
Accessing 1180 MICRO Profile Data Inside the Scanning
Platform
The Scanning Platform 1180M interface for each sensor (pmmBeta01, pmmIR01,
and so forth) creates an instance of profiler each time the system is started up.
Contained within the profiler object, are the instance variables _profile and
_nSamples. _profile is the 480 data box array where the profile data is accumulated.
Each element in the array represents a data box and contains two components, V1,
which is the floating point value of the data box, and V2, a time stamp in
milliseconds. The number of data boxes available to be used is defined by the
1180M host. The defined boxes are equally divided between the home and far
measure limits (LHEOS and LFEOS). The first element in the array which contains
data is defined by the current home scan limit, KHEOS. The actual head position
in customer units for this box can be found in the header information of _profile
under the instance variable name startingPosition. The width of the box (and all
subsequent boxes) is given in samplingInterval. The number of boxes with data
is of course defined by the actual scanned area (KHEOS and KFEOS). An example
of the profiler object display in the inspect utility is shown in Figure 1-8.
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pmmBeta01->profiler
| profiler: 0x391f56 (hid)
I>0x391f56 (Bolded line is a typed command)
0x391f56 (id)
|-------------------
| 0x39156: “0x39156” (struct _PRIVATE)
| isa: PmmProfiler (struct _SHARED *)
| mySelf: 0x39156 (long)
| dataProtected: 0 ‘\0’ (char)
| index(): 0x2279c2 (hid)
| measurementName: 0x393696 (id)
| _measurementSignal: 0x393736 (id)
| _nSamples: 0x393e96 (id)
| _profile: 0x391fb6 (id)
| profilingProcess: 0x3936d6 (id)
| resetProfile: 0 ‘\0’ (char)
| updateProfile: 0 ‘\0’ (char)
| suspended: 0x1 ‘\1’ (char)
| waitingToFree: 0 ‘\0’ (char)
| validityAcceptanceMask 0xffff (short)
| initializeMiniProfile: 0 ‘\0’ (char)
| pmmProfileProcessing: 0 ‘\0’ (char)
| pmmProfileReset: 0 ‘\0’ (char)
| customerUnitsConversion: 0.614452 (double)
| measurementScaleFactor: 100 (double)
| processingRequestor: 0 (id)
| firstBoxToCheck: 0 (short)
| invalidBoxes: 0 (short)
| lastBoxToCheck 0 (short)
| miniProfilePtr: 0x36566c (struct PROFILE_DATA *)
| scanMinBox: 0 (short)
| scanMaxBox: 0 (short)
| -------------------
Figure 1-8 profiler object display
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reproduction, or other means of dissemination may be made without written permission.
Profile data is placed into the _profile array in the following manner. At the start
of each scan, the array is cleared (all zeros). Then, as the head starts the transition
across the sheet, the data boxes are updated with the latest measurement. Each time
a logical zone is crossed, the data from the completed zone is copied into the miniaccess
area array. The complete profile of the scan in this array, is only available
for the short time between the ending of the scan and the clearing of the array prior
to starting the next scan.
The mini-access area in the Scanning Platform is located from the miniProfilePtr
pointer in the profiler object display. This pointer is the starting address of a 480
box array. Access to this array is through use of the md utility (memory display).
In this array, the unused data boxes, those outside the current scan limit range, are
populated with the value of the end data boxes. This means that the data box average
in the box associated with the home scan limit, will be used to fill all those boxes
which occur between the home measure limit and the home scan limit. Likewise,
the box average associated with the far scan limit, will be used to populate the unused
boxes between the far measure limit and the far scan limit. It should also be noted
that there is no clearing of the array after each scan. This means that it is possible
to look at the array when, for example, it contains zone one and two data for the
forward scan while zones three and four contain data for the reverse scan. Therefore
to get a snapshot of the current scan profile, the printing out of the array should be
done at the end of the scan and not during it. One technique might be to take the
head off sheet at the end of the scan, then print out the data.
Displaying the Mini-Access Profile Array
1. Obtain the 0xaddress of the miniProfilePtr pointer from the profiler object
display. See Figure 1-8 on page 43.
2. Exit the inspect utility.
3. In the avos shell ($$), type the following command. Do not include the 0x in
the address from step 1:
md address 48(10d)
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Profile Transmission to a Host Computer
Transmission of the sensor profiles up to the Host Computer is done over a serial
link operating normally at a 9600 baud rate. Where real time permits, this can be
increased to 19200 baud.
The actual transmission of the data involves breaking up the profiles into logical
zones. As each zone is built in the Scanning Platform, that portion of the array is
then transmitted to the Host. There can be anywhere from four to six logical zones.
The number is determined in the minicomputer by a variable called NCZONE
(number of control zones). This variable defines how often during the scan that
machine direction control actions are taken. The number of logical zones needs to
have an even integer relationship to NCZONE. See Table 1-12 for the relationships.
The number of logical zones (NLZONE) computed from the number of control
zones (NCZONE).
Table 1-12 Control Zone Versus Logical Zone Relationship
NCZONE
NLZONE
1 4
2 4
3 3
4 4
5 5
6 6
These logical zone determinations are established in the Host Computer and sent
down to the Scanning Platform software at PMMRLD time via the fsdi specification
table as variable nlogz. The zone calculations performed in the Host Computer are
shown in Table 1-13.
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Table 1-13 Data Box Calculations in the 1180 MICRO
Host ComputerProfile
Variable Calculation Comments
IBOXW (LFEOS-LHEOS)/MBOXES Independent for Data box width (round
up) each frame in A/D units
POBOX [(KHEOS-LHEOS)/IBOXW]+1 Calculated at First data box restart and
when with sensor data scan limits are
changed
PLBOX [(KFEOS-LHEOS)/IBOXW]+1 Calculated at First data box restrart and
when with sensor data scan limits are
changed
PFBOX =1 Defined profile First defined start data
box in AAM
MOBOX POBOX-PFBOX+1 First actual data box in Host Computer
MLBOX MOBOX+PLBOX-POBOX Last actual data box in Host Computer
KBOX MLBOX-MOBOX +1 Host Computer Number of boxes
profile in Host Computer
Profile Development within the Host Computer
The Host Computer performs a variety of calculations at both system restart (of the
Host) and when scan limits are changed. These calculations are to determine the
profile alignment between the process, the Scanning Platform software, and the user
display. There are two aspects to this process. The first is to determine the data
positioning within the profile along with the dimensional aspects of the profile
boxes. The second item is to calculate the partitioning of the profile into logical
zones and their associated parameters. Zone partitioning is used to accommodate
data transmission constraints, and to permit multiple machine direction control
actions within a scan by calculating moving averages as the profile develops on a
logical zone basis.
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Data Box Collection Calculation
Data box calculations use coldstart entries of LHEOS, LFEOS, KHEOS, KFEOS,
NCZONE, and MBOXES to determine the following series of variables. These
variables are generally local variables within the computing program and are not
necessarily available for examination. Table 1-13 contains a description of the
calculations made for each variable. Figure 1-7 shows the relative location of each
data box.
1. Data box width (IBOXW)
2. First data box with sensor data (POBOX)
3. Last data box with sensor data (PLBOX)
4. First defined data box in AAM (PFBOX)
5. First actual data box in Host (MOBOX)
6. Last actual data box in Host (MLBOX)
7. The number of boxes in Host (KBOX)
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Logical Zone Calculations
The final step in completing the initialization and setup process involves
determining the following set of logical zone calculations. As with the data box
calculations, these are generally local variables and not available for examination.
Table 1-14 describes the calculations.
1. Number of logical zones (NLZONE)
2. Zone size (LZNSIZ)
3. Extra data boxes (NBOX)
4. Last box offset in Host (BXLOF)
5. First box offset in Host (BXFOF)
6. First box of zone one (PZ1BX)
7. Zone one box boundary (FZNB)
Table 1-14 Logical Zone Calculations in the 1180 Host Computer
Variable Calculation Comments
LZNSIZ KBOX/NLZONE Zone size in data boxes
(round up
NBOX (LZXIZ)(NLZONE-KBOX) Number of boxes outside scan limits
BXLOF
NBOX
Last box offset in Host Computer
2
BXFOF NBOX-BXLOF First box offset in Host Computer
PX1BX POBOX-BXFOF Defines start of zone one First box of
logical zone 1
FZNB PZ1BX + (LZNSIZ-1) Defines limit of zone one Box number of
all zones are same size zone one boundary
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Sensor Theory
Sensor Processing Overview
Sensor processing from signal to measurement is outlined in Figure 1-9. From this
diagram, the transformation from raw signal to displayable measurement can be
seen. The transformation process involves both hardware and software.
Sensor
Hardware
Filter (ECF/
ECS Board)
Normalize
(STDZ)
Linearize
(Nat. Log)
Correct
(Decouple)
Convert
(Calibrate)
Compensate
(External
Dependencies)
Fine Tune
(Slope and
Offset)
Signal Input
Processing
(allocate
databoxes)
Sensor Processing
(MPRC Board)
Measurement Processing
(MPRC Board)
Measurement
Display Via
PMM Objects
Figure 1-9 Scanning Platform Algorithm Processing
All sensor signal processing can be broken down into three stages. These stages
are input signal processing, signal processing, and measurement processing. These
stages are in turn broken down into sub–functions which include filtering,
normalizing, linearizing, correction, conversion, compensation, and fine tuning. It
should be noted that not all sensors require each and every step.
Filtering
The filtering step is to improve the statistical nature of the incoming signal and is
accomplished in Scanning Platform by providing a filter on the microcontroller
ECS board. This filter provides an excellent frequency response while maintaining
the signal information provided by the sensor. The filter time constant is selected
based on the sampling rate of the particular sensor in question. At this time, the
filtered sensor signals are averaged into the appropriate databox.
Normalization
The normalization step is used to adjust the signal level due to variations caused by
components aging, environmental considerations, and sensor physical conditions.
This is normally accomplished by applying an adjustment determined by the
standardize process. Within Scanning Platform, most of the sensors provide the
normalization stage by subtracting any zero offset introduced by the hardware and
then by dividing the signal by the full scale range which was determined at
standardize. Air profile compensation adjustments are also made at this stage when
appropriate for the sensor.
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Linearization
The linearization stage performs the appropriate mathematical operation to form a
linear sensor signal over the range of interest. This is required for about one half
of the sensors and is done by taking the natural logarithm of the incoming signal.
The output of the linearization stage is in general a signal which is directly related
to some process characteristics and therefore is ready for conversion to a
measurement.
Correction
The correction stage is required whenever there is adjustment to the signal for some
mechanical or electrical variation. Currently, this is only true for the Brightness
sensor in OptiPak where it needs to be adjusted for the sheet opacity. This is the
last of the sensor dependent stages.
Conversion
The conversion stage provides the mathematical conversion from a signal to a
measurement. The most common function at this stage is a polynomial curve-fit
using from two to five coefficients. This is used for approximately three fourths of
the sensors. Other sensors either use a direct mathematical conversion or require
none at all.
Compensation
The compensation stage provides corrections determined by other external
dependencies. This includes such things as window dirt accumulation, other sensor
measurement effects, and one air gap temperature.
Fine Tuning
The fine tuning stage is the final step in the sensor algorithm processing and provides
the last chance to adjust the measurement value to the other system modules,
including display. This stage consists of a product code dependent slope and offset
correction applied mathematically as mx+b. This stage is common to all sensor
measurements.
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Sensor Input Signal Processing
Having presented the general flow of signal to measurement processing, we now
come to some specifics regarding the synchronization of signals with respect to
each other within the Scanning Platform environment. Sensor processing in
Scanning Platform software assumes that each sensor is an independent object with
discrete input and output signals. See Figure 1-10.
inputSignal A
inputSignal B
Sensor
Object
outputSignal
Figure 1-10 Sensor Input/Output Signal Relationship
Usually there are at least two input signals for a sensor, namely, head position and
the sensor signal. The exact name for each input signal can usually be found in
each sensor object as inputName or some similar variable. A sensor signal is
frequently a double signal type (floating point) of object. Figure 1-11 shows an
example of a printout of an input signal array which can be useful in troubleshooting
any of these objects.
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I> betaSensor01->inputSignal
inputSignal: 0x367226 (hid)
I> 0x367226 (id)
|------------------------------------------------
| 0x367226: “0x367226” (struct_PRIVATE)
| isa: DoubleSignal (struct_SHARED *)
| mySelf: 0x367226 (long)
| capacity: 0x32 (int)
| myName: 0x33f326 (id)
| objectToken: 0x100012b (long)
| dataToken: 0x100012c (long)
| timeStamp: (struct_S_5)
| status: 0 ‘\0’ (char)
| subscribed: 0x1 ‘\1’ (char)
| controlledAccess: 0 ‘\0’ (char)
| reserved: 0 ‘\0’ (char)
| owner: 0 (int)
| dataType: 0x1 (short)
| initOption: 0 (short)
| ioPoint: 0x4c (id)
| logicalChannel: 0x352546 (hid)
| samplingInterval: 20 (double)
| units: 0x33fb46 (id)
| =====:0x367264 (struct NDXVAR [50])
| [0]: (struct NDXVAR)
| | V1: 3.68815 (double)
| | V2: 0 0 (short)
| | V3: 34883 0x86b3 (long)
| [1]: (struct NDXVAR)
| | V1: 3.6718 (double)
| | V2: 0 0 (short)
| | V3: 34533 0x86e5 (long)
| [2]: (struct NDXVAR)
| | V1: 3.65788 (double)
| | V2: 0 0 (short)
| | V3: 34583 0x8717 (long)
| [3]: (struct NDXVAR)
| | V1: 3.65324 (double)
| | V2: 0 0 (short)
| | V3: 34634 0x874a (long)
| [4]: (struct NDXVAR)
| | V1: 3.64618 (double)
| | V2: 0 0 (short)
| | V3: 37643 0x930b (long)
| [5]: (struct NDXVAR)
| | V1: 3.6729 (double)
| | V2: 0 0 (short)
| | V3: 37688 0x9338 (long)
| [6]: (struct NDXVAR)
| | V1: 3.67754 (double)
| | V2: 0 0 (short)
| | V3: 37732 0x9364 (long)
Figure 1-11 Example Printout of Input Signal Array
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The following explains some key elements of the inputSignal array.
1. Capacity - The total size of this array; typically this will be the most recent 60
data points (0x3c in hex).
2. Subscribed - The number of external objects which are waiting for data from
this signal
3. logicalChannel - A pointer to the channel information associated with this
signal; the raw A/D data may be accessed via this channel (see Figure 1-12).
3BUS 208 055 R1101
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0289d2 (taken from logicalChannel entry printout of inputSignal)
0x289d2 (id)
......................................................
0x289d2:
“0x289d2”
(struct PRIVATE)
isa:
LUCChanne
myself:
0x289d2
capacity:
0
(int)
myName:
0x289432
parent:
0x2882c2
offset:
0xc
analogType:
0x1230
a2dSignal:
0x2894ba
a2dSignalPtr: 0x2894f8
cFactorRatio: 1
compositeSlope: -10.0103
compositeOffset: 0.0003055
(double)
globalOutputEnabled:
0x1
ioSignal:
ioSignalPtr:
signalSize:
samplingInterval:
====:0x289422(struct NDXVAR [0])
......................................................
I> 0x279822
0x289422 (id)
......................................................
0x289422:
isa:
mySelf:
capacity:
myName:
objectToken:
dataToken:
timeStamp:
status:
subscribed:
owner:
initOption:
ioPoint:
logicalChannel:0
phase:
SamplingInterval:
units:
0x2834da
0x283518
16.6667
0x64
0
0
0
0x3c
“0x289422”
ShortSignal
0x289422
0
0
(struct_S_8)
0
0
0
0
0
0
(id*)
(id)
(char*)->0x2894f8
(double)
(double)
‘\1’ (char)
(id)
(char*)->0x283518
(double)
(struct PRIVATE)
(struct_SHARED*)
(long)
(int)
(id)
(long)
(long)
‘\0’
‘\0’
‘\0’
(id)
(double)
(struct_SHARED*)
(long)
(id)
(id)
(int)
(short)
(int)
(char)
(char)
(char)
(short)
(long)
(id)
Figure 1-12 Locating A2D Data in a Logical Channel
(Continued on next page)
54 Selected Theories of Operation
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
====: 0x27985e (struct NDXVAR [100]).
[0]: (struct NDXVAR)
V1: 1333 0x535 (short)
V2: 0 0 (short)
V3: 6911551 0x69763f (long)
[1]: (struct NDXVAR)
V1: 1339 0x53b (short)
V2: 0 0 (short)
V3: 6911561 0x697649 (long)
Array of raw A2D values for BW
signal. format:V1A2D
V2 validity
V3 snych value
Figure 1-12 (Continued)
4. samplingInterval - The time between consecutive inputs in milliseconds since
startup
5. Converted Input Signal Array - The converted A/D units data array is at the
end of the signal object. It provides raw input values in volts along with validity
and synchronization values. All sensor signal elements within a block are
examined with each other, element by element (each data point in the array is
considered an element). If the synchronization values of the element fall within
the synchTolerance of each other, then the signals are processed normally. It
is assumed that all other elements of that block align properly. If they do not
align within the synchTolerance of each other, then the oldest signal is reread.
If a match does not occur on the re-read, then the data for the outputSignal is
marked invalid.
Sensor Output Signal Processing
The output of each sensor processing algorithm is a stream of data box average
values in customer units along with the associated time and position stamps, and a
validity code. These can be observed in an array called outputSignal. As these
values are determined, the sensor objects collects and places them in profile data
arrays for transmission to a Host Computer. Also, some sensor outputSignal values
are used as inputs to other computed sensor algorithms such as conditioned weight
and apparent density. This relationship can be seen in Figure 1-13.
3BUS 208 055 R1101
Selected Theories of Operation
55

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reproduction, or other means of dissemination may be made without written permission.
raw A2D head position
(shortSignal)
raw A2D Beta input
(ShortSignal)
“sensorGroup01HeadPosition01”
(DoubleSignal) - cm
Beta Sensor
“BetaInputSignal01”
(DoubleSignal) - volts
“BWMeasurent01”
(DoubleSignal) - grams
“IRMeasurement01”
(DoubleSignal) - %
Cond Wt Sensor
“CondWtMeasurement01”
(DoubleSignal) - grams
Figure 1-13 outputSignals as Inputs to Other Sensors
(Example shown here is for conditioned weight)
The layout of outputSignal is similar to that of inputSignal described earlier. In
outputSignal, however, the primary point of interest is the data array at the end.
Each element in the array is made up of five entries. The example in Figure 1-14
shows the arrangement.
56 Selected Theories of Operation
3BUS 208 055 R1101

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outputSignal
BetaSignal -> outputSignal
outputSignal0x2acc52
in
ox2acc52
0x2acc52(id)
................................
0x2acc52: “0x2acc52” (struct PRIVATE)
isa: SheetMeas (struct_SHARED *)
myself: 0x2acc52 (long)
capacity: 0x32 (int)
myName: 0x2ad282 (id)
objectToken: 0x100023e (long)
dataToken: 0x100023f (long)
timeStamp:
(struct_s_7)
timeMS: 0 (short)
timeLS: 0 (long)
status: 0 ‘\0’ (char)
subscribed: 0 ‘\0’ (char)
controlledAccess: 0 ‘\0’ (char)
reserved: 0 ‘\0; (char)
owner: 0x1 (int)
initOption: 0 (short)
ioPoint: 0 (id)
logicalChannel: 0 (hid)
phase: 0 (long)
samplingInterval: 0 (double)
units: 0 (id)
avgFactor: 0 (long)
====: 0x2acc96 (struct NDXVAR [50])
[0]: (struct NDXVAR)
V1: -0.66202 (double) value in customer units
V2: 249.464 (double) cross direction position in customer units
V3: 0 (double) machine direction position in customer units (not used)
V4: 0 0 (double) validity code
V5: 353237171 0x150df8b3 (long) synchronization
[3]: (struct NDXVAR)
V1: 0.13285 (double)
V2: 278.47 (double)
V3: 0 (double)
V4: 0 0 (short)
V5: 353239231 0x150e00bf (long)
[4]: (struct NDXVAR)
V1: -0.221129 (double)
V2: 278.619 (double)‘
V3: 0 (double)
V4: 0 0 (short)
V5: 353239251 0x150e00d3 (long)
Figure 1-14 Example Printout of Output Signal Array
For Software Release 260.0 and later only:
Note:
The number of valid data elements in the array is a function of the
data box width and scan speed. This results in each valid element
being the average of one data box while scanning. In single point
mode, there will be 10 valid entries in the array. All other elements
in the array are marked invalid and should be ignored.
3BUS 208 055 R1101
Selected Theories of Operation
57

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2
General Troubleshooting
Instructions
This section provides you with some actions you can take when you have a problem
with your system. The format is a troubleshooting flow chart which will guide you
through a variety of thought processes which should bring the system back to
acceptable operation. However, you may still have to call ABB in Columbus, Ohio
sometimes. At those times, you should have some documented data from the
subsystem printed out before you make the call. Below is a list of the things of
which you should have a printout:
• dproc A list of all the processors in use
• dfree The amount of free memory available
• bfchk The status of all buffers and stacks
• derr The exception error log
• pe The last 100 application software event messages
• A printout of the instance variables in the object with the problem
This chapter contains the following major sections:
Section ...............................................................................................Page
Data Required for Problem Escalation .......................................................... 60
Troubleshooting Flow Charts ......................................................................... 63
Host Computer Coldstart Data File Overview ............................................... 76
Startup Messages ........................................................................................... 77
Changing the Host/SP BAUD Rate and the Station ID .................................. 85
Radiological Safety Features and Alarms ...................................................... 86
3BUS 208 055 R1101
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Data Required for Problem Escalation
If you are planning to escalate a problem to a high level for assistance, the following
worksheets will assist in gathering pertinent information about the system and the
problem. This will assist the Level III or Level IV support team to respond more
efficiently.
Description of Problem:
System Configuration:
SP Release:
If problem is a result of an upgrade, what was previous SP release
Scanner Feature
FRAME
Auto Edge of Sheet
Scan Limit/Head Position Setup
Check If Applicable
_____
full reduced
Required Supplemental
Information
AEOS/Servo: TrackingDistance: h___f___
WindowClearance:h___f___
Detector Offset: h___f___
EOSDeadband: _____
Pos. Deadband (xdb):_____
Scan Speed: _____
vminActive: _____
Acceleration: _____
Head Clearance: h___f___
curlDist: _____
Head Positions: garage: _____
standardize: _____
MeasureLimit: h___f___
Scan Limit: h___f___
TravelLimits: h___f___
60 General Troubleshooting Instructions
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SENSORS
Basis Weight _____ TLK _____ STLK
_____ TLP _____ STLP
_____ TLS
_____ HAW/CAP
IR Moisture _____ L/T/HEMI
___ BW Comp
_____ HEMI+
___ BW Comp___Ash Comp
_____ REFL
___ BW Comp
_____ REFL+
___ BW Comp___Ash Comp
_____ Head Heater
yes (y) - from frame no (n) - from Product Code File
Top IR Coat Weight
Bottom IR Coat Weight
_____
_____
___ Slot IR 1
___ Slot IR 2
Caliper _____ GT
_____ Air Bearing
_____ Air Bearing Probe Heater
_____ Contacting
_____ Non–Contacting
Apparent Density
_____
Ash _____ 2C _____ Smart 2C _____BW Comp_____Moisture Comp
_____ 3C _____ Smart 3C _____BW Comp_____Moisture Comp
_____ X–Ray Coat Weight yes (y) - from frame no (n) - from Product Code File
OptiPak
_____
Top Gloss
Bottom Gloss
_____
_____
Sheet Temperature _____ _____Algorithm (linear/quadradic)
_____Slot
Top Smoothness
Bottom Smoothness
_____
_____
Microwave Moisture _____ _____Wet End_____Dry End
Top Color
Bottom Color
_____
_____
Unique Sensor
_____
Aseptic, Top Sensor _____ inside
_____ outside
Aseptic, Bottom Sensor _____ inside
_____ outside
IR Ratio _____ top
____Aseptic/EVOH____Trans/Refl____# Ref Filter
_____ bottom
____Aseptic/EVOH____Trans/Refl____# Ref Filter
SYSTEM
Power Frequency______50 HZ______60 HZ
Host ______ 1190______ 1180M______ AccuRay Direct______ Chemical______ Aseptic
Is host sensor configuration at least a subset of Scanning Platform ______
Do host and Scanning Platform have same baud rate ______; station ID ______; Frame Number ______
3BUS 208 055 R1101
General Troubleshooting Instructions
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Diagnostic Utility Results:
Utility Results Notes
derr _____ OK_____ Fail If report shows a bus error,
obtain a printout of dproc
and map -m.
bfchk _____ OK_____ Fail If report shows a buffer
error, run bfchk -s.
dfree
pool 13 ______Frags ______
pool 15 ______Frags ______
pool 31 ______Frags ______
Total ______ Frags ______
Total fragments for any one
pool should be under 99.
Total can be >99.
pe -a ______ done Print out entire report.
Data Validity Problems at Host:
1. Is data valid on the Health Pages ______
2. Is data valid in the tbm arrays (with release SP270.3, run tbmcu utility) ______
62 General Troubleshooting Instructions
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
Troubleshooting Flow Charts
Figure 2-1 is a guide to troubleshooting. The symptoms are addressed in the specific
flow charts labeled A through M.
Table 2-1 Guide to Troubleshooting Flow Charts
Symptoms
System will not reboot.
Cannot communicate with the Host computer.
System halts. One or more LEDs are lit.
Cannot access AVOS shell
Some sensor is not working (measurement, standardize, sample
check, or calibrate sample).
Sensor heads will not move
Scan is erratic (fast, slow, or jerky)
Auto edge–of–sheet problems
Platform stays in local mode.
Console displays:
Cannot operate utilities.
Cannot determine what is wrong.
See Flow Chart
A
B
C
D
E
F
G
H
I
J
K
L
Note:
In all cases, if recovery of the system functionality has been achieved
and nothing done except reset the system, call the 24 x 365 support
line with the information regarding the circumstances surrounding
the problem and recovery. The data will be useful in determining
and rectifying problems in the more obscure areas of the system.
3BUS 208 055 R1101
General Troubleshooting Instructions
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System will not reboot.
A
Is the MPRC
YES
board new
NO
Has it been
updated
NO
Perform the new
board installation
activities.
YES
Are there any startup
response messages
on the console
screen
YES
Compare messages with information
given in Startup Message Chart, and
take corrective action indicated.
NO
Check the static condition of the front
panel LEDs. Compare with Startup
Symptoms/Causes/Corrective Actions.
See page 77.
Is there a
match
YES
Take corrective action
indicated and restart
NO
Reset the Platform and observe the
front panel LEDs sequence. Compare
to sequence given in Startup Sequence
Chart. See page 77.
Figure 2-1 Troubleshooting Flow Chart A
64 General Troubleshooting Instructions
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Cannot Communicate with Host Computer.
B
Is the Host
computer up
NO
Restart the Host
Computer System
YES
Does
Platform
respond to
keyboard
command
YES
NO
Is Platform up
and running
NO
Restart
Platform
YES
Do Platform
Number and baud
rate agree with host
computer
NO
Has this
configuration run in
the past
YES
Execute a
PMMRLD
YES
Check console operation.
May have to reboot Service
Workstation.
Replace the
MPRC Board
NO
Make
corrections
Get connecting
message
YES
All done.
so they
agree.
NO
Check Host hardware interface.
NOTE:
1. Check for any Host Computer communication error messages.
2. The normal Platform based rate is 9600. Some sites are set to 19200
however.
Figure 2-2 Troubleshooting Flow Chart B
3BUS 208 055 R1101
General Troubleshooting Instructions
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System halts. One or more red LED’s are lit.
C
Note the conditions under which
the system was operating when
the halt occurred or was first
noticed.
Is
this a first
occurrence
YES
YES
NO
Is
this a frequent
occurrence
(>1/wk)
NO
Restart the
Platform
Are there any
symptoms prior to
halt
NO
All done.
YES
Record symptomatic data by
executing the utilities: derr,
bfchk, dfree, pe -a, dproc
Put Platform in DEBUG Mode. Restart the Platform
with the StartMode switch in the STOP/DEBUG
position. When appears, go to
CASE K and perform the actions listed. With this data
in hand, contact the Support Line as soon as possible.
The system may continue to be used in the mean time.
Figure 2-3 Troubleshooting Flow Chart C
66 General Troubleshooting Instructions
3BUS 208 055 R1101

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Cannot Access AVOS Shell.
D
At the console type CTRL-q or CTRL-
C, CTRL BREAK or CTRL |.
Is
access to the
shell restored
YES
Note the
occurrence
for future
reference
NO
Reboot the Service Workstation.
Is
access to the
shell restored
NO
Reboot the
Platform
YES
Does
this happen very
often
(>1/wk)
NO
Note the
occurrence
for future
reference
YES
Note the
occurrence
for future
reference
NO
YES
Does
this happen very
often
(>1/wk)
Is
access to the
shell restored
Possible problem with
Service Workstation.
Reboot Service
Workstation with the
backup software.
YES
Collect system
error data
Figure 2-4 Troubleshooting Flow Chart D
3BUS 208 055 R1101
General Troubleshooting Instructions
67

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Some Sensor(s) are not working.
E
Each Sensor Technical Manual should be consulted for specific troubleshooting
procedures for that sensor. Here is a summary list of areas to consider and utilities
to use in the troubleshooting process:
All sensors are failed
Is the sensor data invalid
Check sensor status code.
Check last standardize results.
Health Report
l>()pmmFrame0x stdzErrors](gives all failed parameters)
Check input signals.
aim
SensorObject->inputSignal
Check sensor processed data.
SensorObject->outputSignal
Check setup parameters; slope. offset, Cal Constants.
Health Report
SensorObject->slope
SensorObject->offset
Figure 2-5 Troubleshooting Flow Chart E
68 General Troubleshooting Instructions
3BUS 208 055 R1101

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Sensor head will not move.
F
Has
the head ever
moved
NO
Do Platform
tuning
with the ft
utility.
YES
Check for the following system conditions:
Is
the Platform in
local
NO
Is
system in
correct mode for
requested
function
YES
NO
1. Host Communication down (OFF-SHEET/REMOTE).
2. Process Sheet Break (OFF-SHEET/REMOTE).
3. Sensor Alarm Grid Broken (LOCAL).
4. Air Pressure low at the Platform (LOCAL).
5. Platform split heads condition set (LOCAL).
6. Heads sitting on a limit switch. (Note that this also causes loss of
serial communications to the Platform with a resultant loss of lamp
illumination to the ON/OFF sheet push buttons) (LOCAL).
7. Invalid head position (bad encoder). Check the ft utility encoder
page (LOCAL).
8. No chiller flow (OFF-SHEET/REMOTE).
9. Inherent Sheet Break (OFF-SHEET/REMOTE).
10. Head Tracking error (OFF-SHEET/REMOTE).
11. Auto Edge-of-Sheet error (OFF-SHEET/REMOTE).
12. Head has restricted motion (LOCAL).
13. Bad Edge Detector (OFF-SHEET/REMOTE).
Put system in correct
mode.
YES
Check the pe utility messages
and the requestList display
function in the ft utility.
Figure 2-6 Troubleshooting Flow Chart F
3BUS 208 055 R1101
General Troubleshooting Instructions
69

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reproduction, or other means of dissemination may be made without written permission.
Scan Is erratic.
G
Has
Platform tuning been
done
NO
Tune the Scanning Platform
using the ft utility.
YES
Monitor the scanning
performance using the
ft utility DISPLAY
function.
Does
head move freely
across Platform
width
NO
Troubleshooting for
possible drag on heads.
YES
Check setup of motor
controller. Retune if
changed.
If Platform > 6–7 meters
or < 6–7 meters, manual
tuning of parameters may
be necessary. Consult
section 3 of this manual.
Figure 2-7 Troubleshooting Flow Chart G
70 General Troubleshooting Instructions
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
Auto edge–of–sheet problems.
H
Is
AEOS turned
ON
NO
Turn AEOS on
at the Host
Computer.
YES
Check pe utility for
related AEOS
messages.
Do
edge detectors
work Use dim
utility to
examine.
NO
Troubleshoot
detectors
and repair.
YES
Check AEOS setup with ft
utility display feature.
NOTE: If the far edge detector
could not find the home edge of
sheet, the detector itself may be
defective, or the orientation of the
home edge limits in the scanner
object may be incorrect.
Figure 2-8 Troubleshooting Flow Chart H
3BUS 208 055 R1101
General Troubleshooting Instructions
71

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reproduction, or other means of dissemination may be made without written permission.
Platform stays in local mode.
I
Check for the following system conditions:
1. Host Communication down (OFF-SHEET/REMOTE).
2. Process Sheet Break (OFF-SHEET/REMOTE).
3. Sensor Alarm Grid Broken (LOCAL).
4. Air Pressure low at the Platform (LOCAL).
5. Platform split heads condition set (LOCAL).
6. Heads sitting on a limit switch. (Note that this also causes loss of
serial communications to the Platform with a resultant loss of lamp
illumination to the ON/OFF sheet push buttons) (LOCAL).
7. Invalid head position (bad encoder). Check the ft utility encoder
page (LOCAL).
8. No chiller flow (OFF-SHEET/REMOTE).
9. Inherent Sheet Break (OFF-SHEET/REMOTE).
10. Head Tracking error (OFF-SHEET/REMOTE).
11. Auto Edge-of-Sheet error (OFF-SHEET/REMOTE).
12. Head has restricted motion (LOCAL).
13. Bad Edge Detector (OFF-SHEET/REMOTE).
14. One or more defective Frame Control Panels with a LOCAL
pushbutton stuck in the closed position. Disconnect each panel, one
at a time (one panel must always be connected) to isolate out the
defective panel.
Figure 2-9 Troubleshooting Flow Chart I
72 General Troubleshooting Instructions
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
Console displays
This message appears after the front panel switch on the ASPC is placed in the down
position and the system reset.
J
Note the conditions under which the
message occurred. Such things as
rebooting, scanning with no user
intervention going on, utilities in use, and
so forth.
At the Service Workstation console, type e.
The response will be a report of the
condition.
At the Service Workstation console, type x.
The response will be an exception report of
the bus error(s).
At the Service Workstation console, type d 1
100. The response will be a memory dump of
the first 100 locations.
Restart the Platform. Run
the bfck utility periodically to uncover buffer
problems. Call the Support Line with the
results of the collected report. This should be
done as soon as possible while the event is
fresh in the mind.
Figure 2-10 Troubleshooting Flow Chart J
3BUS 208 055 R1101
General Troubleshooting Instructions
73

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reproduction, or other means of dissemination may be made without written permission.
Cannot operate utilities.
K
Can
the dfree utility be
run
YES
Record the dfree
data and reboot
the Platform
NO
Record pe error messages if
possible, and reboot the Platform
Using dfree and monitor utilities,
get initial usage of memory and
buffers. (Usage should stabilize
after several days.)
Every several hours, gather the
following data:
dfree
bfchk
derr
monitor (resources)
pe -a
Are
resources being
consumed and/or are
errors being
generated
YES
With the collected
data available,
contact the Support
Line.
NO
Increase interval of monitoring to once per
month. If problem reoccurs, call the Support
Line.
Figure 2-11 Troubleshooting Flow Chart K
74 General Troubleshooting Instructions
3BUS 208 055 R1101

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Cannot determine what is wrong.
L
Is the Platform
running with access
to the Service
Workstation
NO
Troubleshoot using
either flow chart A or D.
YES
Execute the following
utilities: derr, bfchk,
dfree, dproc, pe -a.
Note the conditions
surrounding the problem
being experienced and,
together with the
printouts just obtained,
call the Support Line
for assistance.
Figure 2-12 Troubleshooting Flow Chart L
3BUS 208 055 R1101
General Troubleshooting Instructions
75

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reproduction, or other means of dissemination may be made without written permission.
Host Computer Coldstart Data File Overview
The Scanning Platform software requires certain system parameters to be sent from
the Host computer upon the issue of a PMMRLD command, to complete the initial
configuration initialization. The specific set of parameters required will depend on
the type of Host system involved and, if an 1190 (Software Release 3.0 and later)
or AccuRay Direct, on the status of a flag in the pmmFrame01 object called
shortFrameSetup. For Release 3.0 and later of the 1190 and all AccuRay Direct
systems, the shortFrameSetup flag is automatically set to 1 meaning a shorter set
of parameters are required from the host. For 1190 releases prior to 3.0, this flag
must be set to 0, either by using the inspect utility, or by answering the appropriate
query during the extended configuration session.
The following table gives the parameter list for the data transfers during the
PMMRLD command:
Variable 1190/AccuRay Direct/Chem 1180M
Flag=1 Flag=0
Current Far Scan limit 3 3
Current Home Scan Limit 3 3
Far Measure Limit 3 3
Home Measure Limit 3 3
Off Sheet Position 3 3
Standardize Position 3 3
AEOS Enable Flag 3 3 3
Single Point Position 3 3 3
Number of Data Boxes 3 3 3
Number of Control Zones 3
Cond. Weight Factor 3 3 3
Scan Time 3 3 3
76 General Troubleshooting Instructions
3BUS 208 055 R1101

3BUS 208 055 R1101
General Troubleshooting Instructions 77
Startup Messages
Use the following table to troubleshoot the Scanning Platform at startup or after a reset. The table lists the start–up messages
in sequence along with a description of system activities and corrective actions (where appropriate).
Table 2-2 086349-002 MPRC Board
Expected Start-up Console Message Activity Corrective Action
Smart Platform start-up revision IMP 200 001
(c) Copyright 1991, ABB Process Automation Inc.
All Rights Reserved
Prior to messages, the MPRC
is running internal
diagnostics on the CPU memory
and the HDLC serial
interface. The messages are
at the beginning of the startup
file and indicate the first
attempts to read the RAM disk
area.
If the messages never appear
on the screen either the MPRC
diagnostics have failed or
the RAM disk area cannot be
read.
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78 General Troubleshooting Instructions
3BUS 208 055 R1101
Expected Start-up Console Message Activity Corrective Action
HDLC Loop back Test (Dev0/ChanB): PASSED
HDLC Loop back Test (Dev0/ChanA): PASSED
BRAM address:0x2000000
BRAM size:0x200
Checksum Table:0x207fc00
BRAM checksumsOK
BRAM address 0x2080000
BRAM size:0x9ff
Checksum table:0x22ff000
BRAM ChecksumsOK
/bram1 (NO WRITE)
File System: Volume:
** Phase 1 Check Blocks and Sizes
** Phase 2 Check Pathnames
** Phase 3 Check Connectivity
** Phase 4 Check Reference Counts
** Phase 5 Check Free List
46 files 389 blocks 112 free
/bram2 (NO WRITE)
File System: Volume:
** Phase 1 Check Blocks and Sizes
** Phase 2 Check Pathnames
** Phase 3 Check Connectivity
** Phase 4 Check Reference Counts
** Phase 5 Check Free List
70 files 2502 blocks 12 free
These messages are responses
to diagnostic exercises which
include a check on the MPRC
microprocessor serial link
(HDLC) and a check on the RAM
disk area integrity and
condition.
The fsck repair utility is run
for both bram1 and bram2 RAM
disk areas. The utility
response will only be to
report conditions found.
The loading process will not
halt during these checks but
it will be up to service
personnel to go back later and
correct any RAM disk file
errors found. Errors found
during the HDLC checks will
probably prevent
communications with the
micro-controllers and any
BRAM errors will prevent the
libraries from loading.
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.

3BUS 208 055 R1101
General Troubleshooting Instructions 79
Expected Start-up Console Message Activity Corrective Action
lib: /lib01/drv/session.lib loaded. btoken[12]
task: /lib01/drv/hdlc loaded. btoken [13], entry[0x14c8c0], stacksize[2048]
lib: /lib01/lib/libm loaded. btoken [16]
lib: /lib01/lib/libsl loaded. btoken [17]
Using revision file found on: /lib01/avrev, the following diskettes are required:
disk: /lib01/avrev at release av280.5 Avos diskette
.
.
.
.
ss280.5 ss01 diskette
task: /lib01/drv/slvpmm loaded. btoken [18], entry[0x1834a8], stacksize[2048]
lib: /lib01/lib/insp_lib loaded. btoken [20]
expanding and loading po_clas.lc
•
•
•
expanding and loading pm_msdmg.lc
task: /appl/lib/pm_appl.lib loaded. btoken[53], entry[0x23e408], stacksize[4096]
AVOS SCNs and special
operating system drivers
are loaded into memory
from the MPRC PROM area.
A special utility to check
the revision levels of the
diskettes from which the
software was loaded, is
run here.
The system then starts to
load the various libraries
from the bram2 RAM disk
area. The final activity
is to load the appl.lib
configuration.
If there are any
application SCNs, they
will be installed at this
time also.
1. If any AVOS task cannot be
loaded, it will be noted.
The problem is probably a
bad image. Use the last
saved version of the AVOS
lib01 directory.
2. If any AVOS library cannot
be loaded, an “Entering
Migration Mode” message
will be issued. Use the
last saved version of the
AVOS lib01 directory.
Use CTRL-SHIFT |, to get Avos
prompt. Look at the list of
diskettes used to find the
offending diskette. Reload
with the correct diskettes.
If a module cannot be loaded,
the “Entering Migration Mode”
message will be issued.
Restore the system files from
the backup copy.
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reproduction, or other means of dissemination may be made without written permission.

80 General Troubleshooting Instructions
3BUS 208 055 R1101
Expected Start-up Console Message Activity Corrective Action
Smart Platform Application; rev.:@(#)appl_init.m:190.1
[1]:APPL_INIT defining exception handlers
[2]:APPL_INIT defining Network Object Dictionary
[3]:APPL_INIT creating global object collection
[4]:APPL_INIT creating error history
[5]:APPL_INIT creating appl_start community
The system release is: SP280.5 Host communications is set for:
Station ID = 1 Baud Rate = 9600
[01_0]$$
Down-line load Message Banner announcing OK to connect to Host
Computer
The configuration files are
read and the system software
is linked.
Announcement that the downloaded
command from the Host
computer is ready to be
received. Gives conditions
for the manual or automatic
loading.
Any failure in this process
indicates that one or more
configuration files are
defective. Restore the last
saved .init files from
diskette and restart.
Any failure in this process
indicates that one or more
configuration files are
defective. Restore the last
saved .init files from
diskette and restart.
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.

3BUS 208 055 R1101
General Troubleshooting Instructions 81
Table 2-3 086444-001 MPRC Board
Expected Start-up Console Message Activity Corrective Action
Smart Platform start-up revision IMP 200 001
(c) Copyright 1991, ABB Process Automation Inc.
All Rights Reserved
Prior to messages, the MPRC
is running internal
diagnostics on the CPU memory
and the HDLC serial
interface. The messages are
at the beginning of the startup
file and indicate the first
attempts to read the RAM disk
area.
If the messages never appear
on the screen either the MPRC
diagnostics have failed or
the RAM disk area cannot be
read.
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reproduction, or other means of dissemination may be made without written permission.

82 General Troubleshooting Instructions
3BUS 208 055 R1101
Expected Start-up Console Message Activity Corrective Action
BRAM address 0x2000000
BRAM size: 0xaff
Checksum table:0x22bf000
BRAM Checksums OK.
/bram1 (NO WRITE)
File System: Volume:
** Phase 1 Check Blocks and Sizes
** Phase 2 Check Pathnames
** Phase 3 Check Connectivity
** Phase 4 Check Reference Counts
** Phase 5 Check Free List
35 files 155 blocks 2610 free
AccuRay Virtual Operating System
(c) Copyright 1991-1998, Process Automation Business, Inc.
/nram1 (NO WRITE)
File System: Volume:
** Phase 1 Check Blocks and Sizes
** Phase 2 Check Pathnames
** Phase 3 Check Connectivity
** Phase 4 Check Reference Counts
** Phase 5 Check Free List
79 files 3418 blocks 517 free
These messages are responses
to diagnostic exercises which
include a check on the MPRC
microprocessor serial link
(HDLC) and a check on the RAM
disk area integrity and
condition.
The fsck repair utility is run
for both bram1 and bram2 RAM
disk areas. The utility
response will only be to
report conditions found.
The loading process will not
halt during these checks but
it will be up to service
personnel to go back later and
correct any RAM disk file
errors found. Errors found
during the HDLC checks will
probably prevent
communications with the
micro-controllers and any
BRAM errors will prevent the
libraries from loading.
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.

3BUS 208 055 R1101
General Troubleshooting Instructions 83
Expected Start-up Console Message Activity Corrective Action
All Rights Reserved
lib: /lib01/drv/session.lib loaded. btoken[15]
task: /lib01/drv/hdlc360 loaded. btoken [16],entry[0x8aff4f4],stacksize [4000]
lib: /lib01/lib/stack.lib loaded. btoken [19]
Using revision file found on: /lib01/avrev, the following diskettes are required:
disk: /lib01/avrev, at release av300_0 Avos diskette
disk: /appl/clm/prrev, at release pr300_0 Product diskette
disk: /appl/clm/serev, at release se300_0 Sensors diskette
disk: /appl/clm/a1rev, at release a1300_0 APPL1 diskette
disk: /appl/clm/a2rev, at release a2300_0 APPL2 diskette
Using revision file found on: /lib01/avrev, the following disks are required:
SP300.0 SystemRelease
ac300_0 Ace diskette
av300_0 Avos diskette
h1300_0 Health1 diskette
h2300_0 Health2 diskette
pr300_0 Product diskette
se300_0 Sensors diskette
a1300_0 APPL2 diskette
a2300_0 APPL2 diskette
sa300_0 SCNA diskette
sb300_0 SCNB diskette
ss300_0 SS01 diskette
task: /lib01/drv/ethertsk loaded. btoken[20], entry[0x8b3860c], stacksize[8000]
task: /lib01/bin/sokit2me loaded. btoken[23], entry[0x8b3b5a4], stacksize[10000]
Sokit2me Running...
lib: /lib01/lib/insp_lib loaded. btoken [24]
lib: /lib01/lib/libm loaded. btoken[25]
lib: /lib01/lib/libs1 loaded. btoken[26]
AVOS SCNs and special
operating system drivers
are loaded into memory from
the MPRC PROM area.
A special utility to check
the revision levels at the
diskettes from which the
software was loaded,is run
here.
1. If any AVOS task cannot be
loaded, it will be noted.
The problem is probably a
bad image. Use the last
saved version of the AVOS
lib01 directory.
2. If any AVOS library cannot
be loaded, an “Entering
Migration Mode” message
will be issued. Use the
last saved version of the
AVOS lib01 directory.
Use CTRL-SHIFT |, to set the
AVOS prompt. Look at the
list of diskettes used to
find the offending
diskette. Reload with the
correct diskette.
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.

84 General Troubleshooting Instructions
3BUS 208 055 R1101
Expected Start-up Console Message Activity Corrective Action
task: /appl/bin/slvpmm loaded. btoken[28], entry[0x8b45304], stacksize[2048]
lib: p0_clas.lib loaded. btoken[30]
.
.
.
.
.
lib: pm_msdmy.lib loaded. btoken[63]
task: /appl/lib/p1_appl.lib loaded. btoken[64], entry[0x8c757b4], stacksize[4096]
Smart Platform Application; rev.:@(#)appl_init.m 1.12
[1]:APPL_INIT defining exception handlers
[2]:APPL_INIT defining Network Object Dictionary
[3]:APPL_INIT creating global object collection
[4]:APPL_INIT creating error history
[5]:APPL_INIT creating appl_start community
THE SYSTEM RELEASE IS: SP300.0
The current system release number has not been stored in: appl.ini---
you may want to gstore: appl.ini!
HOST COMMUNICATIONS IS SET UP FOR: stationID = 1 baudRate = 9600
task: /lib01/bin/swi loaded. btoken[65], entry[0x8c9013c], stacksize[3000]
task: /lib01/bin/asi loaded. btoken[66], entry[0x8c98fec], stacksize[4096]
asiServer: Using nIndex = 0
startdmp: comout_no in use is 4
AVOS Shell 300.1.1.2
[01_0] $$
If the Host is down it will automatically download files to the Smart Platform
when it is started up.
If the HOST is already up, then request a manual reload of this Smart Platform.
The system then starts to
load the various libraries
from the bram2 RAM disk
area. The final activity
is to load the appl.lib
configuration.
If there are any
application SCNs, they
will be installed at this
time also.
The configuration files
are read and the system
software is linked.
Announcement that the
down-loaded command from
the Host computer is ready
to be received. Gives
conditions for the manual
or automatic loading.
If a module cannot be
loaded, the “Entering
Migration Mode” message
will be issued. Restore
the system files from the
backup copy.
Any failure in this
process indicates that one
or more configuration
files are defective.
Restore the last saved
.init files from diskette
and restart.
Any failure in this
process indicates that one
or more configuration
files are defective.
Restore the last saved
.init files from diskette
and restart.
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. No disclosure, distribution (electronic or otherwise),
reproduction, or other means of dissemination may be made without written permission.
Changing the Host/SP BAUD Rate and the
Station ID
In ABB 1190 Chemical and AccuRay Direct applications, the Station ID is
typically 1. In 1180M applications, it can vary depending on the frame number and
release level of the 1180M. In all cases, the standard host to the Scanning Platform
baud rate is 9600. There are occasions however, where other values for these
parameters may be required. The following procedure will allow the values to be
modified within the Scanning Platform and will require a system reset in all cases.
1. Activate the inspect utility.
2. Enter the following command:
pmmInterface
3. Observe and record the 0x address for the pmmDriver instance variable.
4. To change the Station ID, enter the following command:
()[0Xaaaaaa sid:yyyyy]
Where: xxx is the drop address of the Scanning Platform and aaaaaa is the
pmmDriver address. In the case of the 1180M, it is the LRN. Note that the
X in the address expression is capitalized.
5. To change the baud rate, enter the following command:
()[0Xaaaaaa baudRate:yyyyy]
Where: yyyyy is the baud rate to be used and aaaaaa is the pmmDriver address.
6. Exit the inspect utility.
7. Execute the gstore utility, saving the pmm community.
8. Restart the Scanning Platform.
3BUS 208 055 R1101
General Troubleshooting Instructions
85

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.
Radiological Safety Features and Alarms
The features in this section add safety interlocks to the Ash and Basis Weight Sensor
Package in order to further protect and inform personnel of malfunctions or special
maintenance activities of the sensor.
Broken Grid Alarm
On any Basis Weight sensor having a non-gaseous, radioactive source (such as TLS1
and TLP3), there will be a digital input which will notify the system whenever the
grid is broken. This digital input will put the frame in local mode and display the
alarm message on the Host computer operator console similar to:
BW ALARM GRID BROKEN - FRAMEn
The grid must be repaired before the heads can again be moved by the system.
Inherent Sheet Break (ISB) Alarm
If at any time the process disappears from the gap and the regular sheet break detector
fails to take action, the system will sense the condition and put the frame in local
mode and generate the alarm on the host computer operator console similar to:
BW INHERENT SHEET-BREAK - FRAMEn
ASH INHERENT SHEET-BREAK - FRAMEn
The decision to alarm is based on an adjustable limit located in the Basis Weight
and Ash object. The variables’ descriptions are as follows:
Type Name Default
double percentOfFullScaleForSheetBreak 98
double timeForSheetBreak 5
While these variables can be adjusted in the field, there are hard limits beyond which
values should not be entered. The high limit signal can be a maximum of 99% of
the signal voltage with nothing in the gap. The ISB maximum count delay between
initial sheet-break detection and ISB actuation will not go over 30 seconds. The
ISB override maximum count will not go past 700 seconds.
Any time a change is made to these limits, the gauge must be standardized in order
to make them effective.
86 General Troubleshooting Instructions
3BUS 208 055 R1101

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.
Head Tracking Error
If at any time the heads become severely misaligned or separated, resulting in severe
attenuation of the signal, the system will put the Platform in local mode and display
the alarm on the Host computer operator console similar to:
BW HEAD TRACKING ERROR - FRAMEn
ASH HEAD TRACKING ERROR - FRAMEn
The system will behave exactly as if there was a sheet-break. If the condition persists
after going back on-sheet, the alarm will repeat.
The decision to alarm is based on adjustable limits located in the Basis Weight and
Ash community object. The variables’ descriptions are as follows:
Type Name Default
double percentOfFullScaleForHeadTracking 3 (TLK, TLS, and STLK)
2 (STLP & TLP only)
double timeToTriggerHeadTrackingError 5
Shutter Closed During Prepare to Move
When a prepare to move request is made for Basis Weight or Ash, a countdown
starts. If the end location is not reached before the time limit is exceeded, the shutter
will close. The specified time is a coldstart instance variable, shutterGracePeriod.
It is located in the Frame community Object. shutterGracePeriod allows the
shutters to stay open long enough when the snsor heads need to traverse the full
length of the frame. The shutterGracePeriod time limit reduces the frequency of
shutter cycling and reduces wear. Longer durations in prepare to move indicates a
problem, and the shutter will close.
Shutter Closed When Host Computer is Down
Anytime the Host computer goes down, or is halted, leaving the platform up and
running, the Scanning Platform software will sense loss of communication and close
the shutter. When Host and Scanning Platform communications are restored, the
normal shutter operation will continue.
Invalid Shutter Open Alarm
If the shutter is supposed to be closed and it is not (such as off-sheet), an alarm
message will appear on the Host computer operator console similar to:
BW SHUTTER OPEN ERROR - FRAMEn
ASH SHUTTER OPEN ERROR - FRAMEn
The system takes no other corrective actions beyond this notification.
3BUS 208 055 R1101
General Troubleshooting Instructions
87

Blank Page

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reproduction, or other means of dissemination may be made without written permission.
3
Position and Motion Problems
This chapter is about troubleshooting problems with the platform.
This chapter contains the following major sections:
Section ...............................................................................................Page
Preliminary Troubleshooting Activity ........................................................... 90
Positioning Events Historical Diagnostic ...................................................... 91
Mechanical Influence on Motion Problems ................................................... 94
Comments About the Motor Controller ......................................................... 95
Diagnosis of Platform and Servo Problems ................................................... 96
Servo & Scanner Diagnostic Instance Variables ............................................ 99
AEOS Setup Problems ................................................................................... 107
Frame Tuning and Diagnostic Tool, ft ........................................................... 110
3BUS 208 055 R1101
Position and Motion Problems
89

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reproduction, or other means of dissemination may be made without written permission.
Preliminary Troubleshooting Activity
Prior to attempting to diagnose motion problems, it is strongly advised that complete
Platform setup be performed using the ft utility for each platform on the system. It
is important that the full sequence of head position and motor controller tuning be
performed in this specific order.
90 Position and Motion Problems
3BUS 208 055 R1101

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.
Positioning Events Historical Diagnostic
There is an array of data stored on the ECF boards’ SMI that gives an historical
sequence of the more recent 20 states changes which the ECF board has seen. These
events are generally related to FCP push button status and limit switch operation.
It is useful in sometimes determining the sequence of those events which brought
the system into whatever current situation is being examined. This array is
populated by a state determined program in the ECF board. Various events may
cause the state of the ECF board to change. A rotating buffer of 20 entries are kept
where each entry contains an event and a corresponding state resulting from that
event. Each line in the printout contains two fields following is the absolute address
location in the ECF board (actually the SMI mounted on the ECF). The first field
is the event, followed by the second field which is the state. There is a pointer (first
entry in the buffer, second line in the printout) which indicates the next entry in the
rotating buffer of events and corresponding states that were logged. To examine
this array, execute the following commands:
$$ uc 0x1f
uc 0x1f> md ∆ HisPut.1 ∆ 21(2d)
By looking at the first line in the printout, it can be determined where the next event
will be logged. This will be the decimal offset into the array after the pointer,
ranging from 0 to 19. At startup, the second entry will always have an initial 0 in
the first and second fields, indicating that the buffer has not wrapped around yet.
Always remember to count starting at 0 when counting the entries after the pointer.
Table 3-1 on page 92 is a breakdown of the event codes and states of the ECF board:
3BUS 208 055 R1101
Position and Motion Problems
91

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reproduction, or other means of dissemination may be made without written permission.
Table 3-1 ECF Board Event Codes and States
Event Table
State Table
Code Event Code State
1 Manual (hand) push button is True 0 Initialization
2 Head Split is True 1 Disabled
3 Head Split is False 2 Safety
4 Motor Overload is True 3 Local, Not Jogging
5 Motor Overload is False 4 Local, No Limit Sw, Fwd Jogging
6 Forward Limit Switch is True 5 Local, No Limit Sw, Rev Jogging
7 Forward Limit Switch is False 6 Local, Fwd Limit Sw, Not Jogging
8 Reverse Limit Switch is True 7 Local, Fwd Limit Sw, Rev Jog
9 Reverse Limit Switch is False 8 Local, Rev Limit Sw, Not Jogging
10 Remote (Computer) Push Button is 9 Local, Rev Limit Sw, Fwd Jog
True
11 Jog Forward is True 10 Local, Frame Self Test, Moving in
Rev
12 Jog Forward is False 11 Local, Frame Self Test, Moving Off
Rev Limit Sw
13 Jog Reverse is True 12 Diagnostic
14 Jog Reverse is False 13 Remote, Moving Off Rev Limit Sw
15 Safety Interrupt is True 14 Remote, Moving Off Fwd Limit Sw
16 Safety Interrupt is False 15 Remote, No Limit Sw True
17 Startup Initialization is Complete
18 Encoder is Unsynchronized
19 Encoder is Synchronized
20 ECF hdlc Communications Lost
21 ECF hdlc Communications
Restored
22 FCP Communications Lost
23 FCP Communications Restored
24 Servo Time-out
25 Frame Diagnostic Push Button
True
26 Frame Diagnostic Push Button
False
27 Start Positioning Self Test
92 Position and Motion Problems
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
The example below is the output of the md HisPut.l command execution after the
startup and synchronization of the encoder. It is the expected sequence after any
reset.
Table 3-4
$$ uc 0x1f Request ECF shell
uc 0x1f> md HisPut.1 21(2d) Command to get state array
uc 0x1f
ECF Shell Prompt
00147674: 11 0 Next buffer entry to be used
00147678: 0 0 First event always 0 after a reset; if non-zero, buffer has
wrapped
0014767C: 17 3 Startup Initialization Complete; Local, No Limit, Not
Jogging
00147680: 18 3 Encoder Unsynchronized; Local, No Limit, Not
Jogging
00147684: 21 3 ECF hdlc Comm Restored; Local, No Limit, Not
Jogging
00147688: 11 4 Jog Fwd is True; Local, No Limit Sw, Fwd Jog
0014768C: 12 3 Jog Fwd is False; Local, No Limit Sw, Not Jogging
00147690: 10 2 Remote Push Button True; Safety (Moves toward Rev
Limit Sw)
00147694: 8 13 Rev Limit Sw True; Remote, Moving Off Rev Limit Sw
00147698: 16 13 Safety Interrupt is False; (see note 1)
0014769C: 19 13 Encoder Synchronized
001476A0: 9 15 Rev Limit Sw is False; Remote, No Limit Sw
001476A4: 0 0
001476A8: 0 0
001476AC: 0 0
001476B0: 0 0
001476B4: 0 0
001476B8: 0 0
001476BC: 0 0
001476C0: 0 0
001476C4: 0 0
Note: 1. If a safety interrupt is still present after encoder synchronization
and the reverse limit switch is false, then the safety interrupt
would not clear and the state would be “Local, No Limit Sw, Not
Jogging”.
3BUS 208 055 R1101
Position and Motion Problems
93

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.
2. If a safety interrupt happens while the system is in Remote, the
system goes to the Safety Interrupt state and the head moves
toward the Reverse Limit Switch.
Mechanical Influence on Motion Problems
The Platform hardware sometimes has “sticky” spots due to mechanical binding.
If a high friction spot occurs near the off–sheet or standardize positions, an unusually
large minimum velocity may be computed by the ft utility. Unfortunately, this large
value must be retained for vmin as it is required to override the friction at these
points. However, high friction spots at other positions may not affect the operation,
as they are usually experienced only during the CRUISING phase which uses DDC.
In general, any position which requires the HOMING phase (usually an end point)
must have sufficient minimum velocity to overcome the local friction there.
An alternative to determining a fixed vmin is to activate minimum velocity tuning
permanently by setting vminTune in the Servo object. Permanently setting
vminTune may cause vmin oscillation due to high friction at one end of the scan
and low friction at the other end. This oscillation may result in long delays at the
sticky end and overcontrol (hunting) at the low friction end.
Note:
activeVmin and Vmin are related as follows. Vmin is the coldstart
variable used as a starting point for activeVmin. When vminTune
is turned on, activeVmin is then allowed to ramp up as necessary,
providing the working value for the system.
94 Position and Motion Problems
3BUS 208 055 R1101

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.
Comments About the Motor Controller
The AC motor controller directly affects the perceived tuning of the Servo. The
actual velocity of the head has a non-linear relationship to the velocity output by
the Servo due to motor controller dynamics.
The most noticeable affect of the motor controller on Servo operations is in the
ability of the Platform to overcome static resistance. A “loosely tuned” (low boost
and/or V/F) motor controller requires a much higher output to get the head moving.
If the output required to overcome this resistance is greater than the desired scan
speed, a hang up will result.
The ability to HOME to a position when reaching the end of a trajectory is critical
because the HOMING phase uses minimum velocity (vmin) which should always
be smaller than scan speed. The HOMING function coupled with the looseness
described above, can cause severe hang up problems.
If the scan limits are set very narrow, the computed scan speed may be below the
recommended torque limit of the motor controller. In this case, the heads may not
move at all, or will crawl at a very low speed (cogging action). To correct this
problem, it is possible to give the servo a minimum velocity in a variable called
vmin. Typical values should be determined by the approximate equation:
vmin = minimum scan width/scan time
3BUS 208 055 R1101
Position and Motion Problems
95

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reproduction, or other means of dissemination may be made without written permission.
Diagnosis of Platform and Servo Problems
This discussion of typical symptoms and their causes relating to Servo (or apparent
Servo) operation is intended to provide a general guideline in diagnosing erratic
motion by the Platform. It is not all-inclusive with regards to symptoms. There are
two major categories into which most symptoms will fall: hang up and overcontrol.
In both cases, there is a servo diagnostic utility which may be useful in determining
the cause of any problems encountered.
The most common symptom of a Platform control problem is motion failure. It is
important to first check the Host computer operator console for alarms which would
explain the symptom. For example, if there has been a sheet–break, head tracking
error, an AEOS limit change error, or inherent sheet–break, the head will be locked
off–sheet.
Next, check the pe log on the Scanning Platform console for clues. The AEOS
illegal transition indicates that the detectors saw a sheet when they should not have.
If the edge detectors saw the sheet–break as a legal edge change (> 50% of width),
then a narrow scan may occur on the next first scan. This narrow scan can be avoided
by setting up maxEdgeChange properly.
Head tracking (Basis Weight or Ash < 3% AIS) or inherent sheet–break (Basis
Weight or Ash > 98% AIS) will occur only if there is a loss of apparent signal or
an attempt to measure air. An apparent signal loss can occur if a standardize takes
place with paper in the gap. The sensors may try to measure air following a sheet–
break if the scan velocity is too small. If the scan velocity is too small, there is not
enough torque to carry the head to an on–sheet position.
Having verified the presence or absence of the above conditions, it is strongly
advised that a complete Platform setup be performed via the ft utility for each
Platform on the system. It is important that the full sequence of head position, and
velocity calibrations be performed in this specific order.
Hang Up Problems
If a hang up problem is being caused by tuning problems, then the usual cause is
that insufficient output is getting to the motor controller from the servo0x object.
This insufficient output is typically related to vmin being too small to overcome
friction or the motor controller slope being too small to cause motion, regardless of
the servo0x output.
vmin Too Small
The quickest way to rule out if vmin is too small is to check the command variable
in servo0x. The command is the actual output velocity being sent to the MPRC
board. If it is zero, the cause for the hang up is some other reason (see “servo01
Request Complete” on page 97). If command is non-zero and equal in magnitude
to vmin, then vmin is too small and should probably be increased slightly.
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Motor Controller Slope Too Small
If command is much larger than vmin, then the motor controller slope variable
may be too small. Rerun the motor controller tuning activities using the ft utility.
servo01 Request Complete
If the servo is not trying to move the head (see “vmin Too Small” and “Motor
Controller Slope Too Small” on page 97), then the hang up must be related to a no
motion request from the Platform which indirectly does the Host Computer’s
bidding. By using the Display menus of the ft utility, the status of the Platform’s
request list may be examined to see what has been requested.
Confirmation that servo0x has successfully completed the last request can be
derived from the Current Platform Status display. If the Platform is NOT in Transit,
then the servo0x object has been told to remain stationary. Some reasons for system
logic to be requesting a stationary position are:
• No request from the Host Computer to do anything
• Host/Scanning Platform communications down
• Scanning Platform communications down
• Platform in local
• Sheet contacting sensor is inoperative or secure
• Host Computer has not completed profile updates
Frequently the error log (pe utility) will give some clue as to the current problem.
Overcontrol Problems
Overcontrol of the head is almost always the result of a servo tuning error. Insure
that the frame tuning utility ft has been properly run. The usual reasons for
overcontrol are almost the inverse of hang up (that is, vmin or motor controller
slope is too large). In FIXED_POINT positioning, the symptom will be hunting.
For STOP_PAST (scanning), the symptom will be the head jerking rapidly during
the ACCELERATION mode.
vmin Too Large (or activeVmin)
Determining if vmin is too large is difficult because of the fact that vmin must be
sufficiently big enough to overcome Platform resistance along its entire length and
there may only be a small area of the Platform that has high resistance. If vmin is
nearly the same magnitude as the scanSpeed in the scanner0x object (certainly
never greater than scanSpeed), then it is probably too large. Any vmin which is
more than 50% greater than this predicted value is probably too large.
If motor controller tuning in the ft utility consistently computes a large vmin, then
the motor controller boost adjustment is probably too low.
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Motor Controller Slope and Offset Too Large
The symptoms associated with an excessive ucSlope/ucOffset are usually obvious.
In addition to overcontrol at the edges, the head will have a noticeable jump at the
beginning of each scan. The most definitive proof of an excessive slope condition
is to examine the DDC error variable diagCorrectAvg in the servo0x object during
a scan. If this value is more than 1.05, then the motor controller slope and offset
should be adjusted using the ft utility.
xdb Too Small
In rare cases, the positioning dead band xdb as computed by the ft utility may be
too small. It has been found however, that in most cases of overcontrol, the dead
band is appropriate and that by addressing one of the other causes, the hunting can
be reduced to a negligible amount. Using the smallest xdb possible insures that the
scan end points are accurately reproduced.
Miscellaneous
A sine wave velocity across the scan can be caused by an excessively large integral
gain for the DDC speed control (Ki). The cause of an excessively large integral
gain can be a scan speed which is below the physical capability of the current motor
controller setup. When the cause is related to the physical capabilities of the the
motor controller, increase the scan speed or adjust the Boost or V/F pots on the
motor controller.
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Servo & Scanner Diagnostic Instance Variables
The following selected instance variables found in the servo01 and scanner01
objects are useful for debugging the positioning subsystem and analyzing
undesirable symptoms. Some of the variable descriptions have been further
annotated to describe their use and the likely symptomatic errors which they affect.
servo01 object
xdb
Positioning deadband in customer units. Output velocity to the motor controller
stops once a position complete is achieved within the dead band.
The effect of making xdb too large is to have the scan positioning smooth but less
reproducible. The increased positioning dead band absorbs much of the
deceleration and no further corrections to the target position is made once the head
has stopped. The net effect is to rely on coasting following the zero velocity output,
to place the head in the same spot time after time. This effect is obviously related
to the final head velocity prior to stopping and may be somewhat random.
Making xdb too small will result in overshoot or oscillation of the head. As the
head passes through the xdb area around the target, the head is brought back at
activeVmin speed. If activeVmin is low, the comeback may be slow until , with
vminTune turned on, activeVmin can be corrected. However, if activeVmin is
large enough to overcome some high friction spot on the platform, it is likely that
any overshoot will turn into an oscillation.
vdb
Velocity dead band in customer units per second. Is used to initialize avdb and
dvdb at startup. DO NOT ADJUST!
avdb
Velocity dead band during the ACCELERATION phase. DO NOT ADJUST!
advdb
Velocity dead band used during the DECELERATION phase. DO NOT ADJUST!
vmin/activeVmin
vmin is the coldstart minimum velocity of the head when in the HOMING phase.
activeVmin is the dynamic value that is used for the minimum velocity. If
vminTune is turned off, then the two will always be equal. With vminTune turned
on, activeVmin will increment as necessary to help overcome high friction spots
along the frame. This adjustment is only made during the HOMING phase. If
activeVmin gets too high, it can be brought back down to the original vmin value
by turning off vminTune and re-entering the lower vmin value.
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The effect of activeVmin being too large causes noticeable speed increases when
entering the HOMING phase, typically near the end point of a position request.
Also the head will most likely oscillate around the position target.
If activeVmin is too small, and vminTune is turned off, the head may take too much
time before reaching the desired position target such as standardize, off-sheet, or
the end point of a scan. If vminTune is turned on, then the servo will attempt to
increase activeVmin until sufficient movement causes the position target to be
reached.
vmax
The maximum allowed head velocity in customer units; this value limits any request
for a higher velocity from the scanner01 object. For an English units system, this
should be around 12-13 in/sec. On a Metric units system, it should be around
31-32 cm/sec.
vminFilterFactor
Exponential filter factor used to adjust activeVmin when vminTune is active. DO
NOT ADJUST!
ddcExcessiveErrorPercent
Only operative during the CRUISING phase, it is used to determine if an obstacle
has been encountered. If so, the scanner is put in LOCAL (hand) mode, stopping
the drive to the head. The units are in percent of speed target with failure occurring
if a greater speed is required.
ddcRestrictedMotionPercent
Only operative during the CRUISING phase, it is used to determine if actual motion
is too far below target. If so, the scanner is put in LOCAL (hand) mode, stopping
the drive to the head. The units are in percent of expected motion with failure
occurring if motion is too low.
Accel
The nominal acceleration in speed units per second. Typically this is set to one half
the head velocity during scan. The value is used to determine both the
ACCELERATION at the start of a scan, and the DECELERATION at the end of a
scan. The higher the value, the faster cruise velocity is achieved at the start, and
the quicker the speed drop off will be at the end of the scan. If too high, the head
could appear to surge at the start of the scan, and, by coming into the position target
too fast, can cause head overshoot and oscillation at the end of the scan. Low values
of Accel will make the head appear to be sluggish as it may take a long time to reach
cruising speed.
Kp
Proportional gain term of the DDC algorithm. DO NOT ADJUST!
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Ki
Integral gain term of the DDC algorithm. DO NOT ADJUST!
slopep
Positive direction servo velocity slope (home to far side of platform). DO NOT
ADJUST!
slopen
Negative direction servo velocity slope (far to home side of platform). DO NOT
ADJUST!
biasp
Positive direction servo velocity offset (home to far side of platform). DO NOT
ADJUST!
biasn
Negative direction servo velocity offset (far to home side of platform). DO NOT
ADJUST!
vminTune
Turns on/off the continuous tuning of activeVmin. It is only operative during the
HOMING phase. The adjustment is only in the upward direction, making
activeVmin ramp up as needed.
sampleInterval
The time interval in milliseconds between servo position commands. DO NOT
ADJUST!
xfinal[3]
A three element array showing the intermediate breakpoint positions for
ACCELERATION, CRUISING, and DECELERATION, for the current position
request.
vfinal[3]
A three element array showing the intermediate velocities for ACCELERATION,
CRUISING, and DECELERATION, for the current position request.
increment[3]
A three element array showing the intermediate velocity increments for
ACCELERATION, CRUISING, and DECELERATION for the current position
request. The units for CRUISE are in terms of position, while for ACCELERATION
and DECELERATION, the units are in velocity.
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duration[3]
A three element array showing the intermediate time duration for
ACCELERATION, CRUISING, and DECELERATION for the current position
request.
homingError
During the HOMING phase, it is the current head position error in customer units.
farEdge
The most recent target end point achieved in a forward direction. Not necessarily
the actual far edge of sheet.
homeEdge
The most recent target end point achieved in a reverse direction. Not necessarily
the actual home edge of sheet.
scanner01 object
maxEdgeChange
If a sheet break occurs while the head is scanning, and the edge detectors see the
tail of the sheet, it is possible that the system will incorrectly interpret this false
edge as an edge change, resulting in incorrect scan limits the next time the head
comes back on sheet. This variable will prevent a false edge from being established
by only allowing a defined maximum change to take place. This variable should
be set to correspond with the largest deckle change expected.
dbWidth
This is the databox width in customer units as determined at PMMRLD time. It is
calculated from the max scan limits and number of data boxes.
dbAvgTime
The average amount of millisecond time spent in each databox. It is calculated from
the scan time and the factual number of databoxes used.
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healthRequest
This variable controls the length of time the Workstation will stay in control of the
scanner after exiting the Health Pages. The default time is approximately 15
minutes. After leaving the Health Pages, this time can be extended by sending a
message to the scanner defining the total amount of seconds desired for the extended
control of the scanner by the workstation. The message to be sent while in the
inspect utility is:
()[scanner01 healthRequest:xxxxx]
where: xxxxx is the desired number of
seconds. The maximum time is
32767 seconds.
This permits troubleshooting to take place aside from that which can be done
through the Health Pages alone. This variable must be set up each time the Health
Pages are exited, if extended workstation control time is desired.
maxSpeed
Defines the maximum speed that the scanner can request from the servo. It should
always be equal to or less than vmax in the servo01 object.
positioningSafetyMargin
The amount of buffer distance added to or deleted from the scanning trajectories in
order to assure that the window does not go beyond the scan limits.
target
The current trajectory target in customer units.
autoEOS
An indication that the auto edge of sheet feature is active. This is controlled by the
host computer and cannot be turned on from here.
farEOSUnknown/homeEOSUnknown
Two variables which indicate that there has been no detection of a sheet edge since
startup. This can only be cleared if AEOS is on.
inTransit
Indicates that the head is currently moving or trying to move to a new position.
During scan this is always true.
scanning
If true (1) it is an indication that the head has been told to scan.
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sheetBreakPresent
True (1) if there is a physical sheet break present.
stdzPending
This will be true if a standardize request has been made from any source; host, FCP,
or workstation.
offSheetTimer
Indicates the amount of accumulated time that the head has been off sheet provided
that the offSheetTime instance variable has been set to a positive number of seconds
(turned on).
onSheetTimer
Indicates the amount of accumulated time that the head has scanning on sheet since
last being placed in scan mode, provided that the onSheetTime instance variable
has been set to a positive number of seconds (turned on).
Servo Diagnostic Troubleshooting Utility
The servo system contains within itself, a diagnostic utility which will report the
conditions and activities surrounding all trajectories requested by the scanner. This
diagnostic will report details of how a trajectory achieving its goal, as well as how
the HOMING activity is being adjusted in order to accomplish reaching the desired
target. The bottom line is the ability to observe how close the system comes to
reaching the desired trajectory target on any one scan or position request. The report,
shown in Figure 3-1 on page 105, looks fairly complicated and is not designed for
the casual user. It was intended for development checkout, but does contain
information useful for service concerns.
The structure of the report shows the following sequence of data:
• Where the head is when a new trajectory request is made.
• The mode (STOP_PAST, FIXED_POINT, etc.) and new target.
• The ACCELERATION envelope.
• The CRUISE envelope.
• The DECELERATION envelope.
• The HOMING envelope, including a separate line for each adjustment made
within the HOMING process.
• The final position is achieved.
Activate the inspect utility and send the following message to start the diagnostic:
()[servo01 startDiagnostics]
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Each time a new trajectory is requested, a multi-line report with the above data will
be brought to the screen. The report will continue to come out to the screen each
time a new trajectory is computed until a command to stop is issued. Do this by
again sending a message as follows:
()[servo01 stopDiagnostics]
NEW TRAJECTORY RCV0: at pos = 73.565000, v = 0.000000
STOP_PAST : FROM: x = 73.565000, v = 0.000000 TO: X = 207.245000, V = 0.000000
:ACCELERATING: FROM: x = 73.565000, v = 0.000000 TO: X = 77.530335, V = 4.455063, t = 1.308222, DELX = 0.340543
:CRUISING: FROM: x = 76.235000, v = 4.455060 TO: X = 203.354310, V = 4.455060, t = 28.500000, DELX = 0.445500
:DECELERATING: FROM: x = 203.125000, v = 4.204240 TO: X = 207.245000, V = 0.000000, t = 1.308000, DELX = -0.340540
:REQUEST HONING: FROM: x = 204.815000, v = 2.842080 TO: X = 207.245000, V = 0.000000
:CONTINUE HONING:FROM: x = 204.815000, v = 1.492990 TO: X = 207.245000, V = 0.000000
:CONTINUE HONING:FROM: x = 207.045000, v = 0.000000 TO: X = 207.245000, V = 0.000000
:CONTINUE HONING:FROM: x = 207.175000, v = 0.000000 TO: X = 207.245000, V = 0.000000
:CONTINUE HONING:FROM: x = 207.205000, v = 0.000000 TO: X = 207.245000, V = 0.000000
:CONTINUE HONING:FROM: x = 207.205000, v = 1.492990 TO: X = 207.245000, V = 0.000000
:CONTINUE HONING:FROM: x = 207.205000, v = 1.791580 TO: X = 207.245000, V = 0.000000
:CONTINUE HONING:FROM: x = 207.205000, v = 2.090170 TO: X = 207.245000, V = 0.000000
:CONTINUE HONING:FROM: x = 207.245000, v = 0.000000 TO: X = 207.245000, V = 0.000000
:CONTINUE HONING:FROM: x = 207.255000, v = 0.000000 TO: X = 207.245000, V = 0.000000
:FINISHED HONING:Pos: = 207.255000, COM = 0.000000, TAR = 207.245000, ForStop = 0.244060, RevStop = 0.254530,
HighFreq = 207.2550
00
POSITION ACHIEVED: AT: X = 207.255000: V = 0.000000
Figure 3-1 Servo Diagnostics Report
Selected Servo Diagnostics Definition of Terms:
delx
For Accel and Decel, it is the increment change in velocity. For Cruise, it is the
incremental change in travel distance for DDC.
STOP_PAST
The normal mode for scanning where the goal is to make the head go just past the
target so as to assure full measurement data is collected. In other scenarios, where
a fixed position is sought, the mode will be FIXED_POINT.
CONTINUE HOMING
A line is output every time there is a position change or and incremental velocity
change.
FINISHED HOMING
POS: The actual achieved position.
COM: The final command velocity; normally 0.
Tar: The initial target sought.
ForStop: The forward scan coasting stopping distance after shutting off the
drive.
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RevStop:
HighFreq:
The reverse scan coasting stopping distance after shutting off the
drive.
When the head reaches this position, the drive signal will be
interrupted. It is determined by the following approximate
relationship:
HighFreq = Target + 0.8RevStop (reverse scan)
HighFreq = Target - 0.8ForStop (forward Scan)
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AEOS Setup Problems
Make sure that you consistently use either all metric or all English dimensional
units throughout the scanner, servo, and edgeDetector objects.
If you use extended sheet guides on the head, make sure the edge detectors are
outriggered outside the guide mounting. Placing them inside does not provide
sufficient distance between the far window edge and the far detector. Mounting the
edge detectors too close to the window edge may not give the head sufficient time
to stop at the desired scan speed.
The far and home TrackingDistance should be no smaller than the xdb variable
in servo01. Making the tracking distances too small may position the window over
the edge of the sheet. Also, the smaller EOSDeadband is made the more frequent
edge changes will be reported to the host, resulting in longer edge-of-sheet times.
Set the tracking distance variables so that the scan limit positions allow the edge
detectors to see the edge of the sheet. If the tracking distance is larger than the
DetectorOffset distance, especially on the far side where the farDetectorOffset
distance tends to be short, then the head will move in a jerky manner when it is
close to the edge of the sheet. The tracking distance should meet the following
criteria at the respective far and home sides:
(DetectorOffset - WindowClearance) > (TrackingDistance + EOSDeadband + xdb)
Any time the farDetectorOffset or the homeDetectorOffset distance are changed,
the ECF (platform microcontroller) must be reset using the uc_reset utility:
uc_reset 31 -f
The uc_reset utility writes the new values to the microcontroller from the MPRC
board.
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Problem
Detectors see an edge while the heads
are not moving.
Measure Scan Limits are exceeded.
Neither detector sees a sheet edge while
scanning.
Head position problems.
Detected edge is too close to the
opposite edge.
AEOS reached the limit without seeing
edge.
Table 3-5 Failure Modes
Explanation
When the head is stationary, a valid transition is
unlikely. This invalid transition indicates a
glitch in the edge detector electronics or an
obstruction blocking the detectors from the
sheet.
If the detectors sense an edge–of–sheet which
would cause the computed scan limit to be
outside the MeasureLimit, the system issues an
error message for the far side, or for the home
side and uses that measurement.
If the state of both edge detectors transition
simultaneously, an error message is issued. This
state may be caused by a sheet–break where the
sheet disappears simultaneously from each
detector, or it could indicate a glitch in the edge
detector electronics.
The system console reports several head
position problems. If the head position analog
input is not available or if the position
computation cannot be completed, or if the head
position analog signal is invalid, an error is
issued.
If the detected far edge–of–sheet is closer to the
home edge–of–sheet than the width of the head
(farHeadClearance plus
homeHeadClearance) plus the curl distance,
an error message is issued. If the detected home
edge–of–sheet is closer to the far edge–of–sheet
than the above distance, an error message is
issued. These conditions can occur during a
sheet–break where a tapered tail of the sheet is
passing through the head, or it may also be a
problem in the detector electronics.
If the head is scanning toward the far side and
the edge–of–sheet is not seen before the sensor
window gets to the farMeasureLimit, an error
message is issued. If the head is scanning toward
the home side and the edge–of–sheet is not seen
before the sensor window gets to the
homeMeasureLimit, an error message is
issued.
(continued on next page)
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Problem
Far edge detector sees the paper
machine threading ropes, driving the
head into the ropes.
The far and home edge detectors see a
false home edge when the head is
coming on-sheet, causing the head to go
to a position just inside the
homeMeasureLimit.
Table 3-5 (continued)
Explanation
By setting the scanner01 flag
allowSecondEdgeErrMsg to a 0, it will permit
the AEOS logic to ignore the transition it sees
when the far detector passes over the rope.
The far detector sees the false edge and
determines that is where the home sheet is,
driving the head to a prepare to measure position
based on the supposed edge sighting. This
condition is more likely on a Smart Reflection
Scanner where portions of the paper machine
superstructure may be located such that it is
detectable by the edge detectors. This situation
can be alleviated by setting the flag
allowEdgeOutsideLimits in the scanner01
object to a “1”. This will ignore the error
condition and permit the head to be positioned
in the proper prepare to measure position.
The above problems are visible through the pe utility error log printout.
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Frame Tuning and Diagnostic Tool, ft
The ft utility is a menu driven, interactive program designed to allow the user to set
up and monitor most of the variables associated with the scanner. Figure 3-2 and
Figure 3-3 on the next two pages shows the organizational tree of the menu and is
followed by a brief description of each function.
To use the frame tuning utility, the console must be in the AVOS shell, indicated by
the $$ prompt. Activate the utility by typing ft. Then follow the interactive
instructions, selecting either the MODIFY path, or the DISPLAY path.
In each of the MODIFY operations, the user is given the opportunity to save the
modified data on diskette. The operation is similar to the gstore utility except that
the proper community is selected automatically.
When the option of saving the data is selected, the normal operation is to just press
the carriage return and let the utility write the data to the indicated file using a date
extension to the file name, just as is done using the gstore utility. As with the gstore
utility, the current .init file should be saved on the DOS formatted diskette via the
Service Workstation.
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ENTER
ft
UTILITY
Frame Tuning (ft) Menu Selections
NOTE: After modifying any of the instance variables, remember
to save the data to diskette either using the exit save commands
within ft, or by doing a gstore to the appropriate frame or io
community later.
1
2
MODIFY
VALUES
DISPLAY
STATUS
1
2 3 4 5 6
7 8
CURRENT
SCANNER
POSITION
VALUES
1
CURRENT
SPEED
HEAD POSITION
MOTOR
CONTROLLER
CALIBRATION
2
MOTOR
CONTROLLER
CALIBRATION
3
SCANNER/SHEET
POSITION
SETUP
4
SCANNER
SPEED
SETUP
5
SCANNER
AUTO EDGE
SETUP
(if configured)
CURRENT
SCANNER
REVIEW
OPERATION
6
MANUAL
SERVO
CALIBRATION
CURRENT
SCANNER
REQUEST LIST
CURRENT
SERVO
STATUS
SCANNING
MONITOR
CURRENT
AEOS
VALUES
(if configured)
ENGINEERING
DISPLAY
1 Scanning Monitor
2 Servo Global Data
3 Servo State Data
4 Servo Timing Data
5 Servo Trajectory Data
6 Servo Tuning Data
7 Frame Data
8 Motor Controller Data
9 Encoder Data
Figure 3-2 Frame Tuning Utility Menu Tree
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Enter ft Utility
1. Modify Values
1. Head Position and Motor Controller Calibration
Calibrates the head position encoder by first determining the encoder pulses at the homeTravelLimit, and then repeating the
process at the farTravelLimit. Sets up default values for servo tuning parameters based on length of the frame.
2. Motor Controller Calibration
Determines the slope and offset calibration of the motor controller by driving the head at slow and fast speeds in both directions.
3. Scanner/Sheet Position Setup
Permits adjustment of the specific head positions on the scanner such as standardize position, measure limits, etc.
4. Scanner Speed Setup
Permits adjustment of the max speed, scan speed, on–sheet speed, and scan time.
5. Scanner Auto Edge Setup (if configured)
Permits adjustment of the various dimensions associated with the auto edge of sheet.
6. Manual Servo Calibration
Permits adjustment of variables associated with the tuning of the Servo object and motor controller.
2. Display
1. Current Scanner Position Values
Shows current head positions along the length of the frame.
2. Current Speed Values
Shows the current speed values being used by the system.
3. Current Scanner Review Operation
Shows general operational status of the scanner including current head position, local/remote, sheet break, target position
and velocity, AEOS on/off, and most recent edges.
4. Current Scanner Request List
Shows the current queue of trajectories and conditions that are in use and scheduled for use. The top request is the current
active one.
5. Current Servo Status
Shows the accelerate, cruise, and decelerate target parameters for the servo in the current scan. Also indicates quality of the
servo and motor controller tuning.
6. Scanning Monitor
A dynamic display with a 1/sec update showing a variety of parameters associated with servo tuning and trajectory, as well
as error corrections being applied. Has dynamic picture of current head movement.
7. Current AEOS Values (if configured)
Shows the dimensions associated with the AEOS feature.
8. Engineering Displays
Advanced diagnostic displays. Update rates selectable at none, 1, 2, or 5 seconds. For example, selecting 91 will display the
Encoder Data, updating at a 1/sec rate.
1. Scanning Monitor
A dynamic display with a 1/sec update showing a variety of parameters associated with servo tuning and trajectory, as
well as error corrections being applied. Has dynamic picture of current head movement.
2. Servo Global Data
An update showing the servo parameters being used by the ECF board in both floating point and integer.
3. Servo State Data
Shows the operational condition of the servo
4. Servo Timing Data
A graphic display showing the dynamics associated with the accelerate, cruise, and decelerate phases
of the scan. Includes last dwell time at the edge.
5. Servo Trajectory Data
A summary update of the current trajectory set point.
6. Servo Tuning Data
Shows the servo tuning data as it resides in the MPRC and in the ECF boards.
7. Frame Data
Update summary of the platform’s operational state showing dynamically determined edge positions, AEOS
status, AEOS detector offsets, and setup status.
8. Motor Controller Data
Update of the current activities of the motor controller indicating its tuning, current output commands to the
motor, and operational mode.
9. Encoder Data
Shows the current operational state of the encoder along with historical data regarding missed pulses and
synchronization problems. This is a two-page report. Missed pulses at the home or off-sheet area are to be expected.
Figure 3-3 Description of ft Menu Options
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4
ABB Smart Processing Center
(ASPC) Hardware
This chapter will help you trace signals to and from the ASPC by using specific
software utilities.
This chapter contains the following major sections:
Section ...............................................................................................Page
Host/Workstation Interface to the ASPC ....................................................... 114
Inspecting and Repairing BRAM ................................................................... 116
Digital I/O Utility ........................................................................................... 118
Digital Input/Output Signal Verification and Tracing .................................... 120
Analog Input Monitor Utility ......................................................................... 121
Analog Input Signal Verification and Tracing ............................................... 125
Using the Diagnostic Card Adapter ............................................................... 126
LED Interpretation ......................................................................................... 139
Analog and Digital I/O Documentation ......................................................... 146
Power Down Analysis .................................................................................... 147
Micro-Controller DC Power Log ................................................................... 152
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Host/Workstation Interface to the ASPC
To use the Service Workstation for exercising the Scanning Platform you have to
have the operation and application software loaded into the workstation and install
a cable between the workstation and the platform. Refer to the Scanning Platform
System Software Manual (Software Releases 280.0 and Later),
3BUS 208 051 RXX01.
Connect the custom nine–pin connector from the serial port on the Service
Workstation to the debug port (see Figure 4-1) on the Scanning Platform.
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J1 TOP SIGNAL
J2 DRIVE END P3 P4
TOP POWER PROGRAM
P5
P1
TOP POWER
J3
J4
BOTTOM POWER PROGRAM
P2
J5 DRIVE END
TOP SIG
DIAG
J6 SYSTEM SERIALJ7SERVICE PORT
SHEET BREAK/REEL TURN-UP
J8
Service Port for the
Scanning Platform
1
2
3
J6 Socket Service Serial
LOGIC_COMMON
1
2
3
LOGIC_COMMON 1
4 HOST_20MA_TX+
5 HOST_20MA_TX-
6 HOST_20MA_RX+
7 HOST_20MA_RX-
8 HOST_20MA_DISABLE
9 HOST_RS485_TX+
10 HOST_RS485_TX-
11 HOST_RS485_RX+
12 HOST_RS485_RX-
13 HOST_RX_ENABLE
14 HOST_RTS
15 LCOM
16 LCOM
17 LCOM
086349-002
Board Assignments
J6 Socket Service Serial
4 HOST_20MA_TX+
5 HOST_20MA_TX-
6 HOST_20MA_RX+
7 HOST_20MA_RX-
8 +15V TO AUI
9 AUI TX-
10 AUI TX+
11 AUI CX-
12 AUI CX+
13 AUI RX+
14 AUI RX-
15 LOGIC COMMON
LOGIC COMMON ON
SCREWS
086444-001
Board Assignments
J9
J10
WATER CHILLERS
SMOOTHNESS 1
J11
SMOOTHNESS 2/MICRO WAVE
ENVIRONMENT/HOME LIMIT SWITCH
J12
IDLE END
J13 CONT PNL
J17
J18
J15
J16
J19
MOTOR
DC
IN
J23
J14
BOTTOM AUX SIGNAL
BOTTOM SIGNAL
BOTTOM POWER
J20
POWER MONITOR
DC
IN
J24
REMOTE
CONT PNL
IR IR
SOLA 1SOLA 2
J21
AC
IN
J22
J25
1
2
3
4
5
6
7
8
9
10
11
J7
Socket
Service Port
LOGIC_COMMON
SRVC_20MA_TX+
SRVC_20MA_TX-
SRVC_20MA_RX+
SRVC_20MA_RX-
SRVC-RS232_TX
SRVC_RS232_RX
LCOM
LCOM
The Circuit Panel
is located in the
Idler End Column.
Figure 4-1 Debug Port on the Scanning Platform
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Inspecting and Repairing BRAM
Periodically, the BRAM should be inspected and repaired if necessary, using the
fsck utility. This routine comes with several options. The -n argument merely
checks and notifies if there is a problem. This is done automatically at each startup.
Repair of the BRAM can be done by using the fsck utility with a -y argument. The
fsck utility with the -y argument, is a sophisticated repair routine which will clean
up fragmented, unreadable, or otherwise unconnected files. Note that in the process
of repair, some data may be lost depending on how extensive the repair activity is.
The utility should be run with BRAM dismounted from the operating system. It
should also be at a time when a restart could be made if necessary. Use the procedure
below.
Dismount the diskette to be repaired from the system, but do not remove it
physically.
$$ cd
$$ umount /bram1or$$ umount /bram2
Execute the following command:
$$ fsck -y /bram1or $$ fsck -y /bram2
The console will display the results as the operation progresses. See Figure 4-2 for
an example.
File System: Volume:
** Phase 1 - Check Blocks and Sizes
** Phase 2 - Check Path names
** Phase 3 - Check Connectivity
** Phase 4 - Check Reference Counts
UNREF FILE I=263 OWNER=0
MODE=100666
SIZE=21412 MTIME=04-18-1986 10:12
(NOT EMPTY)
RECONNECT yes
** Phase 5 - Check Free List
84 files 1130 blocks 442 free (example)
Figure 4-2 Example of Diskette Repair Activity
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The repaired files will be placed in the lost+found directory just in case there was
anything useful to be recovered. Generally, this is not the case. The free space will
not be recovered until the bogus files are removed in the next step.
Remount the repaired diskette and make the lost+found directory active by entering
the following:
$$ mount /bram1/ss01 $$ mount /bram2 /appl
$$ cd /ss01/lost+found or $$ cd /appl/lost+found
Remove the bogus files from the lost+found directory with the following command:
$$ rm *
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Digital I/O Utility
The interactive digital I/O utility, dim, is a menu driven display of the digital signals
which are routed through the platform. Refer to Figure 4-3. The functions which
are available are:
• Display of current state and toggle bit masks
• Print out the i/o configuration
• Toggle the bit(s) on a user defined time
dim Main Menu
Enter
DIGITAL I/O DIAGNOSTIC UTILITY
@(#)dim.m:imp200.999; Tue MAY 14 16:24:15 EDT 1992
1 to display digital i/o signals (invert input, toggle outputs)
2 to print i/o configuration
3 to change toggle duration [1200 secs.] or rate [5 secs.]
q to exit
Figure 4-3 Main Menu for the Digital I/O Utility
Procedure for Using the dim Utility
Instructions for using this activity appear at the bottom of the page displayed on the
Service Workstation. They will direct you through the steps to be taken. Refer to
the following pages for examples of the menus.
1. At the $$ prompt type: dim
The dim main menu is displayed.
2. Select item 1 from the dim main menu to look at i/o states.
The active options are displayed.
3. Select the i/o device you want to view by identifying both number and port.
4. Turn off the print function by pressing SHIFT and F2. This prevents the printer
from responding to state changes when they occur.
5. Perform whatever activities are desired. To make a hard copy, press PRINT
SCREEN.
6. To exit, press q. Each time q is pressed, the screen will go back to the previous
page. If invert mask changes have been made, the utility will ask if they are to
be left as is. Then it will remind the user to do a gstore to save the data for the
next restart. The dim utility has been completely exited when the $$ prompt
returns.
Note:
Bit toggling will cease upon exiting the utility.
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dim Reports
I/O Selection
DIGITAL I/O MONITOR (i/o selection)
Device
Name Number Input Ports Output Ports
ucFrame01 0 (1,3) (2,4)
ucbeta01 1 (1) (2)
Selection of Device 0, Input Port 1
Figure 4-4 I/O Selection Menu
DIGITAL I/O MONITOR (invert input)
ucFrame01 [Board:00 Port:01] [Digital Input Session Status01]
Signal Name Channel Value Validity
Figure 4-5 Digital I/O Monitor
Printout of I/O Configuration
State
Changes
Invert
sheetBreak01 0 1 0x0000 0 0
reelTurnUp01 1 0 0x0000 0 0
motorOverLoad01 2 0 0x0000 0 0
airPurge01 3 1 0x0000 0 0
chillerFlowSwitchA01 4 1 0x0000 0 0
chillerFlowSwitchB01 5 1 0x0000 0 0
homeEOSDetector01 6 1 0x0000 0 0
farEOSDetector01 7 1 0x0000 0 0
headsSplit01 8 0 0x0000 0 0
reverseLimit01 9 0 0x0000 0 0
forwardLimit01 10 0 0x0000 0 0
frameBetaShutterNotClosed01 11 0 0x0000 0 0
frameAshShutterNotClosed01 12 0 0x0000 0 0
Not Defined 13 0 0x0000 0 0
Not Defined 14 0 0x0000 0 0
Not Defined 15 0 0x0000 0 0
Enter ‘i’ to change invert flag or ‘q’ to quit
at 0:
ucHardware (UCSubsystem)
at 0:ucFrame01 (UCFrame) [-->FRAME_UC hdlc_addr:0x1f]
at 0:ucFrame01_port00 (UCAnalogPort)
at 1:ucFrame01_port00_ch01 (UCAnalogChan) [-->framePurgeAirFlow01_ai]
Figure 4-6 Partial Example of an I/O Configuration Printout
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Digital Input/Output Signal Verification and
Tracing
All digital inputs and outputs are transmitted via the microcontrollers. Examination
of these digital signals is best accomplished using the dim utility. This interactive
utility provides console access to each of the input and output databases. This utility
will display name, bit number, current status, and invert status for each bit in the
data base.
The dim utility provides the capability of monitoring, inverting, or toggling any bit
located within the system. The toggle feature exercises one or more bits on a user
defined time cycle.
Digital signal tracing between the ASPC assembly and the sensor head package can
be done using the aids and tools described in “Using the Diagnostic Card Adapter”
on page 126.
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Analog Input Monitor Utility
The analog input monitor utility, aim, has a variety of functions to assist in
evaluating the performance of the analog inputs. The services include:
• Input voltage monitoring
• Statistical analysis of any selected input
• Microcontroller board internal gain monitoring
• Display of microcontroller A/D slope and offset
aim Main Menu
Upon entering the utility, a menu is displayed (see Figure 4-7). Except for the menu
and statistics display pages, each page will show the analog input signal name and
board/channel number. Only those analog inputs defined by the system
configuration will be included. The bottom line of the page will give the interactive
instructions to either exit or proceed to another function.
The key to using the aim utility is to select the device first and then select the type
of information you want to collect.
ANALOG INPUT DIAGNOSTIC UTILITY
@(#)aim.m:imp200.999:Thu Sep 12 09:21:07 EDT 1991
Enter
1 to select device (frame/sensor) for analog input display
2 to display analog input signals (statistics)
3 to display AI channel gains
4 to display AI channel slopes and offsets
q to quit
Figure 4-7 aim Main Menu
Procedure for Using the aim Utility
Refer to the following pages for examples of the aim reports.
1. At the $$ prompt type: aim
2. At the aim Main Menu type: 1
The Device Selection Menu appears. (Figure 4-8)
3. At the Device Selection Menu select the number of the device you want to
collect on.
An arrow appears beside the selection you have picked.
4. At the Device Selection Menu type: q
This action returns you to the main menu so you can select the type of
information to collect about the selected device.
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5. At the aim Main menu select:
2 to display Input Signals
3 to display Gains
4 to display Slopes/Offsets
6. To exit, press q.
Each time q is pressed, the display will go back one page. Keep pressing q until
the AVOS prompt returns.
If displaying the input signal page or the statistics page, turn off the print function
by pressing SHIFT and F2. This will prevent the printer from responding to each
refresh of the screen.
To make a hard copy, press SHIFT and PRINT.
aim Reports
I/O Device Selection Report
Select the device you are going to collect data on from this menu. Refer to Figure
4-8.
ANALOG INPUT DIAGNOSTIC MONITOR (i/o selection)
Device Name Number
ucFrame01 0
ucBeta01 1
ucIR01 2
ucOptipak01 4
ucGeneral01 7
Enter device number or ’q’ to return to menu
Figure 4-8 I/O Selections from the aim Report
After you have entered a device number an arrow appears to the right of your
selection as in Figure 4-9.
ANALOG INPUT DIAGNOSTIC MONITOR (i/o selection)
Device Name Number
ucFrame01 0
ucBeta01 1
ucIR01 2
ucOptipak01 4

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reproduction, or other means of dissemination may be made without written permission.
AI Signal Report (Statistics)
Input display maintains a one second refresh of the signal voltage input as it appears
to the micro–controller board. See Figure 4-10 for an example. Selection is
determined by entering the board and channel number as requested by the prompt.
ANALOG INPUT MONITOR (Input values)
Signal Name Bd-Ch Value Signal Name Bd-Ch Value
framePurgeAirFlow01 0-01 5.0394 powerShelfTemp01 0-02 5.0394
motorControllerTemp01 0-03 0.0000 frameAnalogOutVoltage01 0-05 0.0000
frameDigitalSupplyVoltage 0-06 5.0000 frameBoardTemp01 0-07 1.1328
frameThermRefVoltage01 0-08 5.0000 frameA2DPosSupplyVoltage0 0-09 15.0187
frameA2DNegSupplyVoltage0 0-10 -14.691 frameA2DRefSupplyVoltage01 0-11 4.9609
Enter ’s’ to collect/display stats for a signal or ’q’ to return to menu
Figure 4-10 aim Input Values
The statistics function for the selected analog input, will calculate and display the
number of samples, mean, high, low, variance, and standard deviation, for as long
as the display is active. Both the accumulated and the most recent delta values are
displayed. See Figure 4-11 for an example. Keep in mind that any external
interference in the signal, such as a standardize cycle, will be reflected in the
displayed results.
ANALOG INPUT MONITOR (AI channel statistics)
Analog Input Statistics for headPosition01
Accumulated
Delta
Samples 200 50
Mean: 51.050 51.050
High: 51.050 51.050
Low: 51.050 51.050
Variance: 0.000 0.000
Std Dev: 0.000 0.000
Figure 4-11 aim Statistics Display Page
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AI Channel Gains Report
Figure 4-12 shows the gain (attenuation) being applied to analog inputs on channels
1, 2, 3, 5, 6, 7, 8, 9, 10, and 16 on board 0. A gain (or attenuation) of 255 indicates
no attenuation. A Gain of 128 would indicate a 0.5 attenuation.
ANALOG INPUT MONITOR (SOFTWARE GAINS)
Signal Name Bd-Ch Gain Signal Name Bd-Ch Gain
framePurgeAirFlow01 0-01 0 powerShelfTemp01 0-02 0
motorControllerTemp01 0-03 0 frameAnalogOutVoltage01 0-05 0
frameDigitalSupplyVoltage 0-06 0 frameBoardTemp01 0-07 0
frameThermRefVoltage01 0-08 0 frameA2DPosSupplyVoltage0 0-09 0
frameA2DNegSupplyVoltage0 0-10 0 frameA2DRefSupplyVoltage01 0-11 0
headPosition01 0-16 0 0
Figure 4-12 aim Software Gains Report
AI Channel Slopes and Offsets Report
The same channels having gain adjustments also have adjustable slopes and offsets.
All other channels are given a fixed slope of 1.0 and a fixed offset of 0.0. Slopes
and offsets are computed at the beginning of each standardize and after each reset.
See Figure 4-13.
ANALOG INPUT MONITOR (A/D slopes & offsets)
Signal Name Slope Offset Signal Name Slope Offset
framePurgeAirFlow01 0.0394 0.0000 powerShelfTemp01 0.0394 0.0000
motorControllerTemp01 1.0000 0.0000 frameAnalogOutVoltage01 0.0391 0.0000
frameDigitalSupplyVoltage 0.0391 0.0000 frameBoardTemp01 0.0195 0.0000
frameThermRefVoltage01 0.0391 0.0000 frameA2DPosSupplyVoltage0 0.0844 0.0000
frameA2DNegSupplyVoltage0 0.0342 -18.38 frameA2DRefSupplyVoltage01 0.0391 0.0000
headPosition01 1.0000 0.0000
Figure 4-13 aim Slopes and Offsets Report
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Analog Input Signal Verification and Tracing
This section deals with the tools available to analyze these issues and to provide
some direction in pursuing fault detection and isolation including:
• Checking signal level as seen by software.
• Determining the noise level present on the signal.
• Tracing the signal from point of origin in the platform or sensor head to the
microcontroller.
As a quick check to see if analog signals are being received into the system, use the
aim utility. The aim utility displays the complete array of sensor and Platform
related analog inputs giving the name, aim channel, and current value. The current
value is refreshed every five seconds. Figure 4-14 shows an example of the aim
analog input display.
Note:
Since data on this display is refreshed, turn off the printer by pressing
Shift–F2. If you want a hard copy of the data, press
Shift–Print Screen.
aim Diagnostic Utility (input voltage)
Signal Name Channel Volts Signal Name Channel Volts
beta01 16 0.093 headPosition01 19 2.073
IRMoistureAbsorption01 20 6.769 IRFiberAbsorption01 21 5.492
IRMoistureReference01 22 6.632 IRFiberReference01 23 5.639
detectorColumnTemp01 28 1.690 detectorGapTemp01 29 1.670
SourceGapTemp01 30 1.661 sourceColumnTemp01 31 1.680
Enter s to collect/display statistics for a channel or q to return to menu
Figure 4-14 Example of aim Analog Input Display
An additional aim function useful in troubleshooting analog input problems is
Statistical analysis of any analog input. This gives a running calculation of the
mean, high, low, variance, and standard deviation for as long as the variable is
selected. When looking at sensor inputs, it is best to place the system in single
point to avoid the periodic interference of the standardize mode which will affect
the data.
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Using the Diagnostic Card Adapter
It is possible to monitor the signals as they enter the Scanning Platform backplane
connector panel. The signal connector panel on the backplane provides a parallel
set of input connectors labeled Diagnostics, which use the Test Cable assembly
(p/n 085126-002). Figure 4-16 shows the position of these connectors on the
backplane. Test Card Kit (p/n 086086-005) should be used to identify the signal
assignments for each connector.
Note:
The Test Card Kit is primarily for use with the -003 backplane. For
a -004 backplane, use the generic diagnostic card from the kit. It
does not have any predefined functions on it, but does give the
correct pin numbers associated with the diagnostic plug to which the
adaptor is connected. Use the System Functional Diagrams from
the appropriate Scanning Platform Print Book, 3BUS 208 006
RXX01 or
3BUS 208 007 RXX01, to determine the pin numbers for desired
functions.
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Figure 4-15 ASPC Backplane (-003 Version Shown)
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The Scanning Platform diagnostic card 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. Refer to Figure 4-16.
Test Card Kit
Smart Processing Center
Test Board Kit
Scanning
Platform
Top Signal
J3
TOP SIGNAL
J1
TOP
SIGNAL
DIAGNOSTICS
J2
J4
TOP POWER
DVM
Figure 4-16 Test Board Hookup
There is a separate test card for each diagnostic connector. Use a DVM or
oscilloscope to monitor the desired signals at the test panel after inserting the correct
test card.
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Note:
Note that the current diagnostic card inserts when used on the signed
connectors of the ASPC backplane are only for the -003 version of
the backplane. For a -004 backplane, use the universal card insert
and refer to the -004 system functionals for pin function. The
Diagnostic Card Adapter can be used to examine signals from the
carriage assembly. Refer to Figure 4-17.
NOTE: Static Box is not shown
AUX SIGNAL
AUX POWER
SIGNAL
POWER
Idler End View
Figure 4-17 Carriage Assembly
Note:
The Aux Signal is never used. Aux Power is only used with old Ash
Sensors to access the external J–box.
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Diagnostic Cards
The Scanning Platform Top Power card is to be used for diagnostics performed at
the sensor only. Refer to Figure 4-18.
1 POWER COMMON
SYSTEM
-12 VDC
20
2 HV TEST CARRIAGE
21 +12 VDC
ONLY
SYSTEM
IR
120 VAC
ABB®
LO
HI
19
37
CALIPER
PRESSURE LO 36
22 RETURN
GLOSS LAMP
23 POWER
120 VAC
HEATED
AIR WIPE LO 35
HI 34
24 RETURN
OPTIPAK LAMP
ASH
HEATER
LO 33
25
POWER
120 VAC
HI 32
28 -15 VDC
27
SIGNAL
COMMON
28 +15 VDC
SYSTEM
BW
HEATER LO 31
CALIPER
HEAD LIFT
SOLENOID LO 30
SCANNING PLATFORM
TOP POWER
086086-052, SIDE 1, REV A
Figure 4-18 Diagnostic Card: Top Power
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The Scanning Platform Bottom Power card is to be used for diagnostics performed
at the sensor only. Refer to Figure 4-19.
1 POWER COMMON
20 -12 VDC
SYSTEM
ABB®
19
37
21 +12 VDC
BW SHUTTER
LO 36
22 SHUTTER
ASH
23 FLAG
24 RETURN
GLOSS LAMP
25 POWER
CALIPER HEATER/
VACUUM/PURGE LO 35
120 VAC
ASH
HEATER
120 VAC
HI 34
LO 33
HI 32
26 -15 VDC
27 SIGNAL
COMMON SYSTEM
28 +15 VDC
BW
HEATER
HEATED
AIR WIPE
LO 31
LO 30
SCANNING PLATFORM
BOTTOM POWER
086086-052, SIDE 2, REV A
Figure 4-19 Diagnostic Card: Bottom Power
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The Scanning Platform Top Signal card is to be used for diagnostics performed both
at the sensor and the Smart Processing Center -003 backplane. Refer to Figure 4-
20. For a -004 backplane, use the universal card insert and refer to the system
functionals.
1 ASH (Purge)
ABB®
20 COMMON
DIAGNOSTIC
IR LAMP SENSE
19
2 BW (Purge)
21 HI
3 LO
22 HI
4
23
5
24
6
25
7
26
8
27
9
28
10
LO
HI
LO
HI
LO
HI
LO
HI
LO
GAP
SENSOR
CAP
or ATC COLUMN
+4.5V BIAS
BW
ASH
BRIGHTNESS
ATC GAP
BW
INTERLOCK
GLOSS
CALIPER
AIR
BEARING
BW
THERMISTOR
GLOSS CLAMP
OPTIPAK CLAMP
AUTO EDGE
OF SHEET
ELECTROMETER
TEST/CLAMP
SHEET
TEMPERATURE
ASH
IR
LOGIC
SCANNING PLATFORM
TOP SIGNAL
086086-051, SIDE 1, REV A
OFF
ON
ASH
BW
LO
HI
THERMISTOR
+4.5V BIAS
LO
HI
37
18
36
17
35
16
34
15
33
14
32
13
31
12
30
11
29
Figure 4-20 Diagnostic Card: Top Signal
132 ABB Smart Processing Center (ASPC) Hardware
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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.
The Scanning Platform Bottom Signal card is to be used for diagnostics performed
both at the sensor and the Smart Processing Center -003 backplane. Refer to Figure
4-21 for the sensor card and to Figure 4-22 for the Backplane diagnostic card. For
the -004 backplane, use the universal insert card and refer to the system functionals.
1
ASH (Purge)
ABB®
20
COMMON
DIAGNOSTIC
19
2
BW (Purge)
GLOSS CLAMP
37
21
3
22
4
HI (-)
LO
HI
LO
FORMATION
CALIPER
PROXIMITER
OPTIPAK CLAMP
ASH
SHUTTER
SWITCH
CURRENT
MONITOR
MONITOR
COMMON
18
36
17
35
23
5
HI
LO
OPACITY
X-RAY H.V.
MONITOR
16
34
24
6
25
7
26
8
27
9
28
10
INTERNAL CAP
or ATC COLUMN
+4.5V BIAS
HI
LO
HI
LO
HI
LO
THERMISTOR
+4.5V BIAS
GLOSS
OPTIPAK
VACUUM
CALIPER
VACUUM/
THERMISTOR
BW
THERMISTOR
ASH
BW
IR
ALARM
GRID
SHUTTER
SWITCH
INT. CHECK
SAMPLE
GAIN
MONITOR
LO
SIGNAL
HI
DECREASE
GAIN
GAIN
+15V
INCREASE
GAIN
15
33
14
32
13
31
12
30
11
29
SCANNING PLATFORM
BOTTOM SIGNAL
086086-051, SIDE 2, REV A
Figure 4-21 Diagnostic Card: Bottom Signal Sensor
3BUS 208 055 R1101
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133

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reproduction, or other means of dissemination may be made without written permission.
ABB®
TOP POWER
CALIPER HEAD
LIFT SOLENOID
120VAC HI
120VAC HI
CALIPER
PRESSURE
IR 120VAC LO
J3
J4
BW HEATER
ASH HEATER
HEATED
AIR WIPE
IR 120VAC HI
CHASSIS
-12VDC
GLOSS LAMP
RETURN
OPTIPAK LAMP
RETURN
-15VDC
+15VDC
POWER COMMON
+12VDC
GLOSS LAMP
POWER
OPTIPAK LAMP
POWER
SIGNAL COMMON
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
BOTTOM POWER
10
9
8
7
6
5
4
3
2
1
J17
10
9
8
7
6
5
4
3
2
1
J18
BW HEATER
ASH HEATER
CALIPER HEAT/
VACUUM/PURGE
CHASSIS
-12VDC
ASH SHUTTER
GLOSS LAMP
RETURN
-15VDC
+15VDC
HEATED
AIR WIPE
120VAC HI
120VAC HI
BW SHUTTER
POWER COMMON
+12VDC
ASH FLAG
GLOSS LAMP
POWER
SIGNAL COMMON
SCANNING PLATFORM
BACKPLANE POWER
086086-053, SIDE 1, REV A
Figure 4-22 Diagnostic Card: Backplane Power
134 ABB Smart Processing Center (ASPC) Hardware
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
The Scanning Platform Bottom Auxiliary Power card is to be used for diagnostics
performed at the sensor only. Refer to Figure 4-23.
1
20
ASH +15V
-12 VDC
SYSTEM
ASH
FILAMENT
ABB®
VOLTAGE
RETURN
19
37
21
+12 VDC
36
22
ASH COMMON
ASH +28V
35
23
ASH -15V
120 VAC
HI
34
24
25
LO
WIPER
ASH
H.V.
ADJUST
ASH +28V
RETURN
120 VAC HI
33
32
26
-15 VDC
31
27
SIGNAL
COMMON
SYSTEM
30
28
+15 VDC
SCANNING PLATFORM
BOTTOM AUX POWER
(ASH WITH REMOTE J-BOX ONLY)
086086-053 SIDE 2, REV A
Figure 4-23 Diagnostic Card: Bottom Auxiliary Power
3BUS 208 055 R1101
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135

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reproduction, or other means of dissemination may be made without written permission.
The Scanning Platform Detector Module card is to be used for diagnostics
performed at the sensor only. Refer to Figure 4-24.
1
+12 VDC
ABB®
20
PURGE SIGNAL HI
19
2
21
-12 VDC
ELECTROMETER
TEMP C/10
HEATER LO
CHASSIS GROUND
37
18
3
CHASSIS GROUND
HEATER HI
36
22
CAP THERMISTOR
17
4
23
5
+15 VDC CHASSIS GROUND
-15 VDC
THERMISTOR
+4.5V BIAS
GAP SIGNAL LOW
STLK11 AND STLP3 ONLY
35
16
34
24
15
6
25
7
SIGNAL COMMON
SIGNAL COMMON
GAP BD TEMP C/10
STLK11 AND STLP3 ONLY
GAP SIGNAL HIGH
STLK11 AND STLP3 ONLY
ELECTROMETER TEST
(TEST = LOW)
33
14
32
26
13
8
31
27
ELECTROMETER
LOW
12
9
28
10
CHAMBER HV/100
GAP OSCILLATOR
STLK11 AND STLP3 ONLY
ELECTROMETER
HIGH
30
11
29
STLK-11, STLP-3, STLXR-3
SENSOR DIAG. (TOP)
086086-055, SIDE 1, REV B
Figure 4-24 Detector Module Diagnostics Card
136 ABB Smart Processing Center (ASPC) Hardware
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
The Scanning Platform Source Module card is to be used for diagnostics performed
at the sensor only. Refer to Figure 4-25.
1
20
+12 VDC
BW ALARM GRID
(+12V)
ABB®
PURGE SIGNAL HI
19
2
-12 VDC
HEATER LO
37
21
CHASSIS GROUND
18
3
CHASSIS GROUND
HEATER HI
36
22
CAP THERMISTOR
17
4
23
CHASSIS GROUND
THERMISTOR
+4.5V BIAS
35
16
5
34
24
SHUTTER SWITCH
NC (RED)
15
6
33
25
7
SHUTTER SWITCH
NO (GREEN)
ASH FILAMENT
CURRENT
14
32
26
8
27
9
SHUTTER
+5V REFERENCE
STLXR3
CHECK SAMPLE
ASH MONITOR
COMMON
ASH ANODE
CURRENT
13
31
12
30
28
11
10
ASH X-RAY
H.V./1000
29
STLK-11, STLP-3, STLXR-3
SENSOR DIAG. (BOTTOM)
086086-055, SIDE 2, REV. B
Figure 4-25 Source Module Diagnostics Card
3BUS 208 055 R1101
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137

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reproduction, or other means of dissemination may be made without written permission.
Replacement Parts
If the Test Cable assembly has disappeared, order the following parts:
Test Card Kit 086086-003
Test Board Kit 085126-002
Overlays 086086-005
086086-006 (TetraPak)
138 ABB Smart Processing Center (ASPC) Hardware
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reproduction, or other means of dissemination may be made without written permission.
LED Interpretation
Basic troubleshooting that can be done using the LEDs in the Scanning Platform
electronics cabinet.
Power Supply LEDs
The power supply LEDs are in the Scanning Platform electronics cabinet. Use the
following table to assist you in troubleshooting the Scanning Platform electronics.
Refer to Table 4-1 and Figure 4-26.
Table 4-1 Interpretation of LEDs
LEDs
DC IN
on ECPSR
DISABLE
+15 V
-15 V
+5 V
DESCRIPTION
This LED refers to the 24 VDC power
supply for the Scanning Platform
electronics cabinet.
When this LED is lit, the power supply
is on but may not be within acceptable
tolerance.
This LED refers to the 24 VDC power
supply for the Scanning Platform
Electronics cabinet.
When this LED is lit, 24 volts is not
within acceptable tolerance and the
+5V and ± 15V power supply has been
shut down.
These LEDs refer to the presence of
their respective voltages within the
Scanning Platform electronics cabinet.
When these LEDs are lit, the respective
voltages are within acceptable
tolerances.
3BUS 208 055 R1101
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139

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reproduction, or other means of dissemination may be made without written permission.
ECF, ECS, and ECC LEDs
These LEDs are located on the ECF, ECS, and ECC boards in the Scanning Platform
electronics cabinet. Use the following table to assist you in troubleshooting. Refer
to Table 4-2 and Figure 4-26.
Table 4-2 ECF/ECS/ECC LED Interpretation.
LEDs
RTSA (green)
ERROR (red)
RUN (green)
RTSB (green)
DESCRIPTION
The LED flashes when HDLC Port A
has set its request to send and is
attempting to transmit data.
The intensity of the flashing depends
on how much data is being transmitted.
This LED indicates status of local
diagnostics; it is under software control
on a reset.
If the LED stays on after reset, replace
the SMI.
If the LED is flashing, check the service
console.
If the LED is off and the RUN light is
flashing, conditions are normal.
If there are no LEDs lit, check to make
certain there is power to the board.
This LED is driven by the data strobe
and indicates the level of 68332
external bus activity.
The intensity of the LED varies from
dim to bright depending upon bus
activity.
This LED is not currently being used
and should be off.
ECF and ECC Boards (Only)
LEDs
RxA (ECC and ECF)
RxB (ECC and ECF)
RxC (ECF)
RxD (ECF)
RxE (ECF)
RxF (ECF)
DESCRIPTION
These boards have serially connected
devices attached to them. For the ECF
board, it is one or more frame control
modules. For the ECC board, it is one
or two color sensor module pairs. In all
cases, the green LED shows the level
of activity on the serial line.
140 ABB Smart Processing Center (ASPC) Hardware
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
MPRC LEDs
These LEDs are located on the MPRC board in the Scanning Platform electronics
cabinet. Use the following table to assist you in troubleshooting. Refer to
Table 4-3 and Figure 4-26.
Table 4-3 086349-002 MPRC LED Interpretation
LEDs
ERROR (red)
RUN (green)
RX TERMINAL
RX HOST
DESCRIPTION
This LED indicates status of local diagnostics; it is
under software control on a reset.
If the LED stays on for more than 30 seconds after
reset, replace the MPRC board.
If the LED is flashing, check the service console.
During loading, it should be flashing.
If the LED is off and the RUN light is flashing,
conditions are normal.
If there are no LEDs lit, check to make certain there
is power to the board.
This LED is driven by the data strobe and indicates
the level of 68332 external bus activity.
The intensity of the LED varies from dim to bright
depending upon bus activity.
When the LED is lit (flashing), there is a physical
connection to the terminal.
When the LED is not lit, the physical connection to
the terminal is broken.
When the LED is lit (flashing), there is a physical
connection to the terminal.
When the LED is not lit, the physical connection to
the terminal is broken.
3BUS 208 055 R1101
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Table 4-4 086444-001 MPRC LED Interpretation
LEDs
ERROR (red)
RUN (green)
NET TX_B (green)
NET TX_A (green)
RTS 0 (green)
RTS 1 (green)
RTS 2 (green)
RTS 3 (green)
RX TERMINAL
(green)
RX HOST (green)
Description
This LED indicates status of local diagnostics; it is under
software control on a reset.
If the LED stays on after reset, replace the MPRC.
If the LED is flashing, check the service console.
If the LED is off and the RUN light is flashing, conditions
are normal.
If the LEDs are not lit, check to make certain there is power
to the board.
This LED is driven by the “Transfer in Progress” and
indicates the level of 68040 external bus activity.
The intensity of the LED varies from dim to bright
depending upon bus activity.
When lit, the Ethernet port on J2 (Port B) is transmitting
data.
When lit, the Ethernet port on the ASPC Host Connector
(Port A) is transmitting data.
HDLC Port 0 is transmitting to the sensor microcontrollers.
When lit, HDLC Port 1 is transmitting to the sensor
microcontrollers.
When lit, HDLC Port 2 is transmitting (unused in Scanning
Platform).
When lit, HDLC Port 3 is transmitting (unused in Scanning
Platform).
When the LED is lit or flashing, there is a physical
connection to the terminal.
When the LED is not lit, the physical connection to the
terminal is broken.
When the LED is lit or flashing, there is a physical
connection to the host.
When the LED is not lit, the physical connection to the host
is broken.
142 ABB Smart Processing Center (ASPC) Hardware
3BUS 208 055 R1101

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Figure 4-26 Smart Plarform Electronics Cabinet (-003 Backplane)
3BUS 208 055 R1101
ABB Smart Processing Center (ASPC) Hardware
143

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ERROR
RUN
RXA
RXB
RXC
RXD
RXE
RXF
RTSA
ERROR
RUN
RTSB
SMI
Board
RTSA
ERROR
RUN
RTSB
SMI
Board
START MODE
EXTEN
DIAG
ECS
ECF
SHORT
DIAG
STOP/
DEBUG
BRAM
Board
RX HOST
RESET
MPRC
Figure 4-27 Location of SMI and BRAM Boards
144 ABB Smart Processing Center (ASPC) Hardware
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
OPTIPAK
GLOSS 1
GLOSS 2
Lights
DISABLE
DC IN
Lights
I J
300V
Side View
+12V OUT
-12V OUT
Lights
NOTE: If you pull the sled out and it tips down,
the sled disconnects from the rails.
Idler End
Figure 4-28 Location of OSPS2 and EC24V (SP1200)
3BUS 208 055 R1101
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145

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Analog and Digital I/O Documentation
The subsystem can document the channel assignments and configuration of the
analog and digital input/output signals associated with the application. The
information is presented in two different reports. The first one is a list of the channel
assignments broken down by hardware device.
The second report shows the logical groupings of the various inputs and gives the
sampling rates associated with each.
To print out these two reports, proceed as follows within the inspect utility:
• For the I/O configuration:
()[ucHardware printOnConsole]
• For the logical grouping and sampling rate:
()[lucGroup printOnConsole]
at 0: ucHardware (UCSubsystem)
SP Number
ECF/ECS Slot Number
at 0: ucFrame01 (UCFrame) [-->FRAME_UC hdlc_addr:0x1f
Port Number
at 0: ucFrame01_port00 (UCAnalogPort)
Channel Number
at 1: ucFrame01_port00_ch01 (UCAnalogChan)
[-->framePurgeAirFlow01_ai]
Figure 4-29 Example of Analog I/O Documentation
146 ABB Smart Processing Center (ASPC) Hardware
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
Power Down Analysis
The Scanning Platform software monitors temperatures at various points in the
system. Using pre–established limits, the user is advised when safety maintenance
limits are violated, and also when a power shutdown is about to take place. There
are two situations where the system will alert the workstation of a temperature
condition which needs to be attended to. The first is a SAFETY LIMIT ALARM
which warns of a temperature situation which needs attention. The second is a
POWER DOWN ALERT which will output the power down report just before it
trips the main power circuit breaker one minute after it has been announced. Just
before turning off the breaker, the workstation will display a report of the various
board and sensor temperatures in the AVOS window (if the workstation is
connected). This report is also available for at least the first two minutes after the
next restart by invoking the shell script “/ss01/clm/pwrdninf”. This section will
discuss the safety interrupt alert message, the power down report, and the power
history log of the micro-controllers.
Safety Interrupt Alert
The Electronics Health Page will report a safety maintenance condition if any of
the board temperatures in the system exceed the associated maintenance alarm limit.
The Safety Limit and Power Down limits are shown in Table 4-5. This maintenance
level alarm will show on the ALARM PAGE (F2 key) as “A BOARD
TEMPERATURE IS OUT OF LIMITS”. This notification is not sent to the host.
When the temperature exceeds the Power Down limit, there is a notification given
to the host as well as a screen message to the workstation. There is a delay of about
one minute before the actual shutdown occurs. If the workstation screen is being
monitored at the time of the shutdown event, the message to the screen will read:
SETTING SAFETY INTERRUPT bit:x
(safetyInterruptBits = y)!!
Here is how to interpret this information:
x = 0 - Ash Air Temp Safety
1 - Basis Weight Air Temp Safety
2 - Caliper Probe Temp Safety
3 - Power Down Safety
3BUS 208 055 R1101
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147

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reproduction, or other means of dissemination may be made without written permission.
y = 0 - ECF board, UC slot 0 Temp
1 - ECS board, UC slot 1 Temp
2 - ECS board, UC slot 2 Temp
3 - ECS board, UC slot 3 Temp
4 - ECS board, UC slot 4 Temp
5 - ECS board, UC slot 5 Temp
6 - ECS board, UC slot 6 Temp
7 - ECS board, UC slot 7 Temp
8 - End Column Power Supply Temp
9 - Power Shelf Temp
10 - Motor Controller Temp
11 - Beam Air Flow (di)
12 - Chiller Flow (di)
13 - Ash Air CAP/GAP Temp
14 - BW Air CAP/GAP Temp
15 - Caliper Probe Temp
Table 4-5 Alarm Limits for Each Variable
Temperature Categories
Safety limit
(°C)
Power Down
(°C)
All ECS board and platform temperatures 50 65
ECF Board Temperatures 59 69
Basis Weight Temperatures with gap 100 125
Basis Weight Temperatures without gap 130 148
Ash Temperatures with gap 100 125
Ash Temperatures without gap 90 125
Caliper Temperatures 130 148
148 ABB Smart Processing Center (ASPC) Hardware
3BUS 208 055 R1101

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Power Down and DC Power Analysis
If the system resets because of a power down condition, the cause can be determined
by printing out an array of temperature and DC power data through a shell script.
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 and
record, in a buffer, the current values of alll of the temperatures. When the power
down limit is exceeded, the temperature data is again read into the buffer. This
buffer is stored in the /ss01/history BRAM disk area so that it is available at the
next startup. Upon startup, the file is read in and is available for display using a
shell script command. While several variables may have exceeded their safety alarm
limit, the file shows the snapshot of the data at the moment the safety limit or power
down event occurs.
The report is in two parts. The first part is the UCONTROLLER SUBSYSTEM
TEMPERATURES WHERE safety interrupt temperatures are recorded. The
second part of the report consists of a temperature and voltage log for each of the
microcontrollers in the system. In the first report, all temperatures (boards and
sensors) are presented and the offending temperatures is flagged by using up to
three asterisks. A single asterisk (*) will be issued for a maintenance limit violation.
If there is a second asterisk just adjackent to the first one, it means that the offending
signal has created a SAFETY INTERRUPT which will force the head to come offsheet.
A third asterisk position, in the next character position to the right, indicates
that the signal is responsible for a power shutdown condition. it is possible to get
the following combinations of asterisk markers:
• * for safety
• ** for taking head off-sheet
• *b* (the “b” indicates a space) for forcing a power down
There can be other entries in the table with 0.0 values reported. Since this is a report
that supports a maximum configuration, these unavailable entries can be ignored.
In general, the sensor temperatures associated within the head envelope are the ones
which will take the head off-sheet if the safety limit is exceeded. Temperatures
associated with the scanner structure and end column electronics, will take the
power down. In the example shown in Figure 4-30, the topcolor_btmbrdTemp
tamperature is flagged as being the offending temperature giving a safety limit
alarm. This report can be obtained at any time, but will only contain data if an alarm
limit is violated. Otherwise, the data is all 0.0.
Table 4-7 on page 151 shown the subsystem temperature report. The information
in italics is not printed, but is shown here to help decipher the somewhat cryptic
labels.
Table 4-6 on page 150 shows the associated alarm limits for each of the variables.
3BUS 208 055 R1101
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149

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reproduction, or other means of dissemination may be made without written permission.
Table 4-6 Alarm Limits for Each Variable
Temperature Categories Safety Limit (°C) Power Down (°C)
All board and platform temperatures 50 65
Basis Weight Temperature with gap 100 125
Basis Weight Temperature without Gap 130 148
Ash Temperature with Gap 100 125
Ash Temperature without Gap 90 125
Caliper Temperature 130 148
Color SCMM Temperature 65 70
Color SBTM Temperature 65 70
150 ABB Smart Processing Center (ASPC) Hardware
3BUS 208 055 R1101

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Table 4-7 Subsystem Temperature Report
UCONTROLLER SUBSYSTEM TEMPERATURES: 11-11-98 13:30:47
brdTemp[ 0 ]: 26.92 -> (frame)*
brdTemp[ 1 ]: 23.61 -> (basis weight)
brdTemp[ 2 ]: 0.00 -> (IR Moisture)
brdTemp[ 3 ]: 24.45 -> (caliper)
brdTemp[ 4 ]: 0.00 -> (optipak/gloss)
brdTemp[ 5 ]: 0.00 -> (gloss/top refl. IR)
brdTemp[ 6 ]: 25.43 -> (ash/bot refl. IR)
brdTemp[ 7 ]: 23.30 -> (general)
ecpsTemp: 25.34 ->
(end column temperature)
pshelfTemp: 22.36 -> (power supply shelf)
mcTemp: 21.89 -> (motor controller)
beamAirFlowAlm: (BOOL)0OK (beam air flow flag)
chillFlowAlmA: (BOOL)0OK
(LCU 1 flow)
chillFlowAlmB: (BOOL)0OK
(LCU 2 flow)
spare: (BOOL)0 UNUSED
ash_sct: 0.00 -> (smart ash source)
ash_dct: 0.00 -> (smart ash detector)
ash_sht: 0.00 -> (‘old’ ash source)
beta_sct: 54.94 -> (smart weight source)
beta_dct: 55.01 -> (smart weight detector)
beta_sgt: 0.00 -> (‘old’ weight source gap)
beta_dgt: 0.00 -> (‘old’ weight detector gap)
beta_sht: 0.00 -> (‘old’ weight source head)
beta_dht: 0.00 -> (‘old’ weight detector head)
caliper_probTemp: 0.00 ->
(cont. caliper probe)
topcolor_cmmt: 0.00 -> (top color SCMM head)
topcolor_btmt: 50.00 -> (top color SBTM head)
topcolor_btmbrdTemp:65.29 ->
(top color SBTM smi board)
bottomcolor_cmmt: 0.00 ->
(bot color SCMM head)
bottomcolor_cmmt: 0.00 ->
(bot color SBTM head)
bottomcolor_btmbrdTemp: 0.00 -> (bot color SBTM smi board)
* Text shown in this column in italics is shown for clarification and does not
appear in the actual report.
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Micro-Controller DC Power Log
Figure 4-30 shows an example of the historical trend of each microcontroller’s DC
voltages. It is a rotating buffer of the last 20 updates. A snapshot update of all the
DC power on the board is made each time a new high or low value for any of the
DC levels is detected. If there has not been movement of a new high or low in a
24-hour period, the system will take a snapshot of the current values (the actual
interval is slightly more than 24 hours). The check for a high or low is made every
minute. This data can be viewed on demand either by looking at the Electronics
Health Report (pages 3 and on), or by executing the shell script. Reviewing this
data is useful in determining trends in power supply drift. To print out both reports,
at the AVOS shell ($$ prompt), type:
. ∆ /ss01/clm/pwrdninf
The system displays, on the screen and printer (if available), the Power Down report
including the microcontroller temperature and the DC power history for each
microcontroller in the system.
The system displays, on the screen and printer (if available), the Power Down report
including the microcontroller temperature and the DC power history for each
microcontroller in the system.
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Date Temp Vapos Vaneg Vref Vtref Vdig
12-12-1991 11:19:56 33.90 15.10 -14.96 5.00 5.00 5.00
12-12-1991 11:20:58 33.40 15.10 -14.96 5.00 5.00 5.00
12-12-1991 11:25:01 33.90 15.02 -14.96 5.00 5.00 5.00
12-12-1991 11:28:03 33.90 15.10 -14.96 5.00 5.00 5.00
12-12-1991 11:36:07 33.90 15.10 -14.92 5.00 5.00 5.00
12-12-1991 11:52:13 33.40 15.10 -14.96 5.00 5.00 4.96
12-12-1991 13:56:14 32.90 15.10 -14.96 5.00 5.00 5.00
12-12-1991 14:32:40 33.40 15.10 -14.96 5.00 5.00 5.04
12-12-1991 14:40:48 33.40 15.10 -14.96 5.00 5.04 5.00
12-12-1991 16:31:46 33.40 15.10 -14.96 4.96 4.96 5.00
12-13-1991 08:31:33 32.90 15.10 -14.96 5.00 5.00 5.00
12-13-1991 08:32:35 33.40 15.10 -14.96 5.00 5.00 5.00
12-13-1991 08:34:38 33.40 15.10 -14.96 5.00 4.96 5.00
12-13-1991 08:35:39 33.40 15.10 -14.92 5.00 5.00 5.00
12-13-1991 08:36:40 33.40 15.02 -14.92 5.00 5.00 5.00
12-13-1991 08:45:47 33.40 15.10 -14.96 5.00 5.00 4.96
12-13-1991 08:47:49 33.90 15.10 -14.96 5.00 5.00 4.96
12-13-1991 09:20:07 33.40 15.02 -14.96 5.00 4.92 5.00
12-13-1991 10:06:07 33.40 15.10 -14.96 4.96 5.00 5.00
12-13-1991 11:02:43 33.90 15.10 -14.96 5.00 5.04
Figure 4-30 Historical Trend for Microcontroller DC Voltages
Note the following definitions for Figure 4-30:
Vref - is the A to D signal
Vtref -
is the thermistor reference
Vdig - is the logic signal for the A/D test signal on the ECF
board only
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5
Software Diagnostic Tools
This chapter is about using software to diagnose resource, application, and
operations problems.
This chapter contains the following major sections:
Section ...............................................................................................Page
Software Diagnosis ........................................................................................ 156
Identifying Sensor Configuration ................................................................... 164
Identifying Software Release Levels ............................................................. 165
Signal/Measurement Processing Analysis and Reporting (smr) .................... 168
Resource Checks ............................................................................................ 180
How to Start the Scanning Platform .............................................................. 185
Displaying Reports within inspect ................................................................. 187
Preparing On–Site Documentation ................................................................ 190
Operation of the Sensor Health Pages ............................................................ 191
Off-Line Debug .............................................................................................. 195
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Software Diagnosis
This section focuses on general software troubleshooting techniques rather than
specific symptomatic procedures. The idea is to develop an understanding of the
software environment and let the specific procedures evolve from that
understanding. There is also a discussion of the various tools and utilities available
to the user.
General Software Troubleshooting Techniques
While most people agree that system software troubleshooting can be an art,
everyone’s skill on a Scanning Platform system can be increased by knowing how
the tools available can be used to help solve problems. By showing what information
can be gleaned from the existing utilities, it is hoped that problem analysis will
become more efficient.
Troubleshooting may fall into more than one category. The categories are resource,
operating system, and applications. There are utilities that can be used to help with
all of these areas.
Resource
When a system has been running for some time (hours, days, weeks), but then begins
exhibiting strange behavior, such as new symptoms, large utilities no longer loading,
it is conceivable that a resource is running low or is used up.
One resource problem involves the allocation of memory. There are two main
groupings of memory in the Scanning Platform, one for application usage (this
comes from pool 15), and the other for operating system usage. The two buffer
pools are allocated by adjusting the size of pool 15, with all other memory going to
the other buffer pool, pool 31. The amount of memory available is determined by
using the dfree utility. With the information from that utility in hand, the pools can
be adjusted to give the most available memory to applications. Reserving about
50K bytes for pool 31, modify the pool 15 command in the startup_01_0 script to
give the rest of memory to applications.
Sometimes running out of memory from pool 15 is a consequence of other problems,
such as programs allocating buffers without returning them for reuse. This and
other resource problems can be identified by using the monitor utility. The resource
activity section of this utility will show the currently used number of buffers,
processes, semaphores, and mailboxes, as well as the number allocated and de–
allocated in the previous display period. If the resources do not settle out to a stable
number, a software problem could be the culprit. This is not an easy problem to
find and may require a specialist from ABB in Columbus, Ohio.
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Operating System
Operating system problems occur infrequently. Operating system problems initially
appear as application problems. Some of the symptoms of an operating problem are:
• An error from the derr display that cannot be explained from an application
viewpoint.
• An error resulting from an AVOS service call that should not have been returned.
As an example, an AVOS error resulted when the software attempted to store to an
object that did not allow storing. The object should have allowed storing.
Whenever you suspect an operating system problem, attempt to find an application
code reason for the problem.
Any operating system problems should be referred to one of the program designers
for resolution.
Application
Most problems, if they exist, are in this category. While there is not any road map
to finding application problems, there are many techniques that can be applied to
speed things along. First, print out both map -m and map -s to help identify which
program has the error in it. Also, the information from a dproc printout is useful
in associating a process id with a program name. The dproc printout indicates any
processes that have been aborted. In the Scanning Platform system, this usually
indicates that a bus error or an address error has caused the termination. This can
be confirmed by a printout of derr.
This leads to how to start a problem analysis session. Assuming the maps are already
available, (map -s, map -m, and the dproc printout only need to be performed once
after a release update and kept on hand until needed) the following commands
should be executed at the system console. Refer to Table 5-1.
Table 5-1 “First Step” Utilities to be Run
Utility
derr
bfchk
dfree
monitor
Description
If there are any errors here, start troubleshooting from this report.
This tells if the headers or trailers of any buffer have been damaged.
Any printout here is cause for further investigation.
This will indicate if buffers are being used up. If utilities cannot be
executed, it is usually because there is a memory shortage already.
This will indicate if all available real time is being used up, and if so,
can be used to help find the process responsible.
The preceding guidelines for problem analysis assume that the specific problem is
not known. All these steps usually are not necessary if the reported problem is more
specific. However, even when a better problem description is available, these
commands convey an overall picture of the state of the software.
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AVOS and Application Utilities
AVOS is the operating system for the Scanning Platform. The operating system
interfaces the Scanning Platform’s scanning, measurement processing and other
computing resources with the system hardware. AVOS also supports a console
interface between the Scanning Platform’s computer hardware and technicians
requiring access to the software for setup and troubleshooting.
This section will describe some of the important utilities and procedures required
to interact with the Scanning Platform through the Service Workstation.
General AVOS Utilities
As a reference, some commands are listed here with a description of the data they
provide. Refer to Table 5-2.
Utility
aim
bfchk
derr
dfree
Table 5-2 Software Utility Descriptions
Description
This is a display of all the analog voltage entering the system with a one second refresh
update. It is useful in establishing the actual presence of signals coming from sensors and
the platform.
This command checks the header and trailer of all buffers for damage. When this utility
reports an error, serious, bizarre and/or unrepeatable symptoms may be the result.
Errors reported by this command are usually of a serious nature. Bus errors and address
errors cause a process to be terminated. Unless that error came about through the use of
some other utility, it definitely should be identified. Utility errors can usually be identified
by the process id which will be a 12 if the utility was executed from the normal AVOS shell.
Operating from a sub-shell will result in a very high process id. These errors can be ignored
as they are caused by the abnormal termination of the utility other than by CTRL-BRK.
When a user’s stack has overflowed from an AVOS service being called, the process will
be aborted and a stack overflow error will appear in the printout for this utility.
By indicating a memory situation, this command can point out situations that may cause a
system to crash. By using this utility periodically, it might be possible to anticipate an
approaching error situation. Usually, however, this utility is most useful in deciding how
best to allocate available memory for the buffer pools. After the system has been running a
while (several days), dfree indicates how much memory has been used. With this
information, buffer pool 15 allocation can be changed to hold the majority of free memory.
Be sure to keep about 50K for pool 31 operating system usage.
(continued on next page)
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Utility
dproc
dim
Table 5-2 (continued)
Description
This command is useful to help interpret derr information, specifically, the process
number. Armed with the process number, dproc provides its running state, process name
(if any), and name of the AVOS service currently being used by the process.
This utility displays the current status of the digital inputs to the system. It is updated on
a one second basis and also shows the status of the invert mask for each input.
inspect While the use of the inspect utility is seen as too complicated for most users, it is useful
in tracking down Objective-C errors. The :pm (print methods) command of inspect
provides addresses of methods, and indicates which methods to which an object or class
responds. Because messages can be sent through the inspect utility, interactive
troubleshooting can be performed. (That is, if you want to find out the result of a method,
send a message interactively to execute that method.) Additionally, the inspect utility
provides the means to display and modify instance variables in Objective-C objects, which
can also be used in troubleshooting problems.
map
md
mf
Both the -s and -m options are used to provide information needed to determine which
routine or load module contains the code causing the error.
Allows the display of memory in a variety of formats. Among others supported are hex
and instruction disassembly. The format can be sophisticated enough to display data
structures.
The memory find utility provides a means to search a range of memory for a specific hex
pattern or an ASCII string.
mm The memory modify utility can be used to implement temporary modifications, or if in a
script, a semi-permanent modification.
monitor Of the wide range of information provided by the monitor, much of it is useful in
troubleshooting activities. The resource activity portion shows the dynamics of mailboxes,
semaphores, processes, and buffers. Periodic display of this information may point out
problems of excessive resource consumption. The general time and process time portions
of the utility may indicate real-time problems. If there is no available real time, it may
indicate a looping problem. By using the process time pages to find which process number
is responsible, the dproc printout will then identify the name of the process. The interrupt
activity page of the utility may be helpful in tracking down too many or too few interrupts
for a particular device. The miscellaneous page shows spurious interrupts, which may
indicate a hardware problem.
pe This utility records the most recent 100 events that have taken place application wise in
the system. The messages are not problems, but indicate actions which have taken place
as the result of some other problem. For example, if a major streak has caused the IR
Moisture sensor to change the gain setting, this will be recorded. Other messages will
include such things as sheet breaks and AEOS problems. This is very useful as a starting
place to find out why heads have gone off-sheet.
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Using the software utilities assumes that the system can execute shell commands.
If the system has gone into the panic mode (the OFFLINE_DEBUG prompt is
displayed), there are two commands that may be of use. The e command displays
the panic message, why the system is in panic. But the most useful command is x.
This provides a derr type display of the error log. The oldest error is probably the
one that will lead to the problem.
If the system has halted without the system going into the panic mode, the system
must be reset and the off-line debug routine will execute. This allows display of
the error log (using the x command), possibly pointing to a problem. Unfortunately,
the act of resetting the system will cause the exception vectors to be reset, so if
destruction of these vectors caused the problem, it may be difficult to find.
The inspect Utility
The inspect utility allows examination and modification of instance variables
contained in the Scanning Platform software. To use the inspect utility, it is
necessary to know two things: the name of the object where the variable resides,
and the name of the variable.
The names of the objects which are accessible with the inspect utility are given in
the :global printout. The names of the instance variables residing in any given
object, can be listed by entering the object name while in the inspect utility.
The following procedure illustrates how to run the utility and perform some basic
operations.
1. Place the desired Service Workstation in the inspect utility mode by typing
inspect at the $$ prompt.
The response is as follows if it is the first time inspect has been invoked since
the last Scanning Platform restart or if class files need to be reloaded:
inspect - @(#)inspect.c 1.1 - 88/10/05
inspect:reading class files.
I>
During normal operation only the I> will appear. The I> is the line prompt for
the inspect utility.
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2. Use the following format to enter the requested instance variable:
To display an entire object list of instance variables:
objectName
To display a single instance variable and its value:
objectName->instanceVariableName
To change an instance variable’s value:
objectName->instanceVariableName=value
To list all available object names:
:global
Where:
objectName is the name of the software object containing the desired instance
variable.
instanceVariableName is the instance variable name to be examined.
Value is the new number to be added. It must be in the same format as defined
in the instance variable list.
3. For repeated display or value entry, simply enter a period (.) and press
RETURN. The previously entered command will be repeated.
4. For repeated display or value entry, simply enter a period, ., and return. The
previously entered command will be repeated.
5. If it is desired to take a snapshot of all of the Instance Variables in an object
which can then be examined at leisure using the editor, then precede the Instance
Variable command with:
:out filePathName
Where filePathName identifies the diskette location and file name to be used
to store the requested data. An example of a filePathName might be /ss01/
clm/test. This would create a file called “test” in the clm directory of AMS00x
which has as its root directory /ss01.
All inspect commands entered after :out is setup will go directly to the file
instead of the screen. To restore the responses to the screen, simply type :out
with no arguments.
Instance Variables designated as coldstart will not necessarily respond in the
system when changed. These must be implemented by restarting the Scanning
Platform system.
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The gstore Utility
Modified coldstart instance variables must be stored in their respective .ini files
located in BRAM.
Use the following procedure to store modified instance variables.
1. Make the desired value changes to the coldstart instance variables using the
inspect or genrpt utilities.
2. Make a disk copy of all the existing .ini files in the /clm directory using the
backup procedure.
This puts each .ini file onto diskette where it can be retrieved if something goes
wrong with the subsequent gstore command later in this procedure.
3. After all the changes have been made, write the information to the BRAM using
the gstore utility in the AVOS shell at the $$ prompt:
gstore
The utility responds with a menu selection, see Figure 5-1. Use Table 5-3 to
help make a selection. Answer all the interactive messages as required.
When a selection has been made, the utility will offer the opportunity to
overwrite the existing file, write to a new file, or quit without saving the file.
$$ gstore
Object Graph Storing Utility (imp200.002~)
Selection Object Graph Head of Graph
~~~~~~~~~ ~~~~~~~~~~~~ ~~~~~~~~~~~~~
1 frame (scanner01)
2 frameHI (fhi01)
3 io (ucHardware)
4 pmm (pmmInterface)
5 appl (applGraphHead_01_0)
ENTER selection or q to quit:
Figure 5-1 gstore Menu Screen
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Selection
Table 5-3 gstore Menu Item Descriptions
Object
Graph
Head of Graph
Function
(This section is not part of the
actual menu)
1 frame (scanner01) All coldstart variables associated
with the Scanning Platform
scanning and sensors
2 frameHI (fhi01) All coldstart variables associated
with the push button assignments
on the Scanning Platform control
panel
3 io (ucHardware) All coldstart variables associated
with the analog and digital I/O
4 pmm pmmInterface All coldstart variables associated
with the HOST interface objects
5 appl applGraphHead_01_0 Supplies parameters at start up
which set in motion the order in
which the configuration is linked
into memory. Also contains
information for the Health Pages
relative to frame tuning and the
release level
Note:
Object Graph refers to the file_name. Head of Graph refers to the
object_name.
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Identifying Sensor Configuration
To examine the current configuration of a scanner, follow the steps below.
1. At the $$ prompt type: inspect.
2. At the I> prompt type:
( ) [scanner01 print] for the frame community
or( ) [pmmInterface01 print] for the pmm community.
3. You will receive a printout. See the examples below.
The Scanner01 printout contains the following information.
Example: scanner01 (Scanner1180M) : with AEOS
sheetBrkDet01 (SheetBrkDet)
Servo01 (Servo)
head01 (Head)
Real Sensors:
BetaSensor01 (BetaSensor):with ATC
IRSensor01 (IRSensor) : Type HEMI+
Derived Sensors:
CondWtSensor01 (CondWtSensor)
Sensors Not In Operation:
The pmmInterface0x printout contains the following information.
Example: pmmInterface (PmmInterface)
pmmDriver (PmmDriver):
pmmFrames:
pmmFrame01 (Pmm Frame)
pmmSensors:
pmmBeta01 (Pmm Beta)
pmmCondWt01 (pmmCondWt)
pmmIRSensor01 (pmmIRSensor)
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Identifying Software Release Levels
Finding System Release Levels
The system software is made up of several subsystems all gathered under one system
release identification. In any troubleshooting effort, it is important to know that the
individual subsystem release levels are correct for the specified system release.
This system release level is identified as SPxxx.x in the header portion of each
Health Page. It can also be found by looking at the end of the system startup
sequence, a little before the banner.
Finding Subsystem Release Levels
The various subsystem software release levels for a particular system release are
listed in the release memo for that release.
The major subsystem software areas are:
• Application software
• Microcontroller software
• Lib01 library software
• AVOS software
The following procedure will result in a report which identifies the release level of
each major area.
1. Type the following command while in the AVOS ($$) shell:
.∆/ss01/clm/revid
2. The system will respond with a report. See the following example.
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revision level of the application libraries
/appl/lib/p0_phyl.lc:
p0_phyl.lib:120.1
revision level of the micro–controller software
smi_id.c 120.003 02/03/94 (c) Copyright 1991-1995
ecc.id.c 120.003 02/10/94 ECC (c) Copyright 1993 by ABB Process Automation, Inc.
revision level of LIB01 libraries
/lib01/lib01rev:
lib01_rev.c 300.041 Copyright 1993 by ABB Process Automation, Inc.
revision level of AVOS software
@(#)avos_rev.c 300.002
revision level of the ACE2/GONZO software can be obtained by running REVID utility on
ACE2 directory under DOS
revision level of the Health Page Reports
is found on top of each Health page
The underlined portions shown above indicate the release level of the respective
areas and will not be underlined in the actual report.
Release Level Check of Diskettes
With release SP270.3, an additional method of assessing the release level of the
system software is available. The existing “revid” shell script which is used to
identify the release levels of various major subsystems, is supplemented by a new
utility called rev_hist. This utility will run at every startup and upon demand. Its
purpose is to make sure that the different software subsystems are all from diskettes
having compatible revision levels. Each diskette in the release contains a small file
called “xxrev”, where “xx” is a two-character identifier of the particular diskette.
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Table 5-4 rev_hist Utility ID Codes
2-Digit Code
ac
av
h1
h2
pr
se
a1
a2
sa
sb
ss
Diskette
ACE/GONZO
AVOS
HEALTH1
HEALTH2
PRODUCT
SENSORS
APPL1
APPL2
SCNA
SCNB
SS01 BACKUP
This file specifies the release level of the system when the diskette was built and
also contains the revision level of each diskette that makes up the SP system (there
are 11). The revision files are downloaded (by the various scripts used to transfer
images to the MPRC) to the “/appl/clm” directory for the PRODUCT, SENSORS,
APPL1, and APPL2 diskettes and to the “/lib01” directory for the AVOS diskette.
Every time “rev_hist” is executed, it will search through the five revision files
mentioned above and determine the file with the latest system release. It then uses
that revision file to determine if the other revision files are the correct ones. All
discrepancies in the revision files are reported. If the tool finds a problem at startup
time it will cause the system to go into “migration mode”. It will then be up to the
user to get out of that mode (by following the instructions) and correct the condition.
The revision files for the ACE, HEALTH1 and HEALTH2 diskettes are stored in
the “ace2” directory when those diskettes are installed. They can be used to verify
that the correct version of the diskettes were installed. The “xxrev” files for the
SCNA, SCNB, and SS01 BACKUP are not used at this time.
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Signal/Measurement Processing Analysis and
Reporting (smr)
The smr utility is a data collection tool for the Scanning Platform system which
interactively guides the user through its setup and activation. It is designed to
provide both statistical and historical information on analog input signals and sensor
measurements. In addition to data analysis, a flexible data triggering and capture
capability is provided that uses both analog and digital signals internal to the system.
The user will be able to compare other related data values to these over the same
period. The smr utility is simple enough to set up for most elementary data
collections and capable enough to handle sophisticated investigations.
For example, the utility can be set up to examine statistical and historical data of
the basis weight measurement every time the head position is within a certain set
of limits and the moisture is greater than some limit and then print out data on the
system printer. This would define a particular event configuration which could be
reused.
The utility allows the storage of these smr event configurations in XXX.e files
located in the /ss01/clm directory.
The number of different event configurations that can be stored is directly related
to free space on the /bram1 disk area. However, smr will only process up to three
events at a time. When you develop your event configuration, carefully consider
the other uses your system may have for that memory space.
Summary of smr Capabilities
The following is a summary of smr capabilities:
• Collects snapshot and statistical data on up to nine analog input or measurement
output variables for each event.
• Creates multiple trigger condition within an event, thereby creating a logical
“AND” function to the data collection. For example, report basis weight
measurement when the head position ID is between 100 inches and 120 inches;
and the moisture is greater than 5 percent.
• Multiple events (up to three) can be related to form an “OR” function. For
example, report basis weight measurement whenever head position is either at
100 inches, 150 inches or 175 inches.
• Digital and analog signals can both be used as triggers in the setup of conditions.
For example, report the moisture measurement when a sheet break occurs.
• Automatic display to either the screen or ramdisk file of output data upon the
occurrence of some event. The data is in ASCII format.
• Wide selection of parameters surrounding the definition of triggers.
• Coordinated initialization and report printing of multiple events making up an
“OR” collection group.
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Operation Overview
Each smr session creates, modifies, or activates what will be called an Event. An
Event describes all of the characteristics of both the data capture algorithm
(triggering) and the data analysis outputs. Within this file, the data capture algorithm
is known as the Trigger. The analyses are called Outputs. Each Trigger for each
event is defined by a set of conditional tests on a specified input signal(s) or sensor
measurement(s). These are called Conditions. The Trigger for each event may
contain more than one Condition (within the limits of real–time and memory) and
up to nine Outputs may be requested. Not only can there be multiple Conditions
and Outputs, but duplication of signals within each is allowed. This duplication
allows specification of a logical AND for conditions on the same signal. This
duplication allows the user to narrow his (her) view to precisely the area of concern.
Finally, more than one event may be created or activated at one time, thus allowing
the use of a logical OR for complex Triggers. Figure 5-2 shows a hierarchical view
of Events, Triggers, and Outputs.
The smr utility is menu driven, allowing the user to set up any number of different
data collection events by defining the output(s), the triggering event, and the display
device. Figure 5-3 is a selection tree of the available menu items. It is left to the
user to establish creative uses for this tool in troubleshooting and demonstrating
system performance.
smr
Event A Event B Event C
Trigger
Output
Condition 1 Condition n 1 9
Figure 5-2 Hierarchical View of the smr Utility
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1
Revise or Add
To This Event
1
Add A
Condition
1
Select An
Analog Input
For Triggering
smr Menu Tree
2
Start/Stop
Triggering
1
Edit A Condition
2
Remove A
Condition
2
Select A Sensor
Measurement
For Triggering
smr
Select Global Print/Initialize Of Running Events
3
Display Data
Collection Results
3
Review This
Event’s Trigger
Condition
3
Select A
Digital I/O
For Triggering
Select New Or Existing Event
4
Review This Event’s
5
Save This
Configuration
Event
1 Select An Output Device (screen/File)
2 Display Current Statistical Data
3 Display Current Historical Data
4 Display All Current Data
5 Display Operational Status Of This Data
6 Initialize Statistical Data
7 Initialize Trigger Conditions
4
Create a
Timer For
Triggering
1
Select An
Analog For
Analysis
1
Add An
Output
Figure 5-3 smr Menu Selection Tree
2
Edit An Output
2
Remove An
Output
6
Quit
smr
2
Select A Sensor
Measurement For
Analysis
1 or q Retain this event on exit
2 Kill This Event On Exit
3
Review All
Available Signals
3
Review This
Event’s Outputs
4
Setup Automatic
Reporting &
Retriggering
PROPRIETARY DATA: This document contains proprietary data of ABB Inc. No disclosure, distribution (electronic or otherwise),
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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.
Triggers
There is one Trigger per event. This Trigger is described by the logic contained in
all of its conditions. There is no limit to the number of conditions which make up
a Trigger. However, each condition will require as much as 2000 to 4000 bytes of
memory and consumes real–time. A typical Event made up of one Condition and
one Output will consume approximately 21,000 bytes of memory. The logical
combination of Conditions is always additive (for example – Logical AND) within
an Event. Up to three events may be defined for the same signals in order to provide
a logical OR for the conditions. All configured analog input signals and all
configured sensor output signals (measurements) as well as the associated digital
signals, are available for Triggering. These can be identified by selecting the
“Review all available signals” in the menu. The same signal may be referenced
more than once within an event. Mutually exclusive Conditions within an event
may result in failure of a Trigger.
A Condition is either true or false. A Trigger will occur only when all of its
conditions are true (logical AND). Each condition contributes its state to the
combined state which represents the Trigger. The state of each condition is
determined at the update frequency of the signal to which it refers. Therefore, a
condition which refers to the basis weight measurement will be tested once per
second (50 or 60 data points processed each second, depending on the region’s
power frequency). The effective frequency of testing for the trigger will be the
slowest frequency among all the Conditions which make up the Trigger. Each
condition may be limited in its allowed duration or frequency based on its type. In
each case, the limitation is in counts of the total number of true occurrences of that
condition. There are five types of Condition responses:
• WHILE – Collect data while true for n number of times
• AFTER – Start data collection after n number of true groups
• UNTIL – Collect data until n number of true groups
• REPEAT – Collect data every nth true group
• TIMER – Collect data until timer expires
A WHILE type of condition will become true every time that its logic is true up to
a limit of n times. Unlimited response may be requested by setting n to zero. By
requesting unlimited response for all WHILE conditions in an Event, an automatic
reporting of the Event can be obtained, either to a ramdisk file or the console screen.
An AFTER type of condition will become true after its logic has been true n–times
and will remain satisfied forever afterward.
An UNTIL type of condition response remains true only until n–number of true
occurrences of the conditions.
A REPEAT type of condition will be satisfied cyclically every n–number of times
that it is true.
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A TIMER type of condition is the duration of data collection in terms of minutes
or seconds. The minimum collection time is 1 second; the maximum collection
time is 255 minutes. Data collection will occur from the moment of initiation by
the Trigger and cease at the expiration of the timer.
Conditions can be configured for either analog signals, digital signals, or a timer.
There are nine logical operations available for each analog Condition and five logical
operations for each digital condition.
Within each type of condition described above, there are six logical operations
available as follows:
Analog Conditions:
GT
greater than entered value
LT
less than entered value
RANGE
within an entered range of values
NZERO
a non-zero value
ZERO
equal to zero
ANY
any occurrence of the value
PERCENT INVALID greater than x percent invalid out of the total samples
VALIDITY
occurrence of any valid or invalid value
Point–to–Point consecutive data points that differ by more than x
Each of the above value tests (GT, LT, RANGE) is provided with a value or set of
values to compare against the measure value. Satisfaction of a configured logical
operation is sufficient for the condition to be true.
Digital Conditions:
HIGH a digital state of 1
LOW a digital state of 0
TRANSITION any change of state
TRANSITION TO LOW
TRANSITION TO HIGH
Timer Condition:
1 Second to 255 Minutes
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Outputs
Up to nine outputs may be configured for analysis per event. Each output is available
as an historical element ( the last seconds worth of data), and/or a statistical element.
The statistical element is a summary of the high, low, and mean of the current signal
group and the accummulated signal data. In addition, there is a report of the variance
and 2-sigma of all the accummulated valid data values, and a count of all the invalid
samples seen. The selected signals valid data group size is determined by whether
it is part of the process measurement, or if it is a supporting analog. Those analog
signals that are of a supporting nature, such as temperatures and pressures, are
generally sampled at a rate of two per group. Other signals associated with the
process measurements, such as sensor signal inputs and sensor measurements, have
group sizes dependent on the number of data boxes being processed every second.
This is the result of data box width and scan speed.
A view of a historical output report would show 50 to 60 data positions (depending
on if the system is a 50 hz or 60 hz system), however, only the first 10-20 entries
will be used for valid data. Data elements within the packet seen here are a maximum
of 0.1 second in duration. In some cases, where the data box size is large, it may
take two or more data elements to make up a data box. All data points in the group
that are beyond the number of valid data points may be ignored and are considered
as non-participating data. All data in a group are sampled for statistical inclusion
whenever the Trigger occurs.
The historical element of the output is a snapshot of the most recent data group
contents (typically one second of data). Comparison of data between signals within
a history must be done by aligning the synchronization value for each signal (see
Figure 5-4). This is a time stamp which is included in the data display for each
measurement in the output. Historical data may be updated while being displayed
and may result in non-contiguous data elements.
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DATA HISTORY FOR EVENT beta
Column number 1 contains HeadPosition01
Column number 2 contains BWMeasurement01
1 2
SYNCH VALUE INV SYNCH VALUE CD
27471
27491
27511
27531
27551
27571
27591
25.1
25.8
26.5
27.1
27.9
28.6
29.2
0
0
0
0
0
0
0
27471
27491
27511
27531
27551
27671
27591
382.4
382.4
382.4
380.4
379.4
378.4
380.4
25.1
25.8
26.5
27.1
27.9
28.6
29.2
INV
0
0
0
0
0
0
0
ENTER r to re-display or q to return to menu: q
Figure 5-4 Analog and Measurement Historical Data Display
For digital signals, the historical output provides a line of data for each time the
trigger definition occurs. There is no statistical report for digital signals. The history
report (see Figure 5-5) will show the date, time, synch, state, and validity. The synch
value allows multiple digital events to be accurately lined up with each other in time
and space.
DATA STATISTICS FOR EVENT dig_tst2
DIGITAL EVENTS FOR SIGNAL IRDecreaseGain01 - 02-06-1992 13:41:20
Log contains 13 most recent events;
DATE TIME SYNCH STATE VALIDITY
__________________________________________________________
_
02-06-1992
02-06-1992
02-06-1992
02-06-1992
02-06-1992
02-06-1992
02-06-1992
02-06-1992
02-06-1992
02-06-1992
02-06-1992
02-06-1992
02-06-1992
13:41:06
13:41:06
13:41:05
13:41:05
13:41:05
13:41:04
13:41:04
13:41:04
13:41:03
13:41:03
13:41:03
13:41:02
13:41:02
408.892
408.672
408.118
407.881
407.662
407.082
406.833
406.618
406.034
405.790
405.576
405.017
404.793
LOW
LOW
LOW
LOW
LOW
LOW
LOW
LOW
LOW
LOW
LOW
LOW
LOW
valid
valid
valid
valid
valid
valid
valid
valid
valid
valid
valid
valid
valid
Figure 5-5 Digital Historical Data Display
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STATISTICAL DATA FOR SIGNAL BWMeasurement01
TIME OF LAST TRIGGER: 01-09-1991 09:09:22 SYNCH VALUE THIS GROUP: 658471
SAMPLES THIS GROUP: 50 TOTAL SAMPLES: 250
PERCENT INVALID THIS GROUP 0 TOTAL INVALID SAMPLES 0
MEAN THIS GROUP: 381.87 CUMULATIVE MEAN: 381.86
HI VALUE THIS GROUP: 384.41 CUMULATIVE HI VALUE: 384.41
LO VALUE THIS GROUP: 378.41 CUMULATIVE LO VALUE: 378.41
VARIANCE OF VALID SAMPLES: 1.7400
2 SIGMA OF VALID SAMPLES: 3.7600
ENTER r to re-display OR q to return to menu: q
Figure 5-6 Statistical Data Display
Display device selection is provided for the convenience of the user. See
Figure 5-6 for an example. Display of Event Statistics or history is on demand
except for AUTOMATIC REPORTING. Under normal circumstances, the output
will probably be directed to the service workstation screen; however, an option is
provided to output reports to the Scanning Platform ramdisk for future review and
analysis. The ramdisk option is slightly faster than the console screen display and
accumulates the reports as they occur, which means that a trend of group data points
can be collected over time. Use this option with care since the output file will
continue to grow as data is collected. If space is at a premium, this could result in
lost data.
Automatic Reporting and Retriggering
The smr utility has the ability to automatically produce a hard copy report either
to the screen or to a ramdisk file, upon the occurrence of a predefined Event. The
Event and subsequent reports can be repeated a defined number of times by setting
a re–trigger count value. This is done through the Setup selection in the Event
REVISE/ADD sub–menu or by the START/STOP Triggering sub–menu. An entry
is provided in each to select automatic reporting. This includes deciding if the
report is to go to the screen or to a designated file.
Automatic reporting provides a convenient event–wide counter to limit the number
of reported occurrences for the Event in total in which all conditions are true. It
only produces an output when all of the Events’ conditions are true at the same
time, whereas the counters provided in each condition are specific to that condition.
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Global Access
There is a global printing and retriggering capability which allows the user to control
these functions for several Events running at the same time. This invoked by typing
!!. This will bring up the following options for selection:
ACTIVATE/INIT TRIGGER for each Event
DEACTIVATE
each active Event
INITIALIZE TRIGGERS
for all active Events
INITIALIZE STATISTICS
for all active Events
PRINT RESULTS
for all active Events
For the first two, each Event is presented to the user to give either a “yes” or “no”
answer, whereas the third and fourth options (initialization), perform for all
configured Events.
Starting and Stopping Data Collection
Data collection action specific to this Event is controlled by activities available in
the START/STOP triggering sub–menu (and the Global access method). Within
this selection, it is possible to do the following:
Activate Triggering
Deactivate Triggering
Initialize Trigger Conditions
Initialize Statistical Data
Setup Automatic Reporting
The initialization activities are also available from the Display sub–menu.
Overview of Menu Selection
The smr utility is menu driven, allowing the user to set up any number of different
data collection Events by defining the Outputs, the Triggering Event, and the Display
device. Refer to Figure 5-3 for a tree diagram of the smr menu. The menu display
during each session only shows those menu options which are available at that time.
For example, during the definition of a new event, you will not see menus displayed
for the “remove a condition” option.
General Procedure
1. Enter smr while in the AVOS shell on the system console.
2. Either select an existing Event file, or enter a new file name to be created. Events
which have been deleted are no longer available for reactivation or for new
Event names.
3. Start the desired menu sequence to either create a new Event, modify an existing
Event, start or stop an Event, display an output, or display collected data.
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4. Exit the utility when done. The Event can either be left running or terminated
without saving upon leaving the utility. Upon leaving with the Event terminated
and not saved, the configuration of the Event is summarized.
There can only be three Events configured at one time whether they are active
or inactive.
Practical Application
It is important to understand that the triggering and output functions of this utility
are independent from each other. That is, a signal which causes a Trigger is not
necessarily available for examination unless a corresponding Output has been
configured for the same signal. Also, statistical analysis of outputs is only
performed at each Trigger. This may significantly alter the statistical validity of
the data. To capture a truly valid statistical snapshot of a signal, the Trigger should
be set up to capture all of the signal updates.
When a Trigger occurs, it is only guaranteed that the specified logical combinations
of Conditions occurred somewhere within this data group, not necessarily on the
same element. As a result, mutually exclusive conditions on the same signal may
indeed Trigger since the entire group of data is examined independently for each
Condition within the Event.
Example
Collect synchronized data on the head position, the basis weight input signal and
measurement, and the IR moisture input signal and measurement under the
following conditions:
• Collect between head positions 420 cm to 425 cm.
• Only collect after the head has passed the home edge once.
• Collect only if caliper measurement is greater than 125 Microns.
• Collect only if Basis Weight adjacent samples are more than 50 GSM apart.
• Collect five occurrences of the trigger conditions being true.
Trigger Setup
Condition 1 = After head position exceeds 422 cm
(PrepareToMeasurePosition)
type = AFTER
signal = groupAHeadPosition01
logic = GT 422.0
number of samples to start = 1
number of samples to collect = 0 (unlimited)
Condition 2 = Head Position between 420 cm and 425 cm
type = WHILE
signal = groupAHeadPosition01
logic = RANGE 420.0 cm to 425.0 cm
number of samples to trigger on = 0 (unlimited)
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Condition 3 = Caliper Measurement greater than 125 Microns
type = WHILE
signal = caliperMeasurement01
logic = GT 125.0
number of samples to trigger on = 0 (unlimited)
Condition 4 = Basis weight measurement with adjacent points > 50 GSM
type = WHILE
signal = betaMeasurement01
logic = RANGE 420.0 cm to 425.0 cm
number of samples to trigger on = 0 (unlimited)
Setup Auto Report Trigger for 5 reports (only 5 occurrences)
Collect Data On:
Output 1 = Head position
signal = groupAHeadPosition01
Output 2 = Basis Weight analog input
signal = betaInputSignal01
Output 3 = Basis Weight sensor measurement
signal = BWMeasurement01
Output 4 = IR Moisture absorption input signal
signal = IRMoistureAbsorption01
Output 5 = IR Moisture reference input signal
signal = IRMoistureReference01
Output 6 = IR Moisture measurement
signal = IRMeasurement01
smr Work Sheet
Use the work sheet on the following page to design your event collection routine.
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smr Work Sheet
File Name: _________________
Purpose:_______________________________________________________________
_______
______________________________________________________________________
_______
______________________________________________________________________
_______
Output Signals:
_____________________________________________________________
_____________________________________________________________
______________________________________________________________
Conditions For Triggering: (use additional sheets for multiple conditions)
Condition Signal: ____________________________No.: _______
Condition Type (circle one): WHILE/AFTER/UNTIL/REPETITIVELY/TIMER
Condition Logic:
Analog/Measurement
Digital:
GT ___________
High
LT ___________
Low
Average inside/outside low: ________high:______ Transition
Range inside/outside low: ________high:______ High Transition
Non–Zero
Low Transition
Zero
Any
% Invalid __________
Validity invalid/valid
Pt–To–Pt variation
__________
If WHILE: No. consecutive triggers (0=forever) __________
No. additional samples (0=none)
__________
If AFTER:
No. consecutive triggers to start (0=immediately) __________
No. samples to collect (0=all)
__________
If UNTIL: No. consecutive triggers before stop (0=first) __________
No. additional samples (0=none)
__________
If REPETITIVELY:
No. consecutive triggers (0=all requests)
__________
If TIMER:SECONDS MINUTES (circle one)
Number of units:
__________
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Resource Checks
After an upgrade to a new release, it is useful to establish the new level of resource
usage by the software. The resources in question include such things as buffers,
memory, and processes.
Whenever this situation occurs, daily checks on these resources should be made
over a five day period in order to determine two things. First, that the upgrade has
not caused any creeping degradation which will manifest itself in a failure later, and
second, to establish a resource usage base to assist in future troubleshooting activity.
The daily checks involve using the following AVOS utilities. The first one, monitor,
must be used by itself, the rest can be grouped into a shell script to expedite
execution.
• monitor - To check real time, buffer usage, process usage, mailbox usage, and
semaphore usage
• derr - Checks for system bus errors
• bfchk - Checks for damaged buffers
• dfree - Displays the memory usage and fragmentation
Obtaining the monitor Report
This is an interactive report in which entries do not require pressing the return key.
Since it is refreshed on a five second basis, the automatic print should be turned off
(Shift-F2) and the PRINT SCREEN key stroke on the console used to obtain a
printout.
Call up the monitor Command Menu (see Figure 5-7).
$$ monitor (cr)
REPORTS:
a
d
i
m
r
g
p
s
AVOS Service Activity
Driver Activity
Interrupt Activity
Misc Activity
Resource Activity
General Times
Process Times
AVOS Service Times
COMMAND MENU plh - 220.1.1.1 06/19/89
FUNCTIONS:
A Turn Time Accumulation On/Off
F Freeze/Unfreeze Screen
G Turn Process Graphs On/Off
P Set Sample Period
R Reset Resource Activity Counts
T Reset Time Counts
! Escape To Shell
! Next Page
z Previous Page
Command Menu
Q
Quit Monitor
Figure 5-7 Monitor Command Menu
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Enter an A to access turning time accumulation on. Answer y to the next two
questions regarding turning on and resetting the time accumulations.
Select general times by entering a g. This will result in a new display called general
time. Let it run for several minutes, then do a print screen to record the data. See
Figure 5-8. Accumulated idle times should not go below 20%.
GENERAL TIME
Time collection off.
Application
AVOS
Interrupt
MTDS
Idle
Total
DELTA
00.035 1%
00.063 1%
00.091 2%
00.047 1%
04.660 95%
04.896 100%
Accum
00:00:00.035 1%
00:00:00.064 1%
00:00:00.091 2%
00:00:00.047 1%
00:00:04.660 95%
00:00:04.905 100%
Figure 5-8 Monitor General Time Display
Enter a q to get back to the Command Menu.
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Enter an r to select the Resource Activity. This will result in another new display
called Resource Activity (see Figure 5-9). Here there are several items to observe.
RESOURCE ACTIVITY
Mailbox:
Semaphore:
Process:
Buffer:
create
return
send
receive
create
return
reserve
release
create
return
start
terminate
allocate
deallocate
Delta
0
0
6
6
0
0
7
7
6
6
6
6
29
29
Accum
181
88
88457
88455
19
4
738149
738149
83213
83116
83382
83289
437051
432443
Allocations
Mailbox
Semaphore
Process
Current
93
15
97
Peak
95
15
99
Figure 5-9 monitor Resource Activity Display
Under MailBox: Send and receive should be about equal and stable.
Under Semaphore: Reserve and release should be about equal and stable.
Under Process:
Create and return, and start and terminate should be
close and stable respectively.
Under Buffer:
Allocate and deallocate should be within several
thousand with relatively small day to day
variations.
Under Peak Allocations: Process should not ever reach 256.
Any deviations from the above acceptance criteria could be an indication of a serious
operations problem and should be reported to a specialist at ABB in Columbus,
Ohio for analysis and perhaps further examination.
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Obtaining derr, bfchk, and dfree Data
Figure 5-10 shows an example of the reports generated by exercising the derr,
bfchk, and dfree AVOS utilities. The things to look for in these reports are listed
below.
[01_0] $$ derr
derr: No exceptions logged.
[01_0] $$ bfchk
All buffers are OK.
[01_0] $$ dfree
LOCAL POOLS:
Pool
Number
Pool
Size
Memory
Available
Largest
Block
Number of
Fragments
Peak
Usage
14
15
24
25
26
27
28
29
30
31
16
17
18
19
20
21
22
23
TOTAL
10000 10000 10000
2621440 1203064 1183968
1214746 673962 672514
3846186 1887026 1183968
1
14
21
36
272
1438936
557072
Figure 5-10 Example of the Use of derr, bfchk, and dfree
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Under derr:
Under bfchk:
Under dfree:
Any reported error here can be serious. There can be
reported errors if a utility has abnormally aborted during
its use. While this will not necessarily affect normal system
operation, it should also be reported to Columbus.
Any reported errors here are serious. Report them to
Columbus.
The thing to watch here is the stability of the memory
available, largest block, and number of fragments. After
several days of running, these numbers should stabilize.
Number of fragments should never reach 99 or close to it.
Report all problems to ABB in Columbus, Ohio.
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How to Start the Scanning Platform
You must startup the Scanning Platform independently from the Host computer.
The Scanning Platform has its own startup process. Handshaking between the
Scanning Platform and the Host computer can occur only after both computers are
up and running. Follow the steps below to start the Scanning Platform.
1. Momentarily press the RESET switch.
The Scanning Platform will read files from its mass storage areas and load them
into memory. It will then perform the linking and initializing processes. The
following messages will appear after all the images have been loaded in. These
messages are associated with the systems ability to complete certain tasks
during the startup process. The purpose is to provide a diagnostic report which
will show where the startup process stopped in case of failure. A successful
startup will display all of the following data.
[1]:APPL_INIT defining exception handlers
[2]:APPL_INIT defining Network Object Dictionary
[3]:APPL_INIT creating global object collection
[4]:APPL_INIT creating error history
[5]:APPL_INIT creating appl_start community
If all of these messages do not appear during a startup, the startup activity will
halt. Use a backup set of diskettes or call ABB in Columbus, Ohio for
assistance.
2. When the processor has completed Step 2, an instruction message will appear
explaining the procedure for completing handshaking with the Host computer.
The action you should take depends on the status of the Host computer at the
time the Scanning Platform subsystem became functional. Until handshaking
is established, the following message will be displayed at the Service
Workstation:
3. COMMUNICATIONS TIMEOUT
4. If the Host computer is already running and on-line, go to the system console
of the Host computer and request the reloading command for the Scanning
Platform system in question. When this is done, the Service Workstation
responds with the following sequence of messages.
pmmFrame0x: HOST TO AMS RELOAD IN PROGRESS
pmmFrame0x: HOST TO AMS RELOAD COMPLETE
pmmFrame0x: HOST COMMUNICATION ESTABLISHED
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5. If the Host computer has not yet completed its startup, then you do not need to
take any further action. Handshaking automatically takes place after the Host
Computer system is up (provided that the Scanning Platform subsystem is
already up at that point).
When a reload has been requested from the Host Computer, you will receive
the following messages:
pmmFrame0x: HOST TO AMS DOWNLOAD IN PROGRESS
pmmFrame0x: HOST TO AMS DOWNLOAD COMPLETED
pmmFrame0x: HOST TO COMMUNICATION ESTABLISHED
6. When handshaking has been established, the selected host computer data file
information will be sent to the Scanning Platform subsystem. At this point, the
scanner can be placed ON SHEET at the scanner.
7. The Platform will immediately go into the standardize mode of operation when
ON SHEET has been enabled.
8. After the Scanning Platform subsystem has completed the startup, it might be
a good idea to clear out the error buffer of all the messages which accumulated
during the startup. This will make it easier to distinguish between genuine
operational messages and those occurring during a startup only. The startup
error messages are only important if the subsystem fails to finish loading and
initializing. Enter the following command to first print out the message, and
then to clear the buffer:
pe -a
(will display all current messages on the workstation screen).
pe -c
(will clear the buffer).
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Displaying Reports within inspect
The Service Workstation can be used to view Standardize, Check Sample and
Calibrate Sample reports. These reports contain the same information sent to the
Host computer system, but the data is displayed differently.
Standardize Report
There are two report arrays associated with the Standardize results:
stdzResultsPending and stdzResults. stdzResultsPending reports on the results
of the last standardize whether the results are within limits or not. stdzResults
reports the results of the last acceptable standardize.
The procedure for displaying these reports is as follows:
1. Access the inspect utility.
2. Type: betaSensor01->stdzResultsPending (for example)
The system will report back the address of that report.
3. Type in the address of the report.
The system will display the results of the last standardize. See Figure 5-11.
I> betaSensor01->stdzResults
stdzResults: 0x307bb2 (int *)
I> 0x307662
0x307bb2 (id)
0x307bb2: ”0X307bb2” (STRUCT_PRIVATE)
ISA: BWStdzRslts (STRUCT_SHARED *)
mySelf: 0x307bb2 (long)
problemList 0x30d72 (id)
tempCompFlag 0 ’\0’ (char)
zeroScaleInput 0.000338776 (double)
zeroScaleInputSigma 7.21414e-09 (double)
lastCleanStdz: 0x307bd0 (char [20])
dirt: 0 (double)
fullScaleTempRef: 0.800937 (double)
fullScaleTempSigma: 1.2531e-09 (double)
logRangeClean: 7.62371 (double)
logVoltageRange: 7.62371 (double)
voltageSigma: 3.70175e-05 (double)
tClean 0 (long)
Figure 5-11 Standardize Report
To view the results of the last acceptable standardize, type in the variable
stdzResults. When there are no standardize failures, the address of the stdzResults
and stdzResultsPending will be the same. The system will respond with the address
of that report. Type in the address and the system will display the report.
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If you want to know when the last clean standardize occurred, type in the address
of the lastCleanStdz and the system will display the date and time of the last clean
standardize.
Sample Check Report
The procedure for displaying the Sample Check report is as follows:
1. Access the inspect utility.
2. Type: betaSensor01->checkSampleResults (for example)
3. The system will report back the address of that report.
4. Type in the address of the report.
The system will display the results of the last check sample. See Figure 5-12.
|-------------------------------------------------------------------------------|
| I> betaSensor01->checkSampleResults |
| checkSampleResults: 0x30842a (int *) |
| I> 0x30842a |
| 0x30842a (id) |
| |
| 0x30842a: “0x30842a” (struct_PRIVATE) |
| isa: BWChkSmRslt (struct_SHARED *) |
| mySelf: 0x30842a (long) |
| problemList: 0x30848a (id) |
| name: 0x26b182 (id) |
| transPPT: 1000.46 (double) |
| mylarWt: -0.0277454 (double) |
| slope: 1 (double) |
| offset: 0 (double) |
| tempCompFlag: 0 ’\0’ (char) |
| tempComp: 0.80165 (double) |
| wtTempComp: 0 (double) |
| processBW: -0.0277454 (double) |
|-------------------------------------------------------------------------------|
Figure 5-12 Check Sample Report
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Calibrate Sample Report
The procedure for displaying the Sample Check report is as follows:
1. Access the inspect utility.
2. Type: betaSensor01->calibrateSampleResults (for example)
The system will report back the address of that report.
3. Type in the address of the report.
The system will display the results of the last Calibrate Sample. See
Figure 5-13.
|--------------------------------------------------------------------------------|
|I> betaSensor01->calibrateSampleResults |
| calibrateSampleResults: 0x312c7a |
|I> 0x312c7a |
| 0x312c7a (id) |
| |
| 0x312c7a: “0x312c7a” (struct_PRIVATE) |
| isa: BWCalSmRslt (struct_SHARED *) |
| mySelf: 0x312c7a (long) |
| problemList: 0x308b22 (id) |
| name: 0x26b182 (id) |
| headPosition: 64 (double) |
| transPPT: 602.285 (double) |
| mylarWt: 29.3038 (double) |
| slope: 1 (double) |
| offset: 0 (double) |
| tempCompFlag: 0 ’\0’ (char) |
| tempComp: 0.802075 (double) |
| wtTempComp: 0 (double) |
| processBW: 29.3038 (double) |
|--------------------------------------------------------------------------------|
Figure 5-13 Check Sample Report
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Preparing On–Site Documentation
Each time the Scanning Platform subsystem is restarted, it dynamically recreates
the various objects and their linkages. As a result, the absolute address of any object
and their associated instance variables can change from startup to startup. Therefore,
access to the various instance variables and objects is primarily done through ASCII
names and tokens. These are used as arguments to the utility commands which in
turn gives access to the data in memory.
It is important to have available the lists of names and token numbers which are
recognizable within the subsystem. This section identifies the activities which must
be done to obtain these name and token lists. In some cases the list should be printed
out each time the system is upgraded. This will insure that certain address locations
can be accessed for troubleshooting purposes in case of processor halts. See
Table 5-5.
Table 5-5 Hardcopy Reports for On–Site Documentation
Report Name Utility Command Printout
Frequency
System Processor Run
List
Sub-System
Release Levels
Purpose
dproc First startup Gives a list of all of the
processes that are
running
. ∆ /ss01/clm/revid First startup Gives a list of the release
levels within the system
Module Map map -m Each upgrade Provides the name, type,
and stack size of each
module in the order in
which it was loaded
inspect Utility Object
Names
Scanner and
Sensor Instance
Variable List
inspect
:global
inspect
(see partial list below)
scanner01
betaSensot01
IRSensor01
caliperSensor01
ashSensor01
optipakSensor01
pmmFrame01
First startup
After
calibration,
tuning and
setup for each
scanner
has been
completed or
changed
Provides a list of module
names which will be
recognized by the
inspect utility
Provides a complete
list of the instance
variables, their names
and current values, as a
record of setup and
calibration activity
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Operation of the Sensor Health Pages
1. Start up the Health Report by selecting the Health Page window from the
DESQview open window menu.
The first page to appear after the startup data is the Overview page (see Figure
5-14). The Overview page shows the Scanning Platform status of each sensor,
the Frame Control Panel (FCP) status, and the scanner graphic with numeric
positions. Each sensor in the status display shows a key identifier in brackets.
This is the key stroke which will give access to the sensor specific Health Pages.
ABB
[F]
Frame
OK
Scanning Platform Health Overview
FWS140.000
Scanning Platform Status
[E]
ELECTRONICS
SERVICE CHECK
DEBUG
[I]
IR MOISTURE
OK
10–13-93 13:15:20
RELEASE CHECKOUT SP Release: SP250.0 Page 1 of 1
PM 1 Frame Ctrl From: END COLUMN Safety Intr: RESET
REEL Head Command: OFFSHEET System Alarms: NEW
[V]
AIR COLUMN
OK
[C]
CALIPER
SERVICE CHECK
[B]
BASIS WEIGHT
OK
[A]
ASH
SERVICE CHECK
Offsht
*
Manual
RevJog
CalSmp
FCP
OnSht
Comp
*
FwdJog
ChkSmp
ABB
SCANNING PLATFORM
SHUTTER
ShtBrk
BwtISB
HstCom
*
BwtHTE
Stdz
Maint
AshISB
AshHTE
Sngl Pt % Home Edge Head Pos
Far Edge Sht Brk Ovr
10.0 74.18 46.93 171.45 ON
Esc
F1 F2 F3 F4 F5 F6 F7 F8 F9
PRTSC
F10 PGUP PGDN
Figure 5-14 Health Overview Page
In the setup panel of each subsystem page, the TAB key will initially make the
cursor visible. Subsequent pressing of the TAB key will toggle the cursor.
In the interactive setup areas of each page the arrow keys move the cursor
according to the following rules:Left and right arrows move the cursor
horizontally within each setup panel, highlighting each entry area on that line.
The up and down arrows move the cursor to other lines within the selected subpage.
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2. To change data, enter the new value and press RETURN.
3. To select a panel use the F6 through F9 keys which correspond to SETUP,
STDZ, SMPCK, AND CALIB.
The SETUP selection provides one or more panels in sequence which may be
used to enter tuning constants, standardize limits, and other setup parameters
associated with the selected sensor.
The STDZ selection provides pending and last passed Standardize Reports
sequentially in the lower right-hand corner of the page.
The CALIB selection provides the Calibrate Sample Report in the lower righthand
corner of the page.
The SMPCK selection provides the Sample Check Report in the lower righthand
corner of the page.
The PGUP/PRVPG and PGDN/NXTPG keys allow the selection of other sensor
pages which may be available. Not all sensors have multiple pages.
4. To return to the Overview Page, press the ESC key. New subsystem reports can
be selected without going back to the Overview Page.
5. To exit the Health Page Report, press the ESC key while on the Overview Page.
A second prompt will appear to confirm the desire to exit and remind you to do
a gstore if data has been changed.
The F1 HELP key on the Overview Page gives more detailed information on
the Health Report operation.
Many of the functions that are performed using the inspect utility and the genrpt
utility can also be performed using the health pages. For more information,
access the health pages at the Service Workstation (see
Figure 5-15 and Figure 5-16).
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ABB Inc.
Smart Paper Company
Machine Number 1
Reel Frame
Basis Weight Health Report
DEMO
11-21-91 16:39:47
SP Release: 200.000
Frame Ctrl From: HOST
Head Command: SCAN
Page 1 of 2
Safety Intr: RESET
System Alarms:NO
Sensor Type: STLK Sensor Command: FROM HEAD Active Alarms: NO
APC: INACTIVE
CALIBRATION
CONSTANTS
K0 0.0000
K1 0.0000
K2 0.0000
K3 0.0000
Air Column GSM 0.0000
B
W
S
e
n
s
o
r
TUNING CONSTANTS
Electrometer VDC 0.0000
Alarm Grid INTACT
Shutter State:
Sensor I/O NOT CLOSED
Frame I/O NOT CLOSED
Electrometer Test
Engage Int Ck Smpl
Open The Shutter
Gap WCC GRAMS 0.000
Air Mass GSM/MICRON 0.000
TUNING CONSTANTS
SmpChk Avg TImeSec 0
Stdz FS Avg TimeSec 0
No. Stdz/Int SmpChk 0
OFF
NO
TRUE
C
o
m
p
u
t
e
r
AIS VDC
NOMINAL
0.0000
AIZ VDC 0.0000
Dirt GSM 0.000
NOISE Z VDC
NOISE F VDC
NOISE T °C
Range
0.0000
0.0000
0.000
0.0000
0.0000
0.0000
Basis Wt GSM 0.000
Basis Wt
CU
0.000
Sample Check 6/07 8:09:55
PROC WT GSM 0.000
STD WT GSM 0.000
SLOPE 0.000
OFFSET GSM 0.00
PPT 0
TMPCGR GSM 0.000
Src Temp °C 0.00
Det Temp °C 0.00
Gap Wt Corr GSM 0.0000
Esc
EXIT
F1
HELP
F2
ALARM
F3
DATA
F4
F5
F6
SETUP
F7
STDZ
F8
SMPCK
F9
CALIB
F10
PRTSC
PGUP
PRVPG
PGDN
NXTPG
Figure 5-15 Basis Weight Health Report Showing Sample Check
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ABB Inc.
Smart Paper Company
Machine Number 1
Reel Frame
Sensor Type: STLK
Basis Weight Health Report
DEMO
SP Release: 200.000
Frame Ctrl From: HOST
Head Command: SCAN
Sensor Command: FROM HEAD
11-21-91 16:39:47
Page 1 of 2
Safety Intr: RESET
System Alarms: NO
Active Alarms: NO
APC: INACTIVE
CALIBRATION
CONSTANTS
K0 0.0000
K1 0.0000
K2 0.0000
K3 0.0000
Temp Comp GSM 0.0000
TUNING CONSTANTS
Gap WCC GRAMS 0.000
Air Mass GSM/MICRON 0.000
MISCELLANEOUS SETUP
SmpChk Avg TIme Sec 0
Stdz FS Avg Time Sec 0
No. Stdz/Int SmpChk 0
AIS VDC
NOMINAL
0.0000
AIZ VDC 0.0000
Dirt GSM 0.000
NOISE Z VDC
NOISE F VDC
NOISE T °C
Range
0.0000
0.0000
0.000
0.0000
0.0000
0.0000
Basis Wt GSM 0.000
Basis Wt CU 0.000
B
W
S
e
n
s
o
r
Electrometer VDC 0.0000
Alarm Grid INTACT
Shutter State:
Sensor I/O NOT CLOSED
Frame I/O NOT CLOSED
Electrometer Test OFF
Engage Int Ck Smpl NO
Open The Shutter TRUE
C
o
m
p
u
t
e
r
Calib Sample 10/11 12:13:55
PROC WT GSM 0.000
STD WT GSM 0.000
SLOPE 0.000
OFFSET GSM 0.00
PPT 0
TMPCOR GSM 0.000
Src Temp °C 0.00
Det Temp °C 0.00
Cap Wt Corr GSM 0.0000
Esc F1 F2 F3
F4 F5 F6
F7 F8 F9 F10 PGUP PGDN
Figure 5-16 Basis Weight Health Page Showing Calibrate Sample
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Off-Line Debug
The OFFLINE DEBUG prompt is a mode of operation invoked when the AVOS
Operating System is told to run a program called panic. This will happen on demand
if the MPRC front panel diagnostic switch is in the DEBUG or down position when
a reset is initiated. It will happen under normal operating conditions if the Operating
System Software sees a condition it cannot resolve. Typically, that would result in
a reset and startup of the system if the front panel diagnostic switch were in the
SHORT DIAG (mid) or EXTEN DIAG (up) positions.
There are a number of operations available to the user in the OFFLINE DEBUG
mode. These functions are listed and explained in Table 5-6.
Table 5-6 OFFLINE DEBUG Modes
CMND Function Explanation
d addr1 [addr2 or +disp] display memory Prints out in hex-dump
format, the contents of the
addresses from addr1 to
addr2 or a displacement. If
only addr1 is specified, then
only one address is displayed.
e display panic message This is a report of all the
routines that complained to
the panic program.
g [code] startup using entered code This code is the means to tell
the system to continue the
restart operation. If no code
is passed, the system will do a
normal restart. If code is a 1,
the system will do a short
startup. If code is an f, the
system will come up prepared
to reblast the EEPROMs on
the MPRC board.
h display command summary A help function giving the
information from the first two
columns of this table.
i [puid] display/modify processor id
x display exception error log This is basically a summary of
the buss errors as they would
be found using the derr utility
with the system running.
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If the system is experiencing frequent resetting, it will be helpful to determine if it
is caused by power problems or from within the Operating System itself. If resets
are occurring, place the diagnostic switch in the down position and wait for the next
reset. At that time, the OFFLINE DEBUG prompt will appear.
It would be helpful to have a printer connected in order to obtain a hardcopy of the
data about to be dumped. If there is a problem in the Operating System, the data
will have to be forwarded to Measurement Software Engineering in Columbus, Ohio
for analysis and action.
Under the conditions mentioned above, the two commands which should first be
exercised are e and x. If the e and the x results show no exceptions occurred, then
the resetting situation is probably due to a power problem in one of the DC power
supplies or leads. If the results show some exception data, then continue and collect
a memory dump of the first 100 locations. Do this by typing; d 1 100. Before
sending the data to Columbus, there is a high probability that the problem is a
hardware failure in the MPRC board. Install a new MPRC board to make this final
verification.
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6
Sensor Troubleshooting
This chapter contains the following major sections:
Section ...............................................................................................Page
Sensor Compensation - Operation and Setup ................................................ 198
Air Column Compensation for Smart Sensors ............................................... 202
Changing the Measurement Resolution ......................................................... 203
Sensor Measurement Validity Codes ............................................................. 205
Sensor Local Modes of Operation ................................................................. 206
Basis Weight Sensor (TLK, TLP, and TLS) ................................................... 209
Infrared Moisture Sensor ............................................................................... 213
Ash Sensors (TLXR) ...................................................................................... 239
Air Bearing, Contacting, and Non-Contacting Caliper Sensors .................... 246
The following sensors have detailed troubleshooting procedures given in their
respective technical manuals.
• Aseptic
• Smart Ash (STLXR)
• Smart Weight (STLK11, STLP3)
• GT Caliper
• Smart Color (scanning)
• Gloss
• Microwave
• OptiPak
• Sheet Temperature
For other sensors, the troubleshooting procedures can be found in this section.
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Sensor Compensation - Operation and Setup
This section will describe the generic operational flow of applied compensations
and how to set them up for different modes. These comments apply to the three
sensors:
• IR Moisture
• Ash
• Microwave
Definition of Terms
In the following table, the “xx” prefix associated with each variable, identifies the
particular parameter being applied as compensation to the measurement. If
moisture, “xx” is “mo”. If it is Basis Weight, it is “bw”. If it is ash, then “xx” is
“ash”. For sheet temperature, “xx” is “temp”.
Variable
xxDefaultCompFlag
xxCurrentCompFlag
xxCompensation
xxExternalCompensation
Definition
A coldstart variable which selects the normal measuring
arrangement regarding the source of compensation to be
used. The choices are a 0 to select the internally available
measurement, or a 1 to select the externally available
value.
This is a dynamic flag which is set according to the
measuring mode being executed. When it is a 0, it is
directing the internal measurement to be used. When a 1,
it is directing the external value to be used. In normal
measure mode, this flag is the same as the
xxDefaultCompFlag. In Sample Check Mode, the flag is
able to change depending on the Mode selected. If,
however, the xxDefaultCompFlag is already a 1 (external
compensation), then internal compensation for Sample
Check is not available and either external or default
compensation will be selected for that sensor.
This is the value of compensation being applied to the
measurement at the current moment.
This is the value of the compensation which is available
from the external source, typically a product code or grade
file from a host computer
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Variable
xxDefaultCompensation
checkSampleMode3yyyy
Definition
This is the value available within the Scanning Platform
sensor object whenever the external compensation value is
0.0.
This is the Sample Check Mode 3 value used for
compensation. It is located in the sensor’s pmm interface
object. The “yyyy” indicates the particular compensation
parameter; i.e., Weight, Ash, Moisture, or Temperature.
Operation
Figure 6-1 is a flow diagram showing the logical paths followed when a
compensation is selected by the measurement. This diagram is generic for all three
sensors which have applied compensations; IR Moisture (bw and ash), Ash (bw
and mo), and Microwave Moisture (bw and temp). Included is the logical functions
associated with the Sample Check function showing the effect of mode selection.
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axxDefaultCompFlag
SC Mode 2
Set the xxCurrentCompFlag
to the desired configuration.
SC Mode 1
xxDefaultCompFlag
SC Mode 1
SC Mode 2
xxCurrentCompFlag
0001 11
0100 10
0010 01
0101 11
=0
Is CurrentCompFlag
set
=1
0=internal
1=external
Is Smp Chk
Active
NO
1,2
YES
0
What mode
3
BUCKET
Set xxCompensation=
checksSampleMode3yyyy
YES
Is internal compensation
valid
NO
Is
xxExternal Compensation
0.0
NO
YES
YES
Set the xxCompensation=last packet of
measurement.
Set xxCompensation=
xxDefaultCompensation.
Set xxCompensation=
xxExternalCompensation.
Figure 6-1 Flow Diagram of Compensation Selection Logic
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Compensation Flag Setup
The following are the variable names associated with each dependent sensor type.
IRSensor01
ashSensor01
microwaveSensor01
Table 6-1
bwDefaultCompFlag
ashDefaultCompFlag
bwDefaultCompFlag
moDefaultCompFlag
bwDefaultCompFlag
tempDefaultCompFlag
1. Determine the compensation needs of the dependent sensor and identify if the
required compensations are available internally. At initial build time, the
compensations should be selected as internal if the sensor is available.
2. Operating in the inspect mode, set the compensating default flag with the
following command form:
xxxxxSensor01->xxDefaultCompFlag=y (where “y” = 1 for external, =0 for
internal)
3. Exit the inspect utility and save the changes using the gstore utility. Save to
the scanner community.
4. Restart the Scanning Platform to activate the changes made.
5. Make sure the Product Code Files or Grade Files located on the host computer
have appropriate compensation values in place for all compensations, even
those which are to be internal.
Active compensations being used can be seen on a sensor’s Health Page display. It
is located on the left center section of the page. On Smart Sensor types, the Air Col
Comp value will be seen as X.XXX. This is correct as the actual value is currently
unavailable for display.
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Air Column Compensation for Smart Sensors
Both the Smart Basis Weight and Smart Ash sensors are provided with air column
compensation. This compensation is derived from a proximeter sensor physically
located on the Smart Basis Weight module. Under normal conditions, the
compensating signal is always present with the dependent weight and ash sensors
set up to receive and use it. There are cases, however, where the gap proximeter
has failed causing the Smart sensor measurements to go invalid. In these cases, if
the platform is considered stable and without significant beam bending, it is
appropriate to change the setup to the Smart sensors so that they will no longer
require the air column deviation signal to process their measurement.
Procedure to Disable Gap Compensation
1. Using the inspect utility, change the instance variable gapCompDesired in each
Smart sensor object. The command lines are:
betaSensor01 -> gapCompDesired=0
ashSensor01 -> gapCompDesired=0
2. Exit the inspect utility. Save the changes using the gstore utility. This makes
changes continue after any future restart.
3. Run the Air Profile Display routine from the host to determine if the Basis
Weight profile is sufficiently flat in the absence of gap compensation. If there
is deemed too much bending in the profile, it might be wise to not use the Smart
measurement for control purposes.
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Changing the Measurement Resolution
Except for AccuRay Direct interfaces which use floating point data transfers to the
host computer, all profile measurement data transfers to a host are done using scaled
integer. The Scanning Platform acts as the controlling influence as far as how the
scaling is set up. There is a flag in the pmmFrame01 object called
altMeasurementScaleFactorFlag. The host computer looks at the status of this
flag to determine what descaling it needs to apply to measurements from the various
sensors. On the Scanning Platform side, each sensor interface object (i.e.
pmmBeta01, etc.) looks at the flag to determine which of two measurement scale
factors it should use for the measurement. For some sensors, both the standard and
the alternate scale factor are the same, for example in IR Moisture, they are both
set to 100. Sensors which can benefit from increased resolution are Basis Weight
and Caliper. In both cases, however, it depends on the maximum measurement to
be encountered as the process is measured.
Note:
Calibrate Sample and Check Sample data is also sent up to the host
as scaled integer, but they have a separate scaling factor assigned.
This discussion is only for the profile data.
The two scale factors for these two sensors are 10 (std) and 100 (alt). Table 6-2
shows the limitations of when the resolution can be increased. The limitation is
because with certain customer units defined, it will be possible to saturate the integer
format with a large measurement reading.
Table 6-2
Sensor
Customer Units
Largest Value
with STD
Largest Value
with Alt
Basis Weight (all) Reams 3276.7 lbs. 327.67 lbs.
GSM 3276.7 GSM 327.67 GSM
Caliper (all) Mils 3276.7 Mils 327.67 Mils
Microns 3276.7 Microns 327.67 Microns
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It is possible to further increase resolution on those applications where the
measurement value is small and it is desirable to see smaller degrees of variation.
In those cases where an increased resolution will not saturate the scaled integer, the
alternate scale factor may be changed for the sensor in question to 1000. This
requires a comparable descaling change in the host. In this case, a caliper
measurement in Mils would have a maximum reading range of 32.762 mils.
It should be noted that when the alternate scale factor flag is selected, it is selected
for all sensors in the head package. The standard (std) and alternate (alt) scale
factors for each sensor can be found in each interface sensor object (i.e.
pmmBeta01) with the names stdMeasurementScaleFactor and
altMeasurementScaleFactor respectively. Note that for most measurements, the
two factors are the same.
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Sensor Measurement Validity Codes
The validity of various sensor measurements can be answered by examining the
outputSignal instance variable array for each sensor object. The array contains
the most recent batch of measurement signals processed, giving the value, the
associated cross-machine head position, the machine direction position (not used
at present), the validity code, and the synch code. Each measurement point in the
batch has the following format:
V1: meas. value (double)
V2: CD Head position (double)
V3: MD position (double)
V4: dec. validity hex validity (short)
V5: synch code (long)
The validity codes are interpreted using the hex presentation in the array. The hex
value is preceded by a 0x prefix. It is a four digit code with each position having
an example of its interpretation revealed in Table 6-3. See Health Report HELP
Pages (F1 key) for each sensor to get correct interpretation.
To examine the validity codes, use the inspect utility in the long display mode.
Request the array using the following command format:
sensorObject->outputSignal
sensorObject is the name listed in :global; for example, betaSensor01.
Table 6-3 Validity Codes (Basis Weight Shown)
Validity Code
Meaning
0x0001 Analog Input failure
0x0002 No initial standardize
0x0004 In diagnostic mode
0x0008 Cross direction unsynchronized
0x0010 Cross direction measurement invalid
0x0020 Machine direction unsynchronized
0x0040 Shutter closed
0x0080 Measuring air profile
0x0100 Standardize
0x0200 Check Sample
0x0400 Unsynchronized sensor data
0x0800 Invalid Compensation
0x1000 Sensor input out of range
0x2000 Loss of vacuum or sensor changing gain
0x4000 Sensor not measuring
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Sensor Local Modes of Operation
Each sensor can be individually placed in one of several modes of operation, apart
from what is being called for by either the Host or Health Pages. While in one of
these local modes, the sensor measurement is kept invalid so as not to adversely
affect any process control activitiy. These local modes of operation can be useful
in diagnosing problems within a sensor while the system is otherwise providing
measurements in other areas.
Placing a sensor in one of the local modes can be done either from the Host or by
using the Health Page Sensor Command input. The table below provides a
description of the various local modes for all sensors except for the Scanning Color
sensor. The color sensor has a unique set of modes which are covered in the Smart
Color Sensor Manual, 3BUS 208 130 RXX01.
Function
Exit Local
Mode
Sensor to
Sleep
Health Page
Name
Host Code
& Number
Description & Use
From Head 0 All Sensors:
Takes the sensor out of local mode
and makes it available for normal
operation. If the system is already in
a measure mode with other sensors,
it will be necessary to force the
system to cycle through a prepare to
measure sequence to get the
reawakened sensor to start normal
measurement.
Sleep 7 Basis Weight and Ash Sensors:
Closes the shutter and clamps (“old”
weight & ash) the electrometer.
All IR Transmission Sensors:
Sets the gain to the standardize
value.
All IR Reflection Sensors:
Keeps the flag disengaged.
Caliper Sensors:
Lifts the probes, turns on the
pressure, turns off any vacuum or
purge.
OptiPak and Gloss:
Leaves the signals unclamped.
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Function
Clean
Standardize
Health Page
Name
Diag Clean
Stdz
Host Code
& Number
Description & Use
2 All Sensors:
Sends a CLEAN standardize request
to the sensor creating new values in
the standardize reports, both to the
Health Pages and the Host interface.
If the standardize results are valid,
they will be used to update the
current standardize parameters.
Dirty Window
Standardize
Diag Stdz 1 All Sensors:
Sends a DIRTY standardize request
to the sensor. The sensor will then
perform the standardize function as
defined by its defaultStdzMode
flag, creating new values in the
standardize reports, both to the
Health Pages and the Host interface.
If the standardize results are valid,
they will be used to update the
current standardize parameters.
Note that only the Basis Weight,
Caliper, and OptiPak sensors have
unique functions under a DIRTY
standardize request.
Sample Check
Diag Sample
Chk
4 All Sensors:
If the scanner head is off-sheet at the
Frame Control Panel, and the Host is
in Sample Check Mode (1190 is
always in Sample Check mode when
off-sheet), then a Sample Check
routine will be exercised for the
sensor in question and a new report
will be generated to both the Health
Pages and the Host interface.
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Function
Calibrate
Sample
Normal
Measurement
Prepare To
Move
Health Page
Name
Diag Calib
Smpl
Diag
Measure
Diag Prep
Move
Host Code
& Number
Description & Use
5 All Sensors:
The local Normal Measure mode
(Mode 8) must first be selected if the
scanner head is off-sheet. When the
local Calibrate Sample mode is
selected, a Calibrate Sample routine
with a collection time based on the
minimum collection time, will be
exercised for the sensor in question
and a new report will be generated to
both the Health Pages and the Host
interface.
8 All Sensors:
This mode performs the various
prepare to measure routines, then
runs through the normal measuring
routines, allowing the measured
values to be observed on the Health
Page or in the outputsignal instance
variable of the sensor object. The
sensor’s measurement to the Host
will remain invalid.
81 All Sensors:
This mode performs the various
prepare to move routines on the
sensor. The net effect of this mode
is to put the sensor to sleep, making
this mode redundant with the Sensor
to Sleep mode.
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Basis Weight Sensor (TLK, TLP, and TLS)
Troubleshooting Flow Chart
Troubleshooting the Basis Weight sensor is facilitated by using the flow chart, with
its directives, on the next page.
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Basis
Weight Sensor
Has
Sensor
Verification Been
Done
NO
Perform Sensor
Verification.
YES
Does
Operator’s Station
Standardize
Lamp
Go Off
NO
Does
Gauge
Standardize
Get Sensor Alarm
Status.
YES
Get Sensor Alarm
Status.
YES
Is
Data Valid
During
Scan
YES
NO
Check for Invalid Scan Due
to Normal Occurrences
Such As: Calibrate Sample,
Air Profile Collection, Sensor
in Local, Adjusting Scan
Limits.
Perform One Complete Scan
to Clear Errors.
Is
Standardize
Data Stable
and Noise
Free
NO
Perform sensor verification to
resolve stability problems.
YES
Perform Sensor
Verification Section.
NO
Check
Samples OK
(Basis Weight
and PPT)
Calibrate
Sample
OK
YES
YES
Perform sensor
verification to
resolve stability
problems.
NO
Check for Invalid Scan Due to
Normal Occurrences Such As:
Calibrate Sample, Air Profile
Collection, Sensor in Local,
Adjusting Scan Limits.
Perform One Complete Scan to
Clear Errors.
Check for Overflow.
Repeat Calibrate Sample
Except with Shorter
Collection Time.
Get Sensor Alarm
Status.
Figure 6-2 Basis Weight Troubleshooting Flow Chart
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Basis Weight Hardware Diagnostics
The inspect utility will be used to exercise the Electrometer Clamp and the Shutter
will provide a test of on-line hardware performance. These on-line tests utilize the
Scanning Platform software in initiating several combinations of Clamp and Shutter
operation.
1. Place the Basis Weight sensor in the off-sheet position from the operator station.
2. The initial condition will be Electrometer Clamped and Shutter Closed. Using
the inspect utility commands given below, execute the conditions shown in the
matrix of Table 6-4.
To Open or Close Shutter:
()[betaSensor01 private$openShutter] (to open)
()[betaSensor01 private$closeShutter] (to close)
To Unclamp or Clamp Electrometer
()[betaSensor01 private$clampElectrometer] (to clamp)
()[betaSensor01 private$unclampElectrometer] (to unclamp)
Table 6-4 Electrometer Responses to Shutter/Clamp Commands
Command Given Clamp Unclamp
Shutter Open 0 mv ± 6 mv 7.2 to 9.2 vdc*
Shutter Closed 0 mv ± 6 mv 0 mv ± 6 mv
*TLP geometries may be as low as 5.0 vdc.
3. Before leaving the tests, restore the Basis Weight sensor to having a clamped
Electrometer with the Shutter Closed.
Table 6-5 on the next page gives a summary of the fault conditions and actions to
be taken.
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Table 6-5 Basis Weight Electrometer Hardware Diagnostics
Condition Possible Cause Action to Take
Never Clamped Bad electrometer Replace the electrometer.
Always Clamped
Watch source open/close lamps, listen
for shutter or check shutter with a geiger
counter. If shutter is inoperative,
complete the following:
1. Check circuit breaker.
2. Check point-to-point wiring.
3. Check alarm grid relay.
4. Check interlocks.
5. Check thermal fuse.
Bad electrometer
zero circuit
Shutter always open
Loss of Signal
Bad electrometer
1. Poor wiring
2. Bad power supply
3. Bad electrometer
If shutter is operative, complete the
following:
1. Check power supplies.
2. Check high voltage supply.
3. Replace electrometer.
Replace the electrometer.
Watch source open/close lamps, listen
for shutter or check shutter with a
Geiger counter. If shutter is inoperative,
complete the following:
1. Check circuit breaker.
2. Check point-to-point wiring.
3. Check alarm grid relay.
4. Check interlocks.
5. Check thermal fuse.
If shutter is operative, complete the
following:
1. Check power supplies.
2. Check high voltage supply.
1. Check point-to-point wiring.
2. Check power supplies.
• Check 900V power supply
at the output test points.
• Check ± 15V supply.
• Check voltage in head.
3. Replace the electrometer.
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Infrared Moisture Sensor
This section describes methods and hints to use when troubleshooting the Infrared
measurement subsystem. It assumes the user is familiar with how the sensor works
and the Standardize and Sample Check procedures.
The Infrared sensor is considered to be the basic replacement unit. This means that
the sensor is not repairable on site except for lamp replacement.
This troubleshooting procedure is used to decide if you have a System, Platform
and Sensor, or Process related problem. The decision is based on analysis of error
codes and the use of an oscilloscope to observe the sensor signals. These three
areas are defined as follows:
1. System related problems are concerned with that part of the measurement
subsystem from the junction box to the Host.
The problem may relate to system hardware or software. The solution may be:
a. Changing some software limit check, calibration constant.
b. Replacing a circuit board such as MPRC or ECS.
2. Platform and Sensor problems can occur within the moisture measurement
subsystem from the ABB Smart Processing Center (ASPC) to the sensor
module. The solution may be to change wiring or connectors on the Platform
or change the sensor module itself.
3. Process problems are related to some change in the process which has adversely
affected the accuracy of the Infrared moisture measurement subsystem. These
problems may find solution in picking a different sensor model less affected by
the variability, or by compensating for the process change (if the change is
predictable or measurable). The process effect may be related to dust, dirt,
temperature, sheet composition, or others.
Steps may be taken to reduce or eliminate these types of interference.
Problems with the Infrared Moisture measurement subsystem are generally noticed
in two ways. The first is the failure of some limit test causing a sensor alarm code
and sensor data invalid to appear. The second is bad correlation between the
processed measurement output and a lab reading without any particular error
message.
Sensor Alarm Codes
When Sensor Data Invalid alarm occurs, determine the alarm number associated
with that failure. The alarm number will point the direction for the next step which
may be the use of the sensor health pages for Infrared Moisture Measurements or
an oscilloscope to observe sensor signals.
A list of the error codes is provided in Figure 6-7.
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Table 6-6 Infrared Moisture Alarms
Alarm Number
Description
4600/4700 Sequence error other than standardize
4601/4701 Standardize okay - no ‘soft’ errors
4602/4702 AGC failure other than standardize
4603/4703 A or R raw signal out of range
4606/4706 Basis weight at limit (for Infrared)
4608/4708 Calculation over range
4609/4709 A/D failure other than standardize
4611/4711 A signal A/D offset out of range
4613/4713 R signal A/D offset out of range
4615/4715 A signal out of range - air gap
4617/4717 R signal out of range - air gap
4619/4719 A/R ratio out of range (KC or KS) out of range
4621/4721 AGC standardize gain out of range
4622/4722 AGC failure during standardize
4624/4724 A/R ratio noise (SIGMIR) out of limit
4670/4770 Sequence error during standardize
4678/4778 Standardize not completed
4679/4779 A/D failure during standardize
To view these alarms, access the Health Page Report at the Service Workstation or
the alarm report at the Host.
• In the pe report, the full alarm number and mnemonic are displayed.
• In the Health Page alarm overlay, only the mnemonic is displayed.
• At the Host, only the last two digits of the alarm code are displayed.
Alarms 4619/4719 and 4624/4724
This is a typical problem and may be accompanied by measurement correlation
problems or a noticeable DRIFT in the TREND after the sensor has been off-sheet
for a while. The symptom is failure to standardize that may clear on a second or
third standardize and the failure was due to KC ratio being out of limits. Water on
windows will reduce the value of KC. Also coupled with this failure will be a high
SIGMIR reading which may be high enough to cause a failure of that limit. If the
signals look normal and there is no excessive jumping of the signals, then look for
condensation on the outside of the sensor windows.
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The condensation occurs due to the large temperature change between off-sheet
and on-sheet positions. If the condensation is on the sensor windows it may be
eliminated by proper adjustment of the air wipes. In extreme cases of condensation,
a heated air wipe or window heater may be required to correct the problem.
The condensation may be occurring inside the sensor. Since it is difficult to observe
the condensation inside the sensor, the best action is to replace the sensor after
determining the condensation is not on the outside of the sensor window.
In some HemiPlus sensors, unusually high values of the head constant, KF1 or KF2,
may force this error to occur. The expected ratio should be changed to a value equal
to KF1 divided by 512 (or KF2 divided by 512). If KF1 equals 595, then the expected
standardize ratio should be changed to 1.16.
Alarms 4615/4715, 4616/4716, 4617/4717, 4618/4718, & 4622/4722
This is generally the indication if the sensor is “dead.” First, verify if the Infrared
source lamp is on by looking at the following signals available on the Infrared Sensor
Health Page.
Lamp Current (Lamp Curr) 7.2 to 7.7 VDC
Lamp Volts
10 to 14 VDC
Head Revolutions (Hd Revolutions) 50 or 60 rpm
If there is no lamp or voltage, but there are head revolutions, then cycle the circuit
breaker on the Infrared lamp supply in the Scanning Platform. Watch to see if any
of the signals on the Sensor Health Page return. If the lamp signals return, then the
sensor was shut down due to an overtemperature. Check the liquid cooling unit and
be sure there is good water flow to the sensor. If the lamp signals do not return,
change the lamp.
If there are no head revolutions displayed on the Sensor Health Page, then there
may be a problem with the 120 VAC power or the -15 VDC supply to the sensor.
Refer to the functional diagram for the infrared sensor and the diagnostic card to
examine these signals for measurement. An oscilloscope is needed to examine the
logic pulse. Logic signals from the sensor must be present or the lamp current will
not turn on. Refer to Figure 6-3.
If the above signals are correct, examine the head pulses from the detector head.
Use an oscilloscope and the diagnostic card to compare the pulse train to the pulse
train shown in Figure 6-3. If there is no pulse train, the problem is probably a bad
detector head. If the pulse train is correct, the problem may be in the Infrared ECS
board. For HemiPlus sensors, you should also be able to move the pulses up and
down using the increase and decrease commands on the Infrared Sensor Health
report.
The key point in these procedures is deciding if the problem is in the Platform,
sensor or in the system. If the sensor signals are present but saturated, the system
is either not setting the gain (HemiPlus) or the system does not recognize the signals.
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Alarm 4603/4703
Figure 6-3 Sensor Head Signals
Since the pre-amp gain is adjusted every 45 seconds, occasional 4603/4703 alarms
may be seen on a very wide process where there is either a very heavy or very light
weight streak in the process. The software has the capability of coping with a certain
amount of these. The variables which affect this are called
saturatedSignalCounterLimit and smallSignalCounterLimit, and are located in
the IRGmodule. This is the number of 0.125 second readings which are out of
specification (too large or too small) that are allowed per scan. Increasing these
numbers will allow a certain amount of bad data to be processed, so be aware of
how this may affect trends, averages, and Short Term Machine Direction Variability
calculations.
Use the pulse monitor on the Infrared Health Page Report to determine how bad the
problem is, and if it is due to heavy or light weight spots. The problem can also be
due to intermittent wires in the Platform.
Changing the IRGModule coldstart variables highMeanSignalLimit and
lowMeanSignalLimit can affect the frequency of occurrence of 03 alarms if they
are caused by wild process variations. highMeanSignalLimit and
lowMeanSignalLimit define the window that the system attempts to keep the “R”
pulse within. These values may be increased or decreased to keep the signals larger
or smaller but be sure to keep highMeanSignalLimit 1.5 to 1.9 times larger than
lowMeanSignalLimit and less than maxsignalLimit 1.4.
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Alarm 4608/4708
This alarm is generally the result of a wildly varying process. If the
smallSignalCounterLimit number has been made large, then this alarm may occur
by trying to take the ratio (R/A) when “A” is a very small value or 0. Changing
highMeanSignalLimit and lowMeanSignalLimit may reduce the frequency of
these alarms. Use the oscilloscope to determine just why the alarm may be
occurring. Often, intermittent Platform wiring problems will cause 4603/4703 or
4608/4708 alarms. These will be noticed on the oscilloscope while jogging the
Platform around a suspect point. The problem may be the result of AC interference
to the head signals caused by either improper grounds or optical interference in the
detector sensor.
Alarm 4602/4702
Air Gap Conditioner failure other than at standardize may be caused by several
different problems. Using the oscilloscope and calibrate sample reports, determine
if the AGC is being correctly set. Occasionally, circuit card failures inside the sensor
will cause this alarm even if the sensor signals look correct when examined in the
Junction Box.
If the problem persists with a new sensor and the sensor signals look good not
excessively noisy, the failure may be due to the system trying to step the gain below
-3 db, the lower pre-amp limit. Try increasing the highMeanSignalLimit and the
lowMeanSignalLimit as high as possible to get the gain up one more step.
Increasing the chiller temperature to 115° F may decrease the detector signal enough
to make the gain increase one more step.
Alarm 4621/4721
Usually this is the alarm if the sensor is “dead”. On some systems, the
values for airAbsorptionNominal, airAbsorptionRange, airReferenceNominal,
airReferenceRange, normalizationFactorNominal,
normalizationFactorRange, stdzGainNominal, and stdzGainRange may be
inappropriate and cause this alarm. Using the Infrared Sensor Health Page Report
and changing these values may solve this problem.
Alarms 4609/4709, 4611/4711, 4612/4712, 4613/4713, 4614/4714,
and 4679/4779
These alarms are caused by two things. If the logic stream from the sensor is not
getting to the ECS board, this error may be generated. This error may also be caused
by failure of the ECS card. The most usual cause is a bad ECS card.
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Correlation Problems
Correlation problems are disagreements between the indicated sensor moisture and
a lab moisture determination. It is still a good practice to observe the signals on an
oscilloscope to be sure that there is no intermittent noise or other interference
problems. Bright lights or infrared heaters can cause a type of interference which
may be noticed as a calibration shift. On the oscilloscope, the problem would be
noticed as 60 or 120 (50 or 100) Hz interference superimposed on the sensor signals.
Bad grounding will have the same effect.
If the correlation technique is in question, refer to ASTP-10 and ASTP-11.
General Correlation Scatter
After establishing that the sensor signals are interference free, the first area to
examine in correlation problems is the data taking and lab technique. Tests should
be constructed to evaluate the accuracy of the procedure being used. Also, glass or
bagged process samples should be read on the sensor to ascertain the stability of
the measurement subsystem. Off-line bag sample correlation methods are always
preferred; sometimes however, dynamic analysis is required to verify the off-line
data. Some of the following subjects may affect the sensor readings and should be
evaluated if measurement errors are suspected.
Rewet
If rewet showers are used just prior to the measurement, errors may be experienced
in correlation. The best prevention is to have the shower at least 0.5 seconds from
the measurement. There has been some indication that when “hot” water is used
for the rewet, the problem will be less. If a cold water shower is 0.25 seconds from
the measurement, only 60 percent of the added water will be measured. The problem
is due to a transparent layer of water lying on the surface of the sheet. If the water
is “in” the sheet, the problem should not be severe. The problem will always be
more severe for reflection type scanners.
Dirt Buildup on the Sensor Window
The geometry has been designed to be very insensitive to dust on the window. The
only material known to have a noticeable effect on the measurement is a “black”
buildup caused by a graphite, or other oily substances on the sensor windows. This
will cause a lower than normal reading. This problem has been successfully
addressed by using heated air wipes on the sensor. The heated air keeps
hydrocarbons from condensing on the cooler sensor windows. This problem is
more severe on light weight sheets (below 60 g/m 2 ). The size of this problem
will always be less severe for HemiPlus sensors.
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Step-Outs in the Trend
If step-outs or “drifts” are noticed after the sensor has been off-sheet for a while,
the problem is probably condensation. If the condensation is on the sensor windows,
then air wipe adjustment may cure the problem. If the condensation is internal,
then the sensors must be changed. Heated air wipes are a solution for these
problems. Heated air wipes also keep condensate from dripping from the heads
onto the process.
Step-outs which occur during measurement should be examined using the
oscilloscope. It is easier to observe the effects while scanning a constant sample.
Sometimes synchronous noises may get into the Infrared sensor signals due to
grounding problems. The problems may come and go with different gain settings.
Composition Effects on Infrared Sensors
The HemiPlus Infrared sensors have been designed to have low sensitivity to sheet
composition. However, the sensitivity with the 2 Filter option to composition is
not zero. Typical changes in specific scatter coefficient of less than 20 cm 2 /g will
cause errors of less than 0.2% moisture. Changes in specific scatter coefficient in
grade are typically less than 20 cm 2 /g.
Any additive which contains a broadband absorber such as carbon black, iron oxide,
or black liquor will cause a substantial error on these sensors. Specific values for
error are discussed in the ASTP-11 for the appropriate sensor. The direction of the
error is always negative, which means that the sensor reads too low. Carbon black
in the form of recycled newsprint is a major source of error. When the pulp is deinked,
recycle errors are much less. However, depending on the efficiency of the
de-inking process, there may be some problem with correlation in all 2Filter Infrared
sensors.
The HemiPlus sensor has practically no sensitivity to either specific scatter
coefficient or carbon black. The only requirement is that the Infrared signals be
able to penetrate the sheet. This sensor will always give better results compared to
other 2Filter sensors on any readable paper grade.
Operation at Design Limits
On some applications, the sensor has to operate near to or exceed design limits
when it comes to basis weight, moisture, or sheet attenuation levels. It is useful to
know that on the low end (for example, thin capacitor paper), the Infrared signal
changes very little due to moisture, and extreme freedom from noise and good
stability is required to read out accurate moisture.
On the high end, the sensitivity gets very high, and a high moisture content can
cause a very large pulse ratio on a transmission gauge, where alarm conditions can
occur. It is a good practice on heavy weight applications to test the sensor at a little
higher weight than usual in scan mode. This can be done by taping an extra sheet
of paper over the bottom heads (basis weight/moisture) and scanning the process.
3BUS 208 055 R1101
Sensor Troubleshooting
219

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reproduction, or other means of dissemination may be made without written permission.
Insufficient Cooling
At some sites with very hot sheet temperatures and low chiller flow rates, the water
to the heads changes in temperature. If nothing standard can be made to cure the
problem, there is a modification that can be made to increase chiller flow rate.
Contact a Measurement Specialist for further details.
Troubleshooting Flow Charts
Use the following flow charts to correct poor sensor performance. These tests will
completely examine the sensor hardware and software. No special tools are
required. The time required to complete this procedure depends on the condition
of the sensor at the time of examinations.
Note:
The alarm numbers referred to in these flow charts are the last two
digits of the full alarm number, as they would appear at the Host
computer.
220 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
1
NO
Does the sensor
standardize
3
YES
Is the standardize
alarm 01 (OK)
NO
YES
5
Change alarm
limits to alarm
on bad data.
NO
Is the standardize
data reasonable
YES
Does sample check
work
NO
YES
9
NO
Is the status 00 (OK)
4
YES
Is the standardize
data reasonable
NO
YES
10
NO
Does calibrate
sample work
11
YES
Is the status 00 (OK)
NO
YES
4
NO
Is the calibrate sample
data reasonable
12
2
Figure 6-4 Troubleshooting Flow Chart 1
3BUS 208 055 R1101
Sensor Troubleshooting
221

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reproduction, or other means of dissemination may be made without written permission.
2
NO
Does the sensor
measure
13
YES
Is the measurement
data valid
NO
YES
4
NO
Is the scan average
reasonable
14
YES
Is the moisture
profile reasonable
NO
YES
15
NO
Is the correlation
reasonable
16
YES
Quit! You have
done a nice job!
Figure 6-5 Troubleshooting Flow Chart 2
222 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
3
Does the standardize
light go off
Get sensor alarm status
from Channel Code 100.
4
Is the Platform
in local
Is there a sheet
break
YES
Put gauge on sheet
at Platform.
Wait for sheet up or
set sheetbreak
override.
Look at PC (position complete)
in PmmFrame0->fddo
(in:long mode).
PC = 0
YES
Troubleshoot Platform
positioning problem.
PC = 1
Check other Platform.
Look at smode in
PmmFrame0x->fddo
(in:long mode).
Smode < 02
Smode < 03
Troubleshoot faulty sensor
or put it to sleep.
Figure 6-6 Troubleshooting Flow Chart 3
3BUS 208 055 R1101
Sensor Troubleshooting
223

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reproduction, or other means of dissemination may be made without written permission.
4
Soft error
Code 01
YES
Make a valid scan. Error
may be due to calibrate
sample, adjust scan limits, or
air profile setup.
Hard error
Code 02
YES
Make a valid standardize.
Code 04
YES
Sensor in local
Return to system control.
Code 10
YES
Troubleshoot basis weight.
Bais weight invalid
Code 30
YES
Provide valid compensation.
Compensation defaulted
to product code file
Air profile in process
Code 80
Return
YES
Complete air profile
procedures.
Note:
These alarms are determined in the sequence shown so that when
an alarm is encountered each previous alarm condition has passed.
Therefore, some judgement is needed to determine the error.
Figure 6-7 Troubleshooting Flow Chart 4
224 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
5
Standardize alarm is not 01 (ok)
Standardize not completed.
Alarm 78
Re-standardize
NO
A/D failure
standardize.
Alarm 79
YES
Change the IRPC board
first, then the AI32 board.
Average a signal OFSA
with head pulses clamped
is greater than
absorptionOffsetNominal
+
absorptionOffsetRange.
NO
Alarm 11
NO
YES
Average a signal OFSA
with head pulses clamped
is less than
absorptionOffsetNominal
+
absorptionOffsetRange.
Alarm 12
NO
Alarm 13
YES
YES
Average a signal OFSA
with head pulses clamped
is greater than
referenceOffsetNominal
+ referenceOffsetRange.
NO
Alarm 14
YES
Average a signal OFSA
with head pulses clamped is less
than
referenceOffsetNominal -
referenceOffsetRange.
Air gap IR gain which set
R signal at mid A/D
range is outside of limits.
NO
Alarm 22
NO
Alarm 21
YES
YES
7
Check for dust or oil on
window. Check chiller
for flow and temperature.
Check that the StdzGain
is within the
StdzGainNormal + the
StdzGainRange.
Also check the StdzLow
SignalLimit and the
StdzHighSignalLimit.
NO
Air gap IR gain is less than
1 or greater than 31.
6
7
Figure 6-8 Troubleshooting Flow Chart 5
3BUS 208 055 R1101
Sensor Troubleshooting
225

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reproduction, or other means of dissemination may be made without written permission.
6
Standardize alarm is not 01 (ok)
Average a signal AAIR
with air gap is greater
than air
absorptionnominal +
airAbsorption Range.
Average a signal AAIR
with air gap is less than
airAbsorptionNorminal
-airAbsorptionRange.
Average R signal RAIR
with air gap is greater
than
referenceNominal
+ airReferenceRange.
Alarm 15
NO
Alarm 16
NO
Alarm 17
YES
YES
YES
Average R signal RAIR
with air gap is less than
airReferenceNominal
- airReferenceRange.
Alarm 18
NO
YES
Air gap ratio (KS) of AAIR/
RAIR exceeds
normalizationFactorNominal
+
normalizationFactorRange.
NO
Alarm 19
YES
7
Air gap ratio (KS) of AAIR/
RAIR exceeds
normalizationFactorNominal -
normalizationFactorRange.
NO
Alarm 20
YES
Check for dust or oil on
window. Check chiller
for flow and temperature.
Air gap noise (variation in KS)
exceeds
normalizationFactorNominal
+ normalizationFactorRange.
Alarm 24
NO
7
YES
Check for intermittent cable, ground noise,
steam in gap, or unusual ambient light source
near the gap. Verify coldstart values
in IR module, IRG module, and IRS sensor.
Figure 6-9 Troubleshooting Flow Chart 6
226 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
Run hardware test using the Infrared
Sensor Health Page Pulse Monitor.
7
IR sensor measurement is not correct
-15VDC test
reading between -14.5
and -15.5
NO
Check -15VDC power supply
and replace if required.
YES
+15VDC test
reading between 14.5
and 15.5
NO
Check +15VDC power supply
and replace if required.
YES
Is lamp current
between 7.2
and 7.7 AMPS
YES
NO
Turn lamp off and then back
on. Replace if bad.
Check both 6.3VAC
transformers, motor rotation,
safety switch, and cabling.
Run hardware pulse tests with the
Infrared sensor Health Page Pulse
Monitor at min gain, max gain, and
mid range with the lamp on and off.
Head pulse reading
with lamp on:
MIN = 0 to 0.5
MAX = 9 to 10
MID = 4.8 to 5.4
NO
YES
Head pulse reading
with lamp on:
0 to 0.5
NO
8
YES
Replace head pulse tests and monitor with the
Infrared Sensor Health Page Pulse Monitor.
Check voltages at the sensor. Replace the
heads.
Figure 6-10 Troubleshooting Flow Chart 7
3BUS 208 055 R1101
Sensor Troubleshooting
227

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reproduction, or other means of dissemination may be made without written permission.
Run hardware pulse tests in the gain
monitor (GM) position with the
Infrared Sensor Health Page Pulse
Monitor at min gain, max gain, and
mid range with the lamp on.
8
IR sensor measurement is not correct
Hd Revolutions reading
with lamp on: 50 or 60
NO
Run logic pulse tests at the Infrared
Sensor Health Page Pulse Monitor
with the motor on and then off.
YES
Replace head pulse tests and monitor
pulses from the Infrared Sensor Health
Page Pulse Monitor. Check voltages at
the sensor. Replace the heads.
Check for intermittent cabling and
connectors. Replace the IRPC
board.
Figure 6-11 Troubleshooting Flow Chart 8
228 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
9
Is the Platform
in local
NO
YES
YES
Has the wrong
mode been entered
Put gauge on sheet
at Platform.
Enter correct mode in from
the Host.
NO
Look at PC (position complete)
in PmmFrame0x->fddo
(in:long mode).
PC = 0
YES
NO
Troubleshoot Platform
positioning problem.
PC = 1
YES
Look at smode in
PmmFrame0x->fddo
(in:long mode).
YES
Smode < 04
Check other Platform.
NO
Smode < 05
Troubleshoot faulty sensor
or put it to sleep.
Figure 6-12 Troubleshooting Flow Chart 9
3BUS 208 055 R1101
Sensor Troubleshooting
229

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reproduction, or other means of dissemination may be made without written permission.
10
Sample Check Data
is not Reasonable
Was the wrong
mode entered
NO
Is the compensation
wrong
YES
YES
Enter the correct check
sample mode.
NO
Enter the correct compensation.
Are the conversion
factors wrong
NO
Is the slope or
offset wrong
NO
Was the wrong
sample used
NO
Has the sample
changed
NO
YES
YES
YES
YES
Enter the correct conversion
factors in the data files.
Enter the correct slope and
offset up in the data files.
Use correct sample.
Obtain new sample.
Re-standardize and
check another sample.
Figure 6-13 Troubleshooting Flow Chart 10
230 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
11
YES
Is the Platform
in local
Put gauge on sheet
at the Platform.
NO
Is the Platform in scan
or single point
NO
YES
YES
Is the Platform in
single point
Select on sheet and
scan or single point.
Let heads make one
complete scan and
try again.
YES
Look at PC (position complete)
in PmmFrame0x->fddo
(in:long mode).
PC = 0
YES
YES
PC = 1
NO
Troubleshoot Platform
positioning problem.
Troubleshoot calibrate
sample push button and
setup problems.
YES
Look at smode in
PmmFrame0x->fddo
(in:long mode).
Smode > 49
NO
Smode > 50
Troubleshoot faulty sensor
or put it to sleep.
Figure 6-14 Troubleshooting Flow Chart 11
3BUS 208 055 R1101
Sensor Troubleshooting
231

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reproduction, or other means of dissemination may be made without written permission.
12
Calibrate sample data is not reasonable
Was the button
not pressed
long enough
NO
YES
Press the push button for a
minimum of 5 seconds.
Is the compensation
wrong
NO
YES
Use the correct compensation.
Are the conversion
factors wrong
NO
Is the slope or
offset wrong
NO
Was the wrong
product code used
NO
Is the data
repeatable
YES
YES
YES
YES
YES
Enter the correct conversion
factors in the data files.
Enter the correct slope and
offset up in the data files.
Use correct product code.
Determine if unusual additives
or conditions exist.
Is the lab data
repeatable
YES
Review calibration and correlation
procedures.
Figure 6-15 Troubleshooting Flow Chart 12
232 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
The following alarms are determined in the sequence shown so when an alarm is
encountered, each previous alarm condition has passed. Some judgement is needed
to determine the probable cause of the error.
13
Sensor will not measure
NO
A/D failure other
than standardize.
Alarm 09
YES
Change the ECS board.
NO
Air gap IR gain which
set R signal at mid A/D
range is outside of limits.
Alarm 08
YES
Check scale factors
in IR sensor.
NO
Air gap IR gain less
than 1 or greater
than 31.
Alarm 02
Alarm 21
NO
NO
YES
YES
Check for dust or oil on
window. Check chiller
for flow and temperature.
Check that the StdzGain
is within the
StdzGainNormal + the
StdzGainRange.
Also check the
StdzLowSignalLimit and
the StdzHighSignalLimit.
Check for moisture streaks and
process upsets. Check for
intermittent cable, ground noise
stream in gap, or unusual
ambient light source near the
gap.
Figure 6-16 Troubleshooting Flow Chart 13
3BUS 208 055 R1101
Sensor Troubleshooting
233

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reproduction, or other means of dissemination may be made without written permission.
14
Scan average is not reasonable
Has a clean standardize
been performed recently
NO
YES
Clean the window, then
restandardize.
Is the compensation
wrong
YES
NO
Use the correct compensation.
Is the slope or
offset wrong
NO
Was the wrong
product code used
YES
Enter the correct slope and offset
up in the data files.
YES
NO
Is the data
repeatable
YES
Is the lab data
repeatable.
NO
NO
Use the correct product code.
Determine if unusual additives
or conditions exist.
YES
Perform sample check. Review
calibration and correlation
procedures.
Figure 6-17 Troubleshooting Flow Chart 14
234 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
15
Moisture profile is not reasonable
Is IR gain change
excessive
NO
YES
Clean HighGainSignalLimit,
LowGainSignalLimit, and the
counter limits in the IRGModule.
Check for moisture streaks or
process upsets.
Does moisture go
to 0 or excessive
NO
YES
Check for intermittent cabling.
Is the profile of the
compensation erratic
YES
NO
Is the profile
repeatable
NO
Troubleshoot sensor
or compensation variable.
YES
Take dynamic samples for lab. Review
calibration and correlation procedures.
Check for stream, ambient
light, and broke, in cross
machine path.
Figure 6-18 Troubleshooting Flow Chart 15
3BUS 208 055 R1101
Sensor Troubleshooting
235

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reproduction, or other means of dissemination may be made without written permission.
16
Correlation is not reasonable
Are long term standardize
results stable
NO
YES
Determine and correct
source of instability.
Are long term check
sample results repeatable
NO
YES
Determine and correct
source of instability.
Is the on-line
measurement
repeatable
NO
NO
Review lab measurement
and sampling procedures.
Check for rewet too close to sensor,
dirt buildup on window, oil from air
wipe, stream or light in gap, voltage fluctuations,
head alignment, process
additives, insufficient cooling, operation
at design limits.
Figure 6-19 Troubleshooting Flow Chart 16
236 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
Exercising the Gain Using Software Commands
You can use either the Infrared Sensor Health Page Pulse Monitor or the inspect
utility to set the gain.
Using inspect
Use the following procedures to set the gain with the inspect utility commands.
To increment the gain one step
()[IRGModule0x private$causeGainTo:1]
To decrement the gain one step
()[IRGModule0x private$causeGainTo:2]
To set the gain to the mid-range
()[IRGModule0x private$causeGainTo:3]
Increasing or decreasing the signal to the amplifier in the head will then increase
or decrease the pulse coming out of the head amplifier.
If the output signal responds to the increase or decrease in the gain signal, you have
integrity from the output of the ECS board to the sensor gain amplifier in the sensor
head.
Using the Health Page Pulse Monitor
Access page 2 of the IR Health Page. Page two has a section called
IRGAIN Select (+/-/=)
Press the Tab key and use the Arrow keys to position the cursor over the data entry
point for the IRGAIN Select variable.
To increase the gain by one step, press +(cr).
To decrease the gain by one step, press -(cr).
To set the gain at the mid-range, press =(cr).
Exercising the Reflection IR Flag
Insert and remove the Reflection IR flag using the following inspect utility
commands.
To insert the flag:
()[IRSensor01 private$insertReflector]
To remove the flag:
()[IRSensor01 private$removeReflector]
Monitor the Absorption Moisture pulse on the IR Health Page Pulse Monitor before
and after exercising the flag. An increase in voltage indicates the Reflection IR
flag is in place. A decrease in voltage indicates the Reflection IR flag is not in
place. If the flag does not respond, one of the following could be the cause:
• The sensor is not functioning.
• The ECS board is not functioning.
• The software is not sending the signal.
3BUS 208 055 R1101
Sensor Troubleshooting
237

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reproduction, or other means of dissemination may be made without written permission.
Discontinuity Counter
Each IR Sensor and its modules contain a discontinuity counter. This counter
increments whenever a gap occurs in the stream of output data from the sensor or
module. Setting the AVOS shell to run at a very high priority level (>100) may
cause the discontinuities to occur. This parity level is controlled by the nice
command, which should always be at 10 under normal operating conditions.
The discontinuities counters may have a few counts occur during a reset, however,
they should either remain constant from that point on or perhaps increment by one
or two at the edge of sheet during scanning. If it goes up rapidly, then there is a loss
of data occurring. These gaps would show up as invalid data in the profile. Before
viewing the counters, make sure the AVOS parameter nice is set to 10. View the
counters using the following inspect utility commands:
I> IRSensor01->discontinuities
I>0xModuleAddress->discontinuities
Where: ModuleAddress is the address found by examining the myModules
instance variable in IRSensor01
Normally there are no message reports in the pe event log indicating that there are
counts accummulating. If there is a suspicion that invalid data is occurring within
the moisture profile, then the reporting function may be turned on by setting a flag.
This will cause a warning to be logged in the pe utility whenever a discontinuity
occurs. This warning indicates a difference in time between any two batches of
moisture data signals. To set the enabling flag, proceed as follows:
1. In the AVOS window, enter the following command:
$$ mm log_discontinuity.s
2. When the response showing the current status returns, enter a 1.
3. To turn off the reporting, repeat step 1 and enter a 0.
238 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
Ash Sensors (TLXR)
Ash Sensor
Has Sensor
Verification
Been Done
NO
Perform Sensor Verification.
YES
Does
Operator Station
Standardize
Lamp Go
Off
NO
Does
Gauge
Standardize
Get Sensor Alarm Status
YES
Get Sensor
Alarm Status.
YES
Is
Data Valid
During Scan
NO
Check For Invalid Scan Due To
Normal Occurrences Such As:
Air Profile Collection
Sensor In Local
Adjusting Scan Limits
Perform One Complete Scan
To Clear Errors
YES
Is
Standardize Data
Stable And
Noise Free
NO
Verify Measurement Stability.
YES
Perform Sensor
Verification.
NO
Check
Samples OK
(Ash And PPT).
YES
Calibrate
Sample
OK
YES
Verify sensor accuracy.
NO
Check For Invalid Calibrate Sample
Data Due To Normal Occurrences
Such As:
Air Profile Collection
Sensor In Local
Adjusting Scan Limits
Perform One Complete Scan
To Clear Errors
Get Sensor Alarm Status.
Figure 6-20 Ash Sensor Troubleshooting Flow Chart
3BUS 208 055 R1101
Sensor Troubleshooting
239

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reproduction, or other means of dissemination may be made without written permission.
Refer to Table 6-7 for a summary of Standardize Lamp Failure possible causes and
recommended action.
Table 6-7 Possible Causes of Ash Standardize Light Not Going Off
Symptom Possible Cause Recommended Action
Standardize lamp
does not go off
Platform in Local
Sheet Break
Position Incomplete
Defective Sensor
Check the video alarm page for the message,
Platform In Local. At the Platform, take the gauge
out of local.
Wait for the sheet to be up or override sheet break
detector by jumpering or inserting the sheet break
override flag.
Check to see if position is complete for each
Platform not in local by locating pc using the
inspect utility. It can be found in the array
instruction pmmFrame->fddo. If the pc=1, position
is complete. If pc = 0, troubleshoot the Platform.
Check the sensor mode for each Platform by
locating smode using the inspect utility. It can be
found in the array instruction pmmFrame->fddo.
If smode = 01 or 02, check other Platforms.
If smode = 01 or 02, (still trying to standardize), put
faulty sensor to sleep.
Ash Sensor Standardize Results
In addition to the systems standardize report and the sensor correlation report,
information may also be obtained by examining the stdResultsPending table within
the ash object itself. The information available includes a problem list tree and the
current standardize results.
To see whether or not the Scanning Platform subsystem is currently operating with
a good standardize, examine the stdzResults and stdzResultsPending instance
variables using the inspect utility. If the 0x address pointers are qualified, then the
subsystem has performed what it believes to be a good standardize. If the Host
disagrees, then there is a problem in the transferring of the standardize data from
the Scanning Platform to the Host.
If the address pointers are different, then the stdzResultsPending report must be
examined to see what actually failed. This can be done by first putting the inspect
utility in the :long mode and then typing in the entire 0x display given. The resulting
display will contain the address pointer to the problem list string, and the results of
the last attempted standardize. The information which should be examined is the
following:
tempCompFlag:
Indicates if temperature compensation was active during the standardize.
A 1 is On, 0 is Off.
240 Sensor Troubleshooting
3BUS 208 055 R1101

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reproduction, or other means of dissemination may be made without written permission.
zeroScaleInput:
The signal with the electrometer clamped should be about 0 V.
zeroScaleInputSigma:
This is the statistical noise calculation of the zero signal. Should be less than 10 -5
Volts.
fullScaleTempRef:
This is a two-variable array of the temperature compensation applied during
standardize giving the results for both flag in and flag out. If there is no temperature
compensation, they will be 0.
fullScaleTempSigma:
This is a two variable array of the temperature compensation statistical noise during
standardize giving the results for both flag out and flag in. If there is no temperature
compensation, they will be 0.
logVoltageRange:
This is a two variable array giving the computed log value of the voltage range for
the flag out and the flag in.
voltageRange:
This is a two variable array giving the maximum electrometer signal for the flag
out and the flag in.
voltageSigma:
This is a two variable array giving the statistical noise of the maximum voltage for
the flag in and the flag out. It should be less than 10 -5 Volts.
The problemList data can be examined by sending a message in the inspect mode
to the pmmSensor object as follows:
()[pmmFrame01 stdzErrors]
3BUS 208 055 R1101
Sensor Troubleshooting
241

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reproduction, or other means of dissemination may be made without written permission.
Ash Sensor Hardware Diagnostics
The inspect utility will be used to exercise the Electrometer Clamp and the Shutter
providing a test of hardware performance on-line. These tests utilize the Scanning
Platform software to initiate several combinations of clamp and shutter operation.
1. Place the Scanning Platform console window for the Ash sensor in question,
into the inspect utility mode.
2. Monitor the electrometer output voltage.
3. Place the Ash sensor in the off-sheet position from the operator station.
The initial condition will be Electrometer Clamped and Shutter Closed. Use the
commands given below to execute the conditions shown in the matrix of Table 6-8.
To Open or Close Shutter
()[ashSensor01 $private$openShutter]
()[ashSensor01 $private$closeShutter]
Table 6-8 Electrometer Responses to Shutter/Clamp Commands
Command Given Clamp Unclamp
Shutter Open 0 mv ±±± 10 mv 7.2 to 9.2 VDC
Shutter Closed 0 mv ±

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.
Table 6-9 Ash Electrometer Hardware Diagnostics
Condition Possible Cause Action To Take
Never Clamped Bad electrometer Replace electrometer.
Always Clamped
Watch source open/close lamps, listen
for shutter or check shutter with a
Geiger counter. If shutter is inoperative,
complete the following:
1. Check circuit breaker.
2. Check point-to-point
wiring.
3. Check interlocks.
Shutter Always Open
Loss of Signal
1. Poor wiring
2. Bad power supply
3. Bad electrometer
If shutter is inoperative, complete the
following:
1. Check power supplies.
2. Check high voltage
supply.
3. Replace electrometer.
Watch source open/close lamps, listen
for shutter or check shutter with a
Geiger counter. If shutter is inoperative,
complete the following:
1. Check circuit breaker.
2. Check point-to-point
wiring.
3. Check interlocks.
If shutter is inoperative, complete the
following:
1. Check power supplies.
2. Check high voltage
supply.
1. Check point-to-point the
wiring.
2. Check power supplies:
• Check 900 Volts power
supply at the output test
points.
• Check +/- 15 Volts supply.
• Check voltage in head.
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Ash Correlation Problems
Use the following as an aid in troubleshooting for correlation problems.
1. Multiple tuning required on product code basis
The Ash HV or the X-Ray tube is suspected to be incorrectly set and
should be properly set to remove ash compensation sensitivity.
2. Calibration shifts from off-sheet to on-sheet positions over a period
of minutes:
This is Frequently, temperature related. The repair method is to assure that the
sensor temperature is above the highest on-sheet temperature and if this is not
sufficient, add temperature-controlled heated air wipes to control the air gap
temperature to a constant value. If this is not possible, turn On air temperature
compensation from the basis weight into the ash process. The previous listing
order is the presently understood priority rating to solving temperature
problems with ashgauges. The maximum ambient temperature should be less
than 85°C for an Ash gauge from a component survivability viewpoint.
3. Measurements shifts and anode HV or current shifts observed:
Sensor temperatures should be higher than the highest temperature
on-sheet. The X-Ray tube HV supply voltage must be constant to
+/- 2 millivolts of the monitor voltage, which will occur with a good
supply if it is held at a constant temperature.
4. Tuning required for some products but not for others:
Product composition may be suspected for an ingredient for which the
gauge is not calibrated. For 2C operation, if a clay/Ti0 2 gauge is
on-site and an occasional product which has chalk in it is run, the Ash
gauge will show large errors (a +1.5% Ash per +1% chalk addition),
and so on for other high atomic number Ash additives.
5. Ash gauge measures check samples but does not measure customer
product without large tuning changes:
The laboratory ashing procedure must correspond to that given in the
calibration report or be proven to be equivalent in results. Some Ash
materials break down into gases at improperly high ashing
temperatures.
6. Signal is reading lower or higher than normal:
The measurement flag may not be working properly. If the value is
reading 30% lower when the flag is not in the measurement beam, then
the flag is probably stuck and is in the beam. If it is reading higher
than normal with the flag in the beam, then the flag is probably stuck
open and is not in the beam.
See Figure 6-21 for troubleshooting the correlation problems for Ash sensor.
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1. Measure MYLAR check
samples.
N
2. Do Indicated PPT values agrees
with calibration report
N
Adjust anode High Voltage.
N
Y
Y
3. Do indicated Basis Weight
Mesurement values agree
with calibration report
N
Change calibration constants to agree
with calibration report.
N
4. Do indicate % ash values
agree with calibration report
Y
N
Y
Change calibration constants to agree
with calibration report.
N
See a Regional
Measurement
Specialist.
Y
Y
5. Check the process for
composition stability and
check if sensor temperature
greater than on-sheet
temperature.
N
Adjust sensor temperature to customer
composition.
Y
N
Y
6. Examine profile with check
sample for Platform alignment
check.
N
Explore results with Measurement
Specialist.
Review the Check Sample
Readings
Figure 6-21 Ash Correlation Troubleshooting Flow Chart
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Air Bearing, Contacting, and Non-Contacting
Caliper Sensors
These troubleshooting aids and charts can be used to isolate Caliper sensor
malfunctions. Caliper sensor malfunctions are usually indicated by alarm messages,
by observing the standardize sequence and its resultant report, or noting changes in
performance. When troubleshooting, refer to the Caliper Functional Drawings.
Troubleshooting the Caliper sensor and measurement centers around interpreting
the various alarm codes and exercising the mechanical operations of the sensor.
Exercising the Caliper Sensor
The caliper head can be opened or closed by using the following inspect utility
message command. The vacuum and pressure valves can be turned On or Off by
using the same inspect utility message command.
I> ()[caliperSensor0x private$setupCaliperHardware:n pressure:n vacuum:n]
Where n is:
Caliper
Hardware Pressure Vacuum
0 open head On On
1 closed head Off Off
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Troubleshooting Alarms
Code Alarm Message
Text
5010 Proximitor Signal
Failure
5011 Pressure Signal
Failure
5012 Vacuum Signal
Failure
5030 Caliper Proximitor
Output Fail: STDZ
5031 Caliper Electronic
Noise Fail: STDZ
5032 Caliper Zero (Sensor
Zero) Fail: STDZ
5033 Caliper Pressure Fail:
STDZ
5034 Bearing Height Fail:
STDZ
5035 Caliper Air Bearing
Noise Fail: STDZ
5036 Caliper Vacuum Fail:
STDZ
5039 Caliper Lift-Off Fail:
STDZ
5040 Check Proximitor
Output
Table 6-10 Troubleshooting Alarms and Codes
Probable Cause(s)
- Bad Analog Input Circuit
- Proximeter Assembly Defective
- Bad Analog Input Circuit
- Pressure Transducer Defective
- Bad Analog Input Circuit
- Vacuum Transducer Defective
- Proximeter Assembly Defective
- FTI Power Supply Bad
- Temperature Compensation
- Probe Drift
- Unstable Proximeter
- Probe Unstable
- FTI Power Supply
- Target not Making Contact with
The Measure Head
- Low Pressure to Top Head
- Defective Transducer
- Faulty Wiring
- Defective Sensor Cap Assembly
- Defective Press Regulator
- Wobbly Sensor Cap
- Dirty Sensor Cap Assembly
Paper in Gap
- Head Closed at STDZ
- Defective Proximeter
- Proximeter Assembly Defective
- FTI Power Supply Bad
(Continued on next page)
Corrective Action(s)
Check the analog circuit paths.
Check the ABC4 PWA and the
AI32 PWA.
Replace Proximeter.
Replace the Pressure
Transducer.
Replace the Vacuum
Transducer.
Replace the Proximeter.
Replace the FTI.
Replace the Proximeter Probe.
Replace the FTI.
Check the Lift-Off Assembly
Operation.
Restore Pressure.
Replace the Transducer.
Replace the Sensor Cap.
Replace the Sensor Cap.
Clean the Sensor Cap.
Remove paper from the gap.
Check the Proximeter Output.
Replace the Proximeter.
Check Lift-Off Mechanism.
Replace the Proximeter.
Replace the FTI.
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Code Alarm Message
Text
5041 Check Electronic
Noise
Table 6-10 (Continued)
Probable Cause(s)
- Noisy Proximeter
- Poor Grounding
- Probe Drift
5042 Clean Caliper Head Air Bearing:
- Dirt Buildup on Contact Head
- Dirt Buildup on Filtering Head
Contacting:
- Dirt Buildup on Either Contacting
Head
5043 Check Caliper
Pressure
5044 Check Air Bearing
Height
5045 Check Air Bearing
Noise
5046 Check Caliper
Vacuum
(Continued on next page)
Corrective Action(s)
Replace the Proximeter.
Check System Grounds
Clean the Head.
Perform a Clean Standardize.
- Air Pressure Drifting Check the Main Air Supply.
Check the Regulator Output.
- Dirty Target Clean the Target.
Air Bearing:
- Floating Head Is Dirty
Contacting:
- Low Air Pressure to Bottom Head
- Analog Missing
- Low Air Pressure to Bottom Head
- Analog Missing
5047 None - Head has been off-sheet for a period of
time and allowed to cool down
5050 Caliper Proximeter
Output Fail: Measure
5053 Caliper Vacuum Fail:
Measure
5056 Caliper Vacuum Fail:
Measure
5057 Product Code
Slope < 0.9 Or > 1.1
5058 Air Profile
Compensation Too
Large: Measure
- Proximeter Assembly Defective
- FTI Defective
Clean the Floating Head.
Restore Pressure
Check the wiring.
Gauge should automatically
standardize and clear alarm.
Replace the Proximeter
Assembly.
Replace FTI.
- Air Pressure Too Low or High Restore Air Pressure.
- Nothing in Gap
- Pressure to Low
Scan Process or Sample.
Restore Pressure.
- Wrong Entry for Slope in PCF Correct Entry.
- Platform Badly Misaligned
- Paper in Gap
Realign the Platform.
Remove the paper.
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Code Alarm Message
Text
5059 Caliper Lift-Off Fail:
Measure
5058 Air Profile
Compensation Too
Large: Measure
5059 Caliper Lift-Off Fail:
Measure
5078 Standardize Not
Finished
Table 6-10 (Continued)
Probable Cause(s)
- Proximeter Output Out of Range.
- Head Closed
- Platform Badly Misaligned
- Paper in Gap
- Proximeter Output Out of Range
- Head Closed
Corrective Action(s)
Check the Proximeter Output.
Repair Lift-Off.
Realign the Platform.
Remove the paper.
Check the Proximeter Output.
Repair Lift-Off
- Standardize Sequence Interrupted Repeat the Standardize
procedure.
Alarm Code Classification
The Alarm Codes can be classified into four general categories. Refer to
Table 6-11 for that classification.
Table 6-11 Alarm Code Classification
Alarm Codes (Last two digits only)
Classification
10, 11, 12 Analog Input Alarms
30, 31, 32, 33, 34, 35, 36, 37, 38, 39 Standardize Failure Alarms
40, 41, 42, 43, 44, 45, 46, 47 Maintenance Alarms:
These represent a warning of
potential problems.
50, 53, 56, 57, 58, 59, 78 Failure Alarms in Measure Mode
To view these alarms, access the Health Page Report at the Service Workstation or
the alarm report at the Host.
• In the pe report, the full alarm number and mnemonic are displayed.
• In the Health Page alarm overlay, only the mnemonic is displayed.
• At the Host, only the last two digits of the alarm code are displayed.
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Sensor Validity Codes
Caliper sensor validity codes can be located by printing out the contents of the
outputSignal instance variable. While in the inspect utility, obtain the address of
the outputSignal. When the 0x address is typed on the console, the resulting
printout will include, at the end, a collection of data blocks. Each block is made up
of five entries which are the results of processing each data sample in the
measurement. The entries are described in Table 6-12.
Table 6-12 Definitions of Data Found in outPutSignal Structure
Type Name Description
double (value) This is the value of the sheet property
being measured.
double (cd) This is the cross direction location at
which the property was measured.
double (md) This is the machine direction location
at which the property was measured
(Not Used).
short (invalid) This is the validity code for this sample.
long (synch) This is the synch code (time stamp) for
this sample.
Table 6-13 will help you interpret the validity code.
Table 6-13 Definitions of outPutSignal Validity Codes
Code
Meaning
1 Invalid driver data
2 No initial standardize
8 Cross direction unsynchronized
10 Cross direction position invalid
20 Machine direction position invalid
80 Measuring air profile
100 Sensor standardizing
200 Sensor in sample check mode
400 Unsynchronized sensor data
1000 Invalid sensor data
2000 Untuned sensor data
4000 Sensor not measuring
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A
Appendix A:
Quick Reference Guide
This chapter contains the following major sections:
Section ...............................................................................................Page
Scanning Platform Utilities ............................................................................ 252
Utility Commands .......................................................................................... 253
Performing a gstore ........................................................................................ 254
Object Inspector ............................................................................................. 255
Function Keys ................................................................................................ 259
DESQview Operations ................................................................................... 260
Off-Line Debug .............................................................................................. 263
Inspect Messages ........................................................................................... 264
Application Tools ........................................................................................... 265
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Scanning Platform Utilities
Line Prompts
$$ - Primary line prompt, AVOS Shell
$! - Secondary line prompt, AVOS Shell
I> - Object Inspector prompt
: - Editor Prompt
Special Functions
If the system prints “abnormal termination of utility,” then type:
shift, Ctrl, |
or
shift, Ctrl, - (European keyboards)
If the system shows the $! prompt, then you are in the sub-shell. You can exit to
the sub-shell while in the inspect utility if you type::!
Type: exit (cr) to return to the inspect utility (I>)
Utility Command Response to a File
command > /pathname/filename - creates a file overwriting any
existing file of the same name
command >> /pathname/filename - concatenates to existing file of the
same name
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Utility Commands
File Commands
$$cat /pathname/filename - Concatenate and print files
$$more /pathname/filename - Display paged file
$$rm /pathname/filename - Remove file
$$cp /pathname/filename - Copy file
$$mv /pathname/filename - Move file
Maintenance and Debugging
$$derr - Display error history
$$dfree - Display memory free space
$$dobj - Display object list
$$dproc - Display processor
$$droot - Display root directory
$$df /bram1 - Free space check
$$fsck /bram1 - File system consistencies check and
interactive repair
$$date 11-21-91-1991 11:10 - Enter current date and time
$$df /bram1 - List free space
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Performing a gstore
$$gstore (cr)
Type: 1 To save all scanner, servo, and sensor setup data to the frame.ini
configuration file.
Type: 2 To save changes made to the fhi01 object; i.e., Frame Control Panel
changes.
Type: 3 To save all changes made to the I/O portion of the system to the
io.ini file. This includes digital invert masks, analog temperature
limits, and such.
Type: 4 To save all changes made in the host interface objects to the
pmm.ini configuration file.
Type: 5 To save customer site identification data used on the Health Pages
to the appl.ini configuration file.
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Object Inspector
$$inspect
I>:h - Help prints a list of inspector commands
I>:glob(al) - Print a global list of object names
I>:pa off - pa(ge) off
I>:pa on - pa(ge) on
Typing a q, while in pa(ge) on, when
displaying an object will cause the return to the I>
I>:a L abbrev - To set up a single keystroke abbreviation to substitute for
a repeated command string to be used within the current
use of the inspect utility. This abbreviation is not saved
when inspect is exited.
I>:a - To display currently active and available abbreviations
I>:dec - To display integer values in decimal
I>:hex - To display integer values in hexadecimal
I>:long - To display objects in their expanded mode showing the
contents of embedded arrays and structures
I>:short - To display objects with arrays and structures not expanded.
This is the default mode.
I>:out [path] - To route all inspect responses (except from messages) to
a named file.
I>:pa n - To define how many (n) lines are to be displayed when
paging is turned on.
Display Object
I>objectName
I>0xaddress
If the system responds with a 0x address that is an (id):
Type (space bar) (cr) to display the variable data list.
Note:
The ~ key character has been reassigned on European keyboards.
You may have to experiment with the keys until you get the right one.
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Modify Object
I>objectName->variableName=value
I>0xaddress->variableName=value
I>0xaddress->NDXVAR[X]->V1=value
X = variable number
I>:pm objectName - print method; lists all the methods an object can
execute via the message command.
I>:! - go to sub-shell for utility operations. Type exit
exit (cr) at $! prompt, will return to I>.
I>. - Repeat the last Inspect instruction.
I>:q - quit, c-files resident
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Special Characters
’ - Literal string
\ - Delimiter
: - Delimiter between arguments
CTRL BREAK - Terminate command
CTRL C - Terminate command
CTRL U - Delete line
If the system prints the “entering migration mode” message type:
shift, Ctrl, |
or
shift, Ctrl, - (European keyboards)
Type to restore the AVOS prompt.
If the system shows the $! prompt, you are in the sub-shell. Typing :! while in the
inspect utility causes this. Type exit (cr) to return to I> prompt.
Inspect Messages
Command Format
I>(format)[objectName command:argument] (cr)
Format determines the presentation of the response to the message. If left empty,
the default is hex.
Format
char
int
short
long
Double
DDB
bool
id
hid
objectName
command
argument
Description
A one byte character string using typographic symbols such as
A, &, and +.
A signed integer number taking two bytes.
A signed integer number taking two bytes.
A signed integer number taking four bytes.
A double precision (eight bytes) floating point number.
A Double Decimal Byte format used in the PPM emulator.
Used to designate a Boolean logic function. It can either be a
long or a char.
Identifies an object ID address. It is a long size.
The same as an ID but not part of the initialization activity at
startup.
Select from the names printed on the global list.
Selected from the list produced by :pm (print method).
Arguments are used to pass information to an object.
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Examples:
I>()[pmmFrame01 stdzErrors] (cr)
I>()[betaSensor01 stdzFor:0 mode:0] (cr)
mode:0 = dirty standardize
mode:1 = clean standardize
Using the Editor
Enter Editor
$$ed /pathname/file.name
Load the editor and read file contents to the editor buffer.
: Editor Prompt.
Use editor commands to modify a file.
Editor Commands
a - append
c - change
d - delete
i - insert
p - print
q - quit text editor
r - read
u - undo
w - write file to ram disk
s - substitute
/ - search delimiter
. - terminate for a, c, i
Editor Example
: r /ss01/clm/startup Read startup into the editor buffer.
: 1,$p Print the contents of the buffer.
: 35s/19200/9600 Change the value 19200 on line 35 to 9600
and print the contents of the buffer to verify the
change.
: w /ss01/clm/startup Write startup file back to ram disk.
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Function Keys
F1 - Help Menu
F2 - Turn on Print Logging
F3 - Turn on Disk Logging
SHIFT F2 - Turn off Print Logging
SHIFT F3 - Turn off Disk Logging
F4 - Change or Display Configuration
F5 - Terminate task & close ACE window
F6 - Run GONZO (default is +9200 baud)
F7 - Run Health Page Software
ESC - Exit this help screen
CTRL-SHIFT-DEL - Abort, the equivalent of the three finger
crash
CTRL-ALT-DEL - Close active window (but not port)
SHIFT 1 - Close Port, used to reopen a window after Ctrl,
Alt, Del
In the event of lost Serial Communication to the Service Workstation, try:
Ctrl c
Ctrl u
Ctrl Break
Close window and reopen.
Close DESQview and reactivate.
Restart PC.
Restart SP.
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DESQview Operations
ALT
Select Main Menu
o
Open Window
s
Switch Window
c
Close Window
r
Rearrange Window
z
Zoom
m
Mark, Transfer, Scissors
Open Window
Scanning Platform CONSOLE W1
DOS (128K)
D1
REMOTE ACCESS MGR RA
Close Window
Are you sure
Yes
Y
No
N
Switch Window
DOS Window
D1
Health Pages Terminal W1
Remote Access Manager W4
Rearrange
Move
M
Resize
R
Position 123456789
Scroll
S
Freeze
F
Hide
H
Put Aside
(not shown on this menu)
Change Colors
(not shown on this menu)
Video Options
(not shown on this menu)
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Move
Done
(cr)
Move
Resize
Resize
Done
Move
Resize
(cr)
Creating a Hot Key
DO NOT select any key already used by ACE or DESQview. Ctrl s and Ctrl q are
used by Unix to control scrolling. Do not use Ctrl c or Ctrl Break.
Hot Keys are only active in the window in which they are created.
1. Position the cursor in the window, where the script is to be activated.
2. Select the LEARN menu.
Hold shift, tap Alt.
The console will display the LEARN Menu.
3. Select Start Script (cr).
4. The console will respond with Press The Key You Want To Redefine. DO
NOT select any key previously used by console function. Use a combination
of Shift, Alt, Ctrl and a Function Key or letter.
Example:
CTRL, f12
5. The console will display the key selected and ask for a script name. Type a
script name that means something to you, preferably the same as the script.
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6. Type the script.
Example:
scanner01->
CAUTION
Do not type a carriage return (cr). This will become part
of the script. You can put the Service Workstation in an
endless loop, if you do.
7. Select the LEARN menu.
Hold shift, tap Alt.
The console will display the LEARN Menu.
8. Select Finish Script (cr).
9. Try the script, by pressing the new hot key, to see if it works.
10. Select the LEARN menu.
Hold shift, tap Alt.
The console will display the LEARN Menu.
11. Select Save Script (cr).
Note:
The S(ave) option is only present when an unsaved script exists in
the system.
Display Scripts
1. Select the LEARN menu.
Hold shift, tap Alt.
The console will display the LEARN Menu.
2. Select Display Script (cr).
The console will display a list of scripts already in the system.
3. Press Shift, PrtSc to print a copy of the scripts.
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Off-Line Debug
Type e to print the fault condition message.
Type x to print the exception message log.
Type d 1 100 to display the first 100 memory locations.
Offline debug only appears whens the MPRC start mode switch is in the down
position and a reset has been executed. The purpose is to provide access to error
conditions which occurred after the last restart, but the cause(s) of which became
inaccessible due to a system lock up. In some cases an offline debug restart using
the e, x, and d commands used, may uncover the cause.
The g command will continue the startup process after the diagnostic data has been
collected.
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Inspect Messages
Prints the sensor configuration for the indicated scanner, showing real sensors,
dependent sensors, and sensors which are asleep.
I>()[scanner01 print]
Prints the last standardize condition for each sensor on the scanner. For sensors
which have failed standardize, it gives all the failed parameters. For individual
sensors, use the pmm name, such as pmmBeta01.
I>()[pmmFrame01 stdzErrors]
Prints out the current I/O Configuration.
I>()[ucHardware printOnConsole]
Exercising the Basis Weight Shutter:
I>()[betaSensor01 private$openShutter]
I>()[betaSensor01 private$closeShutter]
Exercising the Basis Weight Electrometer Clamp:
I>()[betaSensor01 private$clampElectrometer]
I>()[betaSensor01 private$unclampElectrometer]
Exercising the Reflection IR Flag:
I>()[IRSensor01 private$insertReflector]
I>()[IRSensor01 private$removeReflector]
Exercising the Ash Shutter:
I>()[ashSensor01 private$openShutter]
I>()[ashSensor01 private$closeShutter]
Exercising the Ash Electrometer Clamp:
I>()[ashSensor01 private$clampElectrometer]
I>()[ashSensor01 private$unclampElectrometer]
Exercising the Caliper head/pressure/vacuum:
I>()[caliperSensor01 private$setupCaliperHardware:n pressure:n Vacuum:n]
CaliperHardware Pressure Vacuum
Where n is: 0 open head on on
1 close head off off
Exercising the OptiPak clamp/vacuum:
I>()[optipakSensor01 private$setupOptipakHardware:n Vacuum:n]
OptipakHardware Vacuum
Where n is 0 unclamp on
1 clamp off
264 3BUS 208 055 R1101

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.
Application Tools
$$ft - Platform tuning tool
$$aim - Analog Input Monitor Utility
$$dim - Display or modify Digital I/O status
$$monitor - Real Time Monitor
$$pe -a - Print error all system messages
$$smr - Signal Monitor Report
$$uc_heat (mc id) - Microcontroller temperature setup
$$ gstore - Save configuration change to ram disk
$$tbmcu - Examine contents of tbm arrays
$$sentest - Collect scan and single point data for performance testing
3BUS 208 055 R1101
265

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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.
Index
A
ABB Smart Processing Center (ASPC) Hardware,
113
analog and digital (I/O) documentation, 146
analog input monitor utility, 121
aim main menu, 121
examples of aim reports, 122
AI channel gains report, 124
AI channel slopes and offsets report,
124
AI signal report (statistics), 123
I/O device selection report, 122
procedure for using the aim utility, 121
analog input signal verification and tracing,
125
digital I/O utility, 118
dim main menu, 118
examples of dim reports, 119
I/O selection, 119
printout of I/O configuration, 119
procedure for using the dim utility, 118
digital input/output signal verification and tracing,
120
host/workstation interface to the ASPC, 114
inspecting and repairing BRAM, 116
procedure to repair BRAM, 116
LED interpretation, 139
ECF, ECS, and ECC LEDs, 140
ECF and ECC boards (only), 140
MPRC LEDs, 141
power supply LEDs, 139
micro-controller DC power log, 152
power down analysis, 147
power down reason (reason for shutdown),
149
safety interrupt alert, 147
using the diagnostic card adapter, 126
diagnostic cards, 130
replacement parts, 138
Accel, 100
ACCELERATION Phase Operation, 9
Accessing 1180 MICRO Profile Data Inside the
Scanning Platform, 42
advdb, 99
aim utility
Main Menu, 121
using, 121
Air Bearing, Contacting, and Non-Contacting Caliper
Sensors, 246
Air Column Compensation for Smart Sensors, 202
Al Channel Gains Report, 124
Al Channel Slopes and Offsets Report, 124
Al Signal Report (Statistics), 123
Alarm
4602/4702, 217
4603/4703, 216
4608/4708, 217
4609/4709, 217
4611/4712, 217
4613/4713, 217
4614/4714, 217
4615/4715, 215
4616/4716, 215
4617/4717, 215
4618/4718, 215
4619/4719 and 4624/4724, 214
4621/4721, 217
4622/4722, 215
4679/4779, 217
code classification, 249
troubleshooting, 247
Analog and Digital I/O Documentation, 146
Analog Input Monitor Utility, 121
Analog Input Signal Verification and Tracing, 125
Application, 157
tools, 265
Ash
correlation problems, 244
hardware diagnostics, 242
standardize results, 240
TLXR troubleshooting, 239
Auto Edge-of-Sheet (AEOS), 3
autoEOS, 103
Automatic Reporting and Retriggering, 175
avdb, 99
3BUS 208 055 R1101
Index
267

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.
B
Basis Weight
hardware diagnostics, 211
TLK, TLP, and TLS troubleshooting, 209
biasn, 101
biasp, 101
BRAM
repairing, 116
Broken Grid Alarm, 86
C
Calibrate Sample Report, 189
Caliper
exercising the sensor, 246
Changing the Host/SP BAUD Rate and the Station
ID, 85
Close Window, 260
Collect Data On, 178
Command Format, 257
Comments About the Motor Controller, 95
Compensation, 50
Compensation Flag Setup, 201
Composition Effects on Infrared Sensors, 219
Conversion, 50
Converting tbmcu files for spreadsheet analysis, 32
Correction, 50
Correlation Problems, 218
Creating a Hot Key, 261
CRUISING Phase Operation, 9
D
Data Box Collection Calculation, 47
Data Collection
starting and stopping, 176
Data Required for Problem Escalation, 60
dbAvgTime, 102
dbWidth, 102
ddcExcessiveErrorPercent, 100
ddcRestrictedMotionPercent, 100
DECELERATION Phase Operation, 10
Definition of Terms, 198
DESQview operations, 260
close window, 260
creating a hot key, 261
display scripts, 262
move, 261
open window, 260
rearrange, 260
resize, 261
switch window, 260
Diagnosis of Platform and Servo Problems, 96
Diagnostics
cards, 130
software, 155
Digital I/O
signal verification and tracing, 120
utility, 118
dim Utility
Main Menu, 118
reports, 119
using, 118
Dirt Buildup on the Sensor Window, 218
Discontinuity Counter, 238
Display Object, 255
Display Scripts, 262
Displaying Reports within inspect, 187
duration(3), 102
E
ECF, ECS, and ECC LEDs, 140
editor commands, 258
Enter Editor, 258
Examining Floating Point TBM Arrays, 34
Exercising the Gain Using Software Commands,
237
F
farEdge, 102
farEOS unknown/homeEOSunknown, 103
File Commands, 253
Filtering, 49
Fine Tuning, 50
Flow Charts
troubleshooting, 63, 220
ash (TLXR), 239
ash correlation, 245
basis weight, 209
Frame Tuning and Diagnostic Tool, ft, 110
Function Keys, 259
G
Gap Compensation
disable, 202
General AVOS Utilities, 158
General Correlation Scatter, 218
General Procedure, 176
General Software Troubleshooting Techniques, 156
General Troubleshooting Instructions, 59
changing the host/SP BAUD rate and the station
ID, 85
data required for problem escalation, 60
host computer coldstart data file overview, 76
268 Index 3BUS 208 055 R1101

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.
radiological safety features and alarms, 86
broken grid alarm, 86
head tracking error, 87
inherent sheet break (ISB) alarm, 86
invalid shutter open alarm, 87
shutter closed during prepare to move, 87
shutter closed when host computer is
down, 87
startup messages, 77
troubleshooting flow charts, 63
Global Access, 176
gstore, 254
gstore Utility, 162
H
Hang Up Problems, 96
Head Package Dimensions
definitions, 4
setup, 3
Head Tracking Error, 87
healthRequest, 103
homeEdge, 102
HOMING Phase Operation, 11
homingError, 102
Host Computer Coldstart Data File Overview, 76
Host/Workstation Interface to the ASPC, 114
How Head Position is Determined, 5
How to Start the Scanning Platform, 185
I
I/O Configuration
printout, 119
I/O Device Selection Report, 122
I/O Selection, 119
Identifying Sensor Configuration, 164
increment(3), 101
Infrared Moisture Sensor, 213
Inherent Sheet Break (ISB) Alarm, 86
Inspect Messages, 257, 264
inspect Utility, 160
Inspecting and Repairing BRAM, 116
Insufficient Cooling, 220
Interface
host/workstation to ASPC, 114
Intraframe/Interframe Compensation, 18
inTransit, 103
Introductory Comments, 27
Invalid Shutter Open Alarm, 87
Ki, 101
Kp, 100
K
L
LED Interpretation, 139
Line Prompts, 252
Linearization, 50
Logical Zone Calculations, 48
M
Maintenance and Debugging, 253
maxEdgeChange, 102
maxSpeed, 103
Measurement Analysis
using on-line utilities, 27
using sentest Utility, 35
using tbmcu utility, 27
Mechanical Influence on Motion Problems, 94
Messages
inspect, 264
startup, 77
Micro-Controller DC Power Log, 152
Miscellaneous, 98
Modify Object, 256
Motion Control Theory, 12
Motion Theory, 7
Motor Controller Slope and Offset Too Large, 98
Motor Controller Slope Too Small, 97
Move, 261
MPRC LEDs, 141
N
Normalization, 49
O
Object Inspector, 255
display object, 255
inspect messages, 257
command format, 257
modify object, 256
special characters, 257
using the editor, 258
editor commands, 258
enter editor, 258
Obtaining derr, bfchk, and dfree Data, 183
Obtaining the monitor Report, 180
Off-Line Debug, 195, 263
offSheetTimer, 104
3BUS 208 055 R1101
Index
269

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.
onSheetTimer, 104
Open Window, 260
Operating System, 157
Operation, 199
Operation at Design Limits, 219
Operation of the Sensor Health Pages, 191
Operation Overview, 169
Outputs, 173
Overcontrol Problems, 97
diagnosis of platform and servo problems
overcontrol problems, 97
Overview of Menu Selection, 176
P
Performing a gstore, 254
Position and Motion Problems, 89
comments about the motor controller, 95
diagnosis of platform and servo problems, 96
hang up problems, 96
motor controller slope too small, 97
servo01 request complete, 97
vmin too small, 96
overcontrol problems
miscellaneous, 98
motor controller slope and offset too
large, 98
vmin too large (or activeVmin), 97
xdb too small, 98
Frame Tuning and Diagnostic Tool, ft, 110
mechanical influence on motion problems, 94
preliminary troubleshooting activity, 90
servo and scanner diagnostic instance variables,
99
scanner01 object, 102
autoEOS, 103
dbAvgTime, 102
dbWidth, 102
farEOS
unknown/homeEOSUnknown,
103
healthRequest, 103
inTransit, 103
maxEdgeChange, 102
maxSpeed, 103
offSheetTimer, 104
onSheetTimer, 104
positioningSafetyMargin, 103
scanning, 103
sheetBreakPresent, 104
stdzPending, 104
target, 103
servo01 object, 99
Accel, 100
advdb, 99
avdb, 99
biasn, 101
biasp, 101
ddcExcessiveErrorPercent, 100
ddcRestrictedMotionPercent, 100
duration(3), 102
farEdge, 102
homeEdge, 102
homingError, 102
increment(3), 101
Ki, 101
Kp, 100
sampleInterval, 101
slopen, 101
slopep, 101
vdb, 99
vfinal(3), 101
vmax, 100
vmin/active vmin, 99
vminFilterFactor, 100
vminTune, 101
xdb, 99
xfinal(3), 101
Positioning System Overview, 2
positioningSafetyMargin, 103
Power Down Analysis, 147
Power Down Reason (reason for shutdown), 149
Power Supply LEDs, 139
Practical Application, 177
Preliminary Troubleshooting Activity, 90
Preparing On-Site Documentation, 190
Printout
I/O configuration, 119
Profile Data, 36
Profile Development
1180 host computer, 46
1180 systems, 38
1190 host computer, 26
1190 systems, 19
Scanning Platform, 21, 39
Profile Transmission
1180, 38
1180 host computer, 44
Scanning Platform, 25
Q
Quick Reference Guide, 251
R
Radiological Safety Features and Alarms, 86
Rearrange, 260
270 Index 3BUS 208 055 R1101

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.
Reflection IR
exercising the flag, 237
Release Levels
check of diskettes, 166
Finding, 165
Replacement Parts, 138
Reports
AI channel gains, 124
AI channel slopes and offsets, 124
AI signal statistics, 123
aim, 122
calibrate sample, 189
dim, 119
I/O device selection, 122
monitor, 180
sample check, 188
standardize, 187
Resize, 261
Resource, 156
Resource Checks, 180
Rewet, 218
S
Safety Interrupt Alert, 147
Sample Check Report, 188
sampleInterval, 101
scanner01 object, 102
scanning, 103
Scanning Platform Software Diagnostic Tools
disiplaying reports within inspect
calibrate sample report, 189
displaying reports within inspect, 187
sample check report, 188
standardize report, 187
how to start the Scanning Platform, 185
identifying sensor configuration, 164
identifying software release levels
finding subsystem release levels, 165
finding system release levels, 165
release level check of diskettes, 166
obtaining the monitoring report
obtaining derr, bfchk, and dfree data, 183
off-line debug, 195
operation of the sensor health pages, 191
preparing on-site documentation, 190
resource checks, 180
obtaining the monitor report, 180
signal/measurement processing analysis and reporting
(smr), 168
automatic reporting and retriggering, 175
global access, 176
operation overview, 169
outputs, 173
overview of menu selection, 176
collect data on, 178
example, 177
general procedure, 176
practical application, 177
trigger setup, 177
smr Work Sheet, 178
starting and stopping data collection, 176
summary of smr capabilities, 168
triggers, 171
software diagnosis, 156
application, 157
AVOS and application utilities, 158
general AVOS utilities, 158
general software troubleshooting techniques,
156
gstore utility, 162
operating system, 157
resource, 156
the inspect utility, 160
software release levels, 165
Scanning Platform Utilities, 252
line prompts, 252
special functions, 252
utility command response to a file, 252
Selected Theories of Operation, 1
head package dimensions setup, 3
auto edge-of-sheet turned off, 3
auto edge-of-sheet turned on, 3
how head position is determined, 5
measurement analysis using on-line utilities,
27
1190 measurement analysis using sentest
utility, 35
1190 measurement analysis using the
sentest utility
profile data, 36
single point drift data, 37
converting tbmcu files for spreadsheet
analysis, 32
examining floating point TBM arrays, 34
introductory comments, 27
measurement analysis using tbmcu utility,
27
using tbmcu utility in standalone, 31
motion theory, 7
motion control theory, 12
servo theory of operation, 7
ACCELERATION phase operation, 9
CRUISING phase operation, 9
DECELERATION phase operation,
10
HOMING phase operation, 11
3BUS 208 055 R1101
Index
271

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.
system response to some position parameters,
13
intraframe/interframe compensation,
18
positioning system overview, 2
definition of head package dimensions, 4
profile development for 1180 systems, 38
accessing 1180 MICRO profile data inside
the Scanning Platform, 42
logical zone calculations, 48
profile development in the Scanning Platform,
39
profile development within the host computer,
46
profile transmission and development, 38
profile transmission to a host computer, 44
data box collection calculation, 47
profile development for 1190 systems, 19
profile development in the 1190 host computer,
26
profile development in the Scanning Platform,
21
profile transmission to the host computer,
25
time based measurement, 19
sensor theory, 49
sensor input signal processing, 51
sensor output signal processing, 55
sensor processing overview, 49
compensation, 50
conversion, 50
correction, 50
filtering, 49
fine tuning, 50
linearization, 50
normalization, 49
Sensor Alarm Codes, 213
Sensor Compensation - Operation and Setup, 198
Sensor Input Signal Processing, 51
Sensor Local Modes of Operation, 206
Sensor Output Signal Processing, 55
Sensor Processing Overview, 49
Sensor Theory, 49
Sensor Troubleshooting, 197
air bearing, contacting, and non-contacting caliper
sensors, 246
alarm code classification, 249
exercising the caliper sensor, 246
sensor validity codes, 250
troubleshooting alarms, 247
air column compensation for Smart sensors,
202
disable gap compensation, 202
ash sensors (TLXR), 239
ash correlation problems, 244
ash sensor hardware diagnostics, 242
to open or close shutter, 242
to unclamp or clamp the electrometer,
242
ash sensor standardize results, 240
basis weight sensor (TLK, TLP, and TLS), 209
basis weight hardware diagnostics, 211
to open and close shutter, 211
troubleshooting flow chart, 209
infrared moisture sensor, 213
correlation problems, 218
composition effects on infrared sensors,
219
dirt buildup on the sensor window,
218
general correlation scatter, 218
insufficient cooling, 220
operation at design limits, 219
rewet, 218
step-outs in the trend, 219
discontinuity counter, 238
exercising the gain using software commands,
237
using inspect, 237
using the health page pulse monitor
, 237
exercising the reflection IR flag, 237, 238
sensor alarm codes, 213
alarm 4602/4702, 217
alarm 4603/4703, 216
alarm 4608/4708, 217
alarm 4621/4721, 217
alarms 4609/4709, 4611/4711, 4612/
4712, 4613/4713, 4614/4714,
and 4679/4779, 217
alarms 4615/4715, 4616/4716, 4617/
4717, 4618/4718, and 4622/
4722, 215
alarms 4619/4719 and 4624/4724,
214
troubleshooting flow charts, 220
sensor compensation - operation and setup, 198
compensation flag setup, 201
definition of terms, 198
operation, 199
sensor local modes of operation, 206
Sensor Validity Codes, 250
Servo and Scanner Diagnostic Instance Variables,
99
Servo Theory of Operation, 7
servo01 object, 99
servo01 Request Complete, 97
sheetBreakPresent, 104
272 Index 3BUS 208 055 R1101

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.
Shutter Closed During Prepare to Move, 87
Shutter Closed When Host Computer is Down, 87
Signal/Measurement Processing Analysis and Reporting
(smr), 168
Single Point Drift Data, 37
slopen, 101
slopep, 101
smr Work Sheet, 178
Software Diagnosis, 156
Software Diagnostic Tools, 155
Special Characters, 257
Special Functions, 252
Standardize Report, 187
Starting and Stopping Data Collection, 176
Startup Messages, 77
stdzPending, 104
Step-outs in the Trend, 219
Summary of smr Capabilities, 168
Switch Window, 260
System Response to Some Position Parameters, 13
T
target, 103
Time Based Measurement, 19
To Open or Close Shutter, 211, 242
To Unclamp or Clamp the Electrometer, 242
Tools
application, 265
Triggers, 171
setup, 177
Troubleshooting
alarms, 247
flow charts, 63, 209, 220
U
Using inspect, 237
Using tbmcu Utility in Stand-Alone, 31
Using the Diagnostic Card Adapter, 126
Using the Editor, 258
Using the Health Page Pulse Monitor, 237
Utilities
aim, 121
dim, 118
gstore, 162
inspect, 160
Utility Command Response to a File, 252
Utility Commands, 253
file commands, 253
maintenance and debugging, 253
V
vdb, 99
vfinal(3), 101
vmax, 100
vmin Too Large (or activeVmin), 97
vmin Too Small, 96
vmin/activeVmin, 99
vminFilterFactor, 100
vminTune, 101
X
xdb, 99
xdb Too Small, 98
xfinal(3), 101
3BUS 208 055 R1101
Index
273

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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.
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3BUS 208 055 R1101
Measure IT Scanning Platform Troubleshooting Procedures Manual