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Proprietary Data: This document contains proprietary data of ABB Industrial Systems Inc. No disclosure, reproduction, or use may be made except by written permission. Preliminary Document
PROPRIETARY DATA This document contains proprietary data of ABB Industrial Systems Inc. No
disclosure, reproduction, or use of any part thereof may be made except by written permission.
ii 3BUS209548
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A July 08
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Preface
ABB HemiPlus and ReflectionPlus Sensor Manual with Network PlatformTM , 3BUS20954, covers
MO4226 and MO4227, typically referred to as HemiPlus and ReflectionPlus respectively. This
manual applies to their use on Network Platform interfaced to 1190/Nexus or and 800xA systems.
Basic installation, operation, maintenance and theory are covered.
The user should be familiar with the 1190 and/or 800xA, and Network Platform manuals and
utilities.
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Table of Contents
1 THE BASICS ............................................................................................ 1-1
1.1 Features .......................................................................................................1-2
1.2 Principles .....................................................................................................1-3
1.3 Legacy ..........................................................................................................1-7
1.4 Application...................................................................................................1-8
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Table of Figures
Figure 1-1 IR HemiPlus (top), ReflectionPlus (bottom) ....................................................... 1-3
Figure 1-2 Infrared spectrum................................................................................................. 1-5
Figure 2-1 Source lamp power supply................................................................................... 2-2
Figure 2-2 Basic filter wheel and logic stream...................................................................... 2-3
Figure 3-1 HemiPlus sensor alignment ................................................................................. 3-8
Figure 3-2 Alignment of the ReflectionPlus sensor .............................................................. 3-9
Figure 3-3 alignment of the ReflectionPlus Sensor to the process........................................ 3-9
Figure 3-4 Air wipe slot ...................................................................................................... 3-10
Figure 3-5 Air wipe adjustments ......................................................................................... 3-10
Figure 3-6 HemiPlus wipe flow........................................................................................... 3-11
Figure 3-7 ReflectionPlus wipe flow................................................................................... 3-11
Figure 3-8 Circuit breakers.................................................................................................. 3-12
Figure 3-9 Measure pulses & logic stream.......................................................................... 3-13
Figure 3-10 HemiPlus head constant tag............................................................................. 3-14
Figure 3-11 NP health page - HemiPlus head constants ..................................................... 3-16
Figure 3-12 NP health page – ReflectionPlus head constants ............................................. 3-16
Figure 3-13 -Configuration for HemiPlus – default entries ................................................ 3-17
Figure 3-14 Health report for HemiPlus – ‘Current’........................................................... 3-18
Figure 3-15 Health report for ReflectionPlus – ‘Current’ ................................................... 3-18
Figure 3-16 NP HemiPlus health report standardize limits................................................. 3-20
Figure 3-17 ReflectionPlus health report - standardize limits............................................. 3-20
Figure 4-1 HemiPlus standardize results ............................................................................... 4-4
Figure 4-2 ReflectionPlus standardize results ....................................................................... 4-4
Figure 5-1 HemiPlus / ReflectionPlus Lamp port ................................................................. 5-4
Figure 5-2 Lamp block assembly .......................................................................................... 5-4
Figure 5-3 HemiPlus / ReflectionPlus Lamp......................................................................... 5-5
Figure 6-1 Check sample repeatability.................................................................................. 6-9
Figure 6-2 Moisture sensor reproducibility graph............................................................... 6-10
Figure 6-3 IR Moisture reproducibility XY graph .............................................................. 6-10
Figure 6-4 Conditioning samples ........................................................................................ 6-13
Figure 6-5 Bagged wet samples........................................................................................... 6-14
Figure 6-6 Bagged dry samples ........................................................................................... 6-15
Figure 6-7 Sample holder .................................................................................................... 6-16
Figure 6-8 Sample in Aclar® bag......................................................................................... 6-16
Figure 6-9 Sample holder / protector................................................................................... 6-20
Figure 6-10 Sample rack assembly...................................................................................... 6-23
Figure 6-11 Cutting a dynamic sample................................................................................ 6-26
Figure 6-12 Calculate percent moisture............................................................................... 6-27
Figure 6-13 Mini scan setup ................................................................................................ 6-28
Figure 7-1 NP HemiPlus health report - Gain selections .................................................... 7-34
Figure 7-2 Manually selecting HemiPlus gain .................................................................... 7-34
Figure 7-3 HemiPlus / ReflectionPlus health report – Inputs.............................................. 7-36
Figure 7-4 HemiPlus gain histogram................................................................................... 7-38
Figure 8-1 HemiPlus sample check ....................................................................................... 8-2
Figure 8-2 ReflectionPlus sample check ............................................................................... 8-2
Figure 8-3 HemiPlus calibrate sample Figure 8-4 ReflectionPlus calibrate sample ......... 8-4
Figure 8-5 - Ash compensation ............................................................................................. 8-7
Figure 9-1 HemiPlus decomposition constants ..................................................................... 9-2
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Tables
Table 1-1 - HemiPlus ranges ................................................................................................. 1-8
Table 1-2 - ReflectionPlus ranges ......................................................................................... 1-8
Table 3-1 - HemiPlus head constants .................................................................................. 3-15
Table 3-2 - ReflectionPlus head constants .......................................................................... 3-15
Table 3-3 - Standardize limits for HemiPlus ....................................................................... 3-19
Table 3-4 - ReflectionPlus standardize limits...................................................................... 3-19
Table 6-1 - Conditioning salts ............................................................................................. 6-24
Table 8-1 - Definition of terms used in the sample check reports......................................... 8-3
Table 8-2 - Definition of terms used in the Calibrate Sample Report................................... 8-5
Table 10-1 - Part numbers ................................................................................................... 10-1
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1 The basics
1.1 Features .......................................................................................................1-2
1.2 Principles .....................................................................................................1-3
1.3 Legacy..........................................................................................................1-7
1.4 Application...................................................................................................1-8
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1.1 Features
HemiPlus and ReflectionPlus moisture measurement features sense and display web process
percent moisture. Sensing is accomplished via infrared absorption spectroscopy providing
display of moisture profiles, trends, and reports. The measurement output is used for cross
direction and machine direction moisture control. The feature consists of more than just
sensor hardware, a measurement feature includes:
o End Column Hardware and Software, for processing the raw data into a
moisture measurement and controlling modes of operation
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1.2 Principles
Functional overview, HemiPlus and ReflectionPlus
Functional diagrams of the two sensors are shown in Figure 1-1 below. A key to the
functional diagram is shown below the figures.
D
E
F
A
B
C
T G
I
L R
Q
N M
K
J O
U
P
P
C O
R
Q I
N
J
M
L
H
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C. Detector output analog signal with gain applied, HemiPlus & ReflectionPlus
E. Printed wiring board, low noise high voltage power supply for detector (±100
VDC), HemiPlus
F. Printed wiring board, gain select board, controlled by digital gain board,
HemiPlus only
L. Rotating filter wheel. Four filters typical in wheel, Five for IRCW, two for some
legacy models, HemiPlus and ReflectionPlus
M. Logic pickup, senses iron slugs in the rotating filter wheel, HemiPlus &
ReflectionPlus, logic stream used for signal decomposition.
N. Source lamp, a 375W DWZ lamp operated at 100 W typical, 200W for IRCW,
HemiPlus and ReflectionPlus
P. Printed wiring board, lamp protection circuits and logic squaring circuit HemiPlus
& ReflectionPlus. In ReflectionPlus the board is also populated with analog gain
control electronics.
Q. 120 VAC switched called120 VAC protected, controls AC voltage to the primary
of the lamp transformer. It turns off power to lamp if the sensor over heats or the
filter wheel stops spinning, HemiPlus & ReflectionPlus.
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Theory
Infrared sensor measurement principles are based on differential absorption
spectroscopy. Infrared absorption bands occur in the measured material. Infrared
wavelengths are selected that correspond to specific absorption bands. Specific
wavelengths are discriminated using infrared band-pass filters inserted into the filter
wheel. A detected pulse response is measured via the infrared detector (see functional
item H); filters are time multiplexed into the source beam.
1000
Absorption Coefficient [cm ]
-1
Water
Rw Mw
100
Cellulose
10
0.1
1.0 1.5 2.0 2.5 3.0 3.5
Infrared Wavelength - [µm]
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The act of taking the ratio normalizes first order effects of:
o Intensity variation of the source
o Sensitivity changes in the detector
o Broadband attenuation effects in the process
o Broadband scattering effects in the process
o Sensor deflections
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0 20 40 60 80 100 120
As shown above, the response of Ratio versus areal weight of a material property
(water weight is shown, but it could be a different material property) is approximately
a negative exponential. The response may be made more linear by taking the natural
logarithm of Ratio. Computation of a material property is based on functions of one
or more ratios. The functions consist of linearization models, sensor constants,
standardization values and product code coefficients all utilized in simultaneous
equations to derive engineering units for a material property.
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In most applications HemiPlus and ReflectionPlus do not require input from other on-
line sensors for accurate measurement. In some applications accuracy is improved by
use of inputs from basis weight and / or X-ray ash sensors. These algorithmic
changes are controlled via user selective product code entries.
1.3 Legacy
Many obsolete and application specific special infrared sensors are still in use. There
may be capability to interface these to Networked Platform. The SupportLine should
be consulted before an attempt is made to interface models other than HemiPlus or
ReflectionPlus. Details of these sensors are outside the scope of this manual. Typical
names of these obsolete or custom sensors are:
o Heavy Hemi
o Light Hemi
o Standard Hemi
o Two filter Reflection
o PolyPlus Transmission
o Poly coating Reflection
o Fiberglass mat
o Fiberglass wool
o Rewet Hemi
o Streaked HemiPlus
o Ultra Heavy Hemi
o Ultra Heavy HemiPlus
o Lid stock coat weight, reflection
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1.4 Application
HemiPlus provides the best accuracy since it measures total moisture. A
ReflectionPlus sensor measures surface moisture. This means that 85% of the
measurement comes from the first 20-30 g/m² of the web. Web moisture gradients, in
the thickness direction, typically exist on a paper machine. ReflectionPlus may be
mounted on a single sided scanner; which often fits into places where am “O” scanner
may not. ReflectionPlus also has no upper weight limit; therefore, it measures on
heavy sheets where HemiPlus would fail.
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2 Hardware overview
2.1 Source ..........................................................................................................2-2
2.2 Detection......................................................................................................2-4
2.3 Air Wipe........................................................................................................2-5
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2.1 Source
Source Lamp
The source assembly and lamp is common between HemiPlus and ReflectionPlus.
The source is a 375 Watt quartz halogen lamp that is operated at 100 watts in most
applications. Voltage across the lamp is 12.6 VAC drawing about 7.5 ampere. Under
normal conditions the lamp should have a 5 year MTBF. The lamp may be changed in
the field. Typical recommended lamp changes are once per three years. A stable
lamp output is maintained by using a Sola transform that supplies a constant 120
VAC to the primary of the lamp step-down transformers. Lamp current and voltage
can be monitored via a service work station display. The displayed current is the high
side of the step-down transformer, and is about one amp. See Figure 2-1 Source lamp
power supply below.
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If the safety switch turns off lamp, power due to loss of water flow, power is latched
off. This means it will not automatically turn on if water flow is restored. The user
must cycle sensor power off / on via the end column circuit breaker. This action will
unlatch the safety switch. An indicator of the safety switch state is the “IR ON” lamp. This
lamp is shown in Figure 2-1 on page 2-2. The output circuit of the Safety Switch is
called 115 VAC protected in wiring diagrams.
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Logic signals
Figure 2-2 on page 2-3 shows the logic (sync) generated by the magnetic pickup. The
signals are typically 0 to +12 volts peak to peak and are observable with the
diagnostic card. The sync stream is used to demodulate the pulse signals generated at
the detector. Both HemiPlus and ReflectionPlus generate logic signals.
2.2 Detection
HemiPlus and ReflectionPlus use a common detector. The detector Cell is a lead
sulfide cell with about 100 mm2 of surface area. Cell resistance decreases as
impinging infrared radiation increases. The cell is part of a voltage divider circuit in series
with a fixed load resistor. A constant voltage supply biases the network. The bias supply is
generated in the sensor and derived from the end column ±15 VDC supply.
Current variations induce a voltage change that is coupled to a preamplifier. The temperature
of the cell is maintained at 90 °F or 33 °C by the water from the Water Cooling Unit. The
short term water temperature variation (within about 1 hour) of about ±3.5°F or ±2°C is
acceptable. Acceptable long term variation is about +15°F or 8 °C. Best operation is
obtained with cooling water at 90 °F or 32 °C, this is the temperature the sensor was
calibrated and tested.
Preamplifier
The signal from the detector is amplified by a preamplifier. The amplifier hardware is
very different for HemiPlus versus ReflectionPlus. HemiPlus employs direct digital
control (DDC) of the amplifier gain. Gain moves is 3 db steps covering a range of -3
to 90 db. The maximum usable gain for HemiPlus is about 72 db, typical air gap gain
is 3 to 12 db. The DDC gain control is executed by Network Platform software. Gain
is reported in steps, versus decibels (db). Steps go from 0 to 15. To convert steps into
db multiply steps by three then subtract three.. Step 4 would be 9 db.
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The DDC gain link is via two lines (up 3db / down 3db). Toggling both lines
simultaneously sets midrange gain, or 45 db, step 16. Software attempts to keep the
reference signal (usually the largest signal) close to a maximum voltage, about 7 volt
pulses height (the limit can be changed). The Network Platform sets proper gain
during the Prepare to Measure sequence when first brought on sheet. At each edge of
sheet thereafter, the computer may toggle the gain one step up or down if required.
The gain Up/Down lines pass through the carriage board and can be used as
troubleshooting aids. Pulling a line to ground causes the gain to toggle, closing both
lines to ground sets mid-gain (step 16, 45 db).
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3 Installation Procedures
This chapter contains the following main sections:
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Proper alignment of HemiPlus is dependent on the alignment of the scanner head carrage
assembly. Verify static alignment of HemiPlus as follows:
1. Verify the alignment of the Scanner head carriage; see the Network Platform
Installation and Maintenance Manual.
2. Verify HemiPlus source and detector are properly mounted by removing a side cover
and measuring the gap with a rule; the gap should be between 12.7 and 14.3 mm (0.5
to 0.563 inches). Ensure the heads are parallel within 1.6 mm or (0.0625 inches) in
both the cross-machine direction and machine direction. See Figure 3-1 below.
Cross Machine
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Verify the basis weight sensor alignment. Then remove the side covers and measure
the vertical distance from the basis weight sensor top plate to the top plate of the
ReflectionPlus sensor. If the basis weight sensor is an STLK-11 or STLP-3, the
distance should be 28 mm ±1.5 mm (1.09375 in. ±0.0625 in.). If the basis weight is
TLK-5, 8, or 9, the distance should be 24.9 mm ±1.5 mm (1.0 in. ±0.0625 in.).
See Figure 3-2 below.
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Retaining Screws
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o If air wipe air pressure is adjusted too high the boundary air will depart from
the face-plate. Air will rise away from the face-plate and be directed into the
air gap. See Figure 3-6 below and Figure 3-7 below.
Air Pressure
Too High
Figure 3-6 HemiPlus wipe flow
o If air wipe air pressure is adjusted too low, there will be insufficient air
volume to wipe the window and dust is not removed. Air used for the air wipe
should be free of oil or oil aerosols.
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3.4 Power-up
o Turn the liquid cooling unit (LCU) on making sure there is at least a flow of 10
gallons/hr. If no flow meter is present, ensure the flow switch in the LCU is actuated.
Complete information on the LCU) is found in the Liquid Cooling Unit Manual,
101333-003.
o Set HemiPlus / ReflectionPlus lamp power supply circuit breaker, CB1, to the ON
position. CB1 is located in the end column or a remote junction box.
o
IR Circuit Breaker
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Verify detector signal (pulses) using an oscilloscope connected to the diagnostic card
plugged into the carriage board. Insert a sample in the process plane. On a
ReflectionPlus sensor the signals should automatically adjust themselves via an
internal analog gain control circuit.
For a HemiPlus, you may manually, select a proper head gain by momentarily
connecting the increase or decrease terminal to ground until the signal is visible and
out of saturation. Alternately you can adjust the gain through the Service
Workstation Health Page for IR gain. The signals should resemble those in Figure 3-9
below. Difference in amplitude and individual pulse size depends on type of sample and type
of sensor (HemiPlus versus ReflectionPlus).
3BUS209548 3-13
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Head constants are entered or changed via the HemiPlus or ReflectionPlus R Health Report
on the “Calibration” tab. Figure 3-12 on page 3-16, is for ReflectionPlus and Figure 3-11 on
page 3-16 is for HemiPlus. The user should be advised that some constants are application or
grade dependent, these are too be entered in the system product code file, also see
Compensating variables on page 3-17
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These values may be entered using the configuration utility under the tab called
“Measurement Limits” tab. See Figure 3-13 below. These default values are seldom
used, but reasonable values for the customer process should be entered. If all other
means of compensation fail, these values may be useful.
The compensation values may be viewed on the sensor health page, under tab “current”.
Examples for a HemiPlus running in two filter mode with basis weight compensation and for
a ReflectionPlus running in multi-wavelength mode but using ash compensation are shown
on page 3-18.
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4 Measurement Processes
This chapter contains the following main sections:
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4.1 Algorithm
Changing a HemiPlus or ReflectionPlus sensor from 4 Filter (multi-wavelength) mode to 2
filter mode is via the product code file. They are usually operated in multi-wavelength mode.
See on page 1-8 for more information when mode may be changed.
HemiPlus gain changes are based on the relationship between the reference signal and
software target values as described below. If the process weight changes while the
sensor is on-line then single step gain changes are executed based on the statistical
behavior of the reference signal over a specified time interval (this is independent of
the scan time). The frequency of gain changes is dependent on variability and
stability of the process.
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d) Minimum VDC – This is the minimum allowed voltage for reference signal and
moisture absorption signal, values lower than this are considered “missing” for
reference and “small” for moisture.
Five (5) counters are used in the decision making of gain change while scanning see Figure
7-1 on page 7-34:
a) Good Counter: Incremented when an average of three reference signals exceeds Lo
Mean VDC.
b) Low Counter: Incremented when an average of three reference signals falls below
Lo Mean VDC.
c) Missing Counter: Incremented when an average of three reference signals falls
below Minimum VDC.
d) Saturated Counter: Incremented when an average of three reference signals
exceeds Maximum VDC.
e) Small Counter: Incremented when an average of three moisture absorption signals
falls below Minimum VDC.
The following conditions will lead to Gain Change being performed during the Frame
scanning. See Figure 7-1 on page 7-34 for names used for limits.
1) When the Saturated Counter exceeds the Saturated CNTS limit, the gain is
decremented by one.
2) When the Missing Counter exceeds the Missing CNTS limit, the gain is incremented
by one.
3) If ((Good Counter + Low Counter) >= 100) AND
(Good Counter < (Low Counter + Gain Acceptability Minimum Count Limit)))
the gain is incremented by one.
The value 100 works as a delay before evaluation start.
Note that if Gain Acceptability limit is set too high, gain will automatically ramp up
independent of Good Counters versus Low Counters.
4) However if there are too many small pulses (small signal counter value exceeds its
prescribed limit) a warning is generated but gain change is NOT invoked.
There is a configurable Reset Time (Counter Reset Period SECS) for all the Gain
Counters. If the reset period elapses or a gain change occurs all counters are reset.
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4.3 Standardize
For a Standardize Check, perform the following:
1. Request standardize at the operator station or at the Frame Control Panel.
2. At the NP Service Work Station (SWS) IR Health Report verify that no video alarm
for moisture is displayed. If standardize fails, use the SWS IR Health Report to
check the meaning of the alarm.
3. At the NP Service Work Station (SWS) IR Health Report select the STDZ Pend tab.
STDZ Pend shows the last standardize, STDZ Curr shows the last successful
standardize. Verify the value of IR standardize ratio. There are two KC values for
HemiPlus: one for IR1 and one for IR2. They should be between 0.8 and 1.2.
4. Enter the first Standardize Report in the log book as a permanent record.
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4.4 Calibration
HemiPlus and ReflectionPlus sensors are pre-calibrated using a set of laboratory
standard samples. This is intended to make all sensors of the same model read the
same. Sensor head constants define the pre-calibration. The sensor response to the
client’s process may be somewhat different than the base curve response, due to
different process furnish and / or a bias between the client’s laboratory and the ABB
laboratory. These differences are linear transforms from the base curve and requires
only slope and offset fine tuning as shown in the equation below.
Calibration Adjustment
Calibration adjustment may be made using both slope and offset, or only slope or
only offset. Before making any change accumulate sufficient data to make sure that a
change is necessary. Do not make an offset change based on data grouped around
one moisture level. Following are general guidelines:
o If data cannot be obtained over a range of moisture levels, then use the
product code slope adjustment procedure to make the adjustment.
o If the application is “dry” (<3% M) use offset for fine tuning explained in the
Offset Adjustment procedure on page 4-6.
o If the offset is zero, you do not need to read the rest of this section in detail.
Just remember the following relation:
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4.5 Correlation
The most effective way to determine slope and offset for laboratory versus sensor
correlation is use of data analysis tools found in Excel®. Excel® templates are
available on the SolutionsBank.
The laboratory and sensor data are entered in the spread sheet as shown below. A
chart is inserted to view the data. In the chart put the independent data (laboratory)
on the X-axis (abscissa). Put the dependent data (sensor) on the Y-axis (ordinate).
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The SUMMARY OUTPUT is shown below. The important values for our correlation
evaluation are shown in yellow. Some arithmetic calculations are required to evaluate
our correlation. This could be built into the user’s worksheet.
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In SUMMARY OUTPUT data, in the upper 95% and lower 95% fields we find data
that help with the questions. We compute the upper and lower confidence intervals
for the NewSlope and NewOffset as follows:
CI Offset Lower = -CI Intercept Lower / ’X Variable 1’
CI Offset Upper = -CI Intercept Upper / ’X Variable 1’
CI Slope Lower = 1 / ‘CI X Variable 1 Lower’
CI Slope Upper = 1 / ‘CI X Variable 1 Upper
Therefore:
CIOffset Lower = -(-1.057) / 1.052 = 1.005
CIOffset Upper = -(2.081) / 1.052 = -1.978
CO Slope Lower = 1 / 0.933 = 1.072
CI Slope Upper = 1 / 1.171 = 0.854
In this example, at the 95% confidence level we find:
o The statistical range of Slope is: 0.853 to 1.072
o The statistical range of Offset is -1.98 to 1.005
And
o OldSlope was 1.033, NewSlope is 0.982
o OldOffset was 0.220, NewOffset is -0.278
The new calibration is not statistically different from the old calibration, at a 95%
confidence interval. We’d need either more data, or less scatter to make a better
decision. It may be worth while to redo the correlation and use the Constant is Zero
option (slope only correlation) on page 4-7. Then evaluate the difference in slope
(offset will remain the same). You may find the slope change is not statistically
significant.
This is a good example of how a user can “chase” the calibration, moving slopes and
offsets around but not really gaining much improvement in accuracy.
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5 Maintenance Procedures
Preventive maintenance and continuing sensor certification is necessary to maintain the sensor
performance for a long period. This chapter contains the following major sections:
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5.1 Stability
Plot values from the standardize results, time versus value, on a chart and watch for
step change or continuous drift. Initially values should be added at least each day.
See on page 4-4 for typical reported values. The important ones are KC1, KC2
(standardize ratios) and SigmaIR1 and SigmaIR2 (noise of ratios). For HemiPlus
IRGain is an important reported value.
In case of stepping or trending values, run the glass check samples more frequently to
see if M values are influenced. Glass check samples should be measured at least once
each month. The %M values for each sample should be charted.
Avoid using the customer laboratory as a sole judge of sensor performance. A proper
preventive maintenance program finds potential problems before they cause on-line
measurement errors. Excel® worksheets for charting and limit checking
standardization and glass check sample results are available on the SolutionsBank.
o Clean the glass encapsulated check samples with a window cleaner containing
ammonia and a lint-free cloth.
o The HemiPlus and ReflectionPlus source lamp should be changed each two or
three years. Mean time to failure is about 5 years (half the lamps have failed). See
on page 5-3.
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It is important to minimize the amount of time the sensor’s lamp change port is open.
This reduces the amount of moisture absorbed by the sensor’s desiccant. Normally the
desiccant is good for 7 to 8 years, or about four lamp changes. Leaving the port open
for more than 10-15 mintues may cause premature failure due to internal
condensation.
The cylindrical surface of the port hole is its sealing surface. Be sure not to scratch it
with your tools and keep the surface clean.
Procedure
1. Remove the sensor from the frame or scanning platform.
3. Inspect the sensors electrical connector for bent or burnt pins, especially pins
E, G, J, L, V and Y which carry lamp current. If damage is found inspect the
frame electrical connector. Replace the frame cable if necessary.
5. Position the sensor in its side, with the port up, and remove the five screws
from the port plug. The two short screws are used to keep the threads in the
“jacking” holes clean.
6. Start two of the long screws in the “jacking” holes shown in Figure 5-1 on
page 5-4. Alternately tighten the screws until the plug is free.
7. Remove the screws from the “jacking” holes and set the plug aside.
8. Remove the exposed hex socket head screw with the hex drive from this lamp
kit. This screw secures the wire lug to the lamp contact assembly, and is the
only screw accessible at this point. All parts of the contact assembly,
including the lug and screw, are held captive. See Figure 5-2 on page 5-4.
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Window
Jacking Screws
9. Loosen the exposed hex socket head screw, which holds the ceramic
contact block assembly, by using the same hex driver. The parts of
this assembly are also held captive. See Figure 5-3 on page 5-5.
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11. Unpack the new lamp. The lamp may be handled by its ceramic ends. See
Figure 5-3 above.
12. Insert the new lamp. Be sure that the tip of the lower contact assembly is in
the lamp’s contact well. The pointed tip on the lamp must be point away from
the sensor’s window.
13. Reinstall the ceramic contact block and the contact assembly by reversing the
procedures in Steps 7 and 8. Be sure that the tip of the upper contact assembly
is in the lamp’s contact well and is centered, side to side, in the contact block.
14. Check for continuity between pins J and L on the sensor connector. Resistance
should be less than 0.25 ohms. If resistance is higher, or no continuity, then
the tip of the lower contact is not seated in the lamp contact well. Repeat
Steps 8 through 14 if resistance is incorrect.
15. After continuity is verified reinstall the port plug and the five screws.
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6 Sensor Verification
This chapter contains the following main sections:
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6.1 Overview
Sensor Verification is accomplished in three phases, (1) prove sensor capability, (2)
apply the capability to the customer’s process, and then (3) track long term
performance.
Phase 1
The initial verification is to insure the sensor is capable. Stability, repeatability, and
check samples are used to document this phase.
Phase 2
In this phase we ensure the sensor accurately measures the customer's process. It is
important that the customer be heavily involved in this phase.
Phase 3
This phase provides continuing certification that the on-line sensor remains capable.
This captures potential problems before they causes on-line measurement error.
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The test is performed by placing each standard sample in the sensor and measuring it
at least 20 times in succession using the sample check utility. Results may be charted,
including allowed limits, as shown in Figure 6-1 below. An Excel® template for
graphing sensor stability with limits is available on the SolutionsBank. Allow the
non-dry samples to equilibrate in the sensor gap for several minutes. Heated air
wipes may interfere with this test, by causing moisture to migrate inside the check
sample. Compute the average and the two-standard deviation value for these data.
The two-standard deviation for each sample should be less than 0.06 %M. Record the
average value for each sample to be used in subsequent tests.
4.25
4.15
% Moisture
4.05
3.95
3.85
3.75
3.65
1 4 7 10 13 16 19 22
Sample Number, Consecutive Measurements
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Reproducibility
Reproducibility is the closeness of agreement among repeated measurements of the
output for the same value of input under the same operating conditions over a period
of time, approaching from both directions. Select at least two samples from the check
sample set. Over a period of many hours or weeks periodically read these there
samples. Compare the individual readings versus the average value recorded for that
sample in the Repeatability test (above) by plotting the deviation versus time.
The deviation should be less than ±0.15 % moisture when expressed as two standard
deviations. Results may be presented graphically as shown in Figure 6-2 below or
Figure 6-3 below. Excel® templates for graphing sensor repeatability and
reproducibility with limits are available on the SolutionsBank.
Moisture Verification
Sensor Reproducibility
0.50
0.30
Diff. %M
0.10
-0.10
-0.30
-0.50
Dry 37 GSM Wet 39 GSM Dry 112 GSM Wet 118 GSM Dry 188 GSM Wet 199 GSM
Sample and Weight
Moisture Verification
Sensor Reproducibility
7
6
Percent Moisture (Sensor)
0
0 1 2 3 4 5 6 7
Sensor Value Percent Moisture (Initial Test)
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Profile
This ensures that scanning the sensor does not produce noise or artifacts related to
sensor misalignment, scanning induced vibrations, electrical noise, or external light
interference.
When paper is not being produced, scan the sensor with a glass sample in the gap.
Record the %M unfiltered profiles. Ensure any high intensity lighting proximate to
the scanner is energized. The profiles should be flat and show no repeatable features,
or excessive noise. Unfiltered profile noise (when data boxes have 50 ms temporal
widths, or more) should be less than 0.25%M two-standard deviations. Composite
profiles (filter factor 0.666) should be less than 0.10 % moisture, two-standard
deviations.
A perceived weakness of Aclar bag methods is that the correlation is performed using
“static” samples. Therefore, on-line dynamic influence parameters are not seen. Such
influence parameters may be web temperature or potential layering of water in the
web thickness direction. Layering may be induced by rewetting the web or by drying
the web surface more than the inside.
Materials needed
o An analytical balance having a capacity of, at least, 160 Grams and a
resolution of, at least, 0.5 milligrams. A Faraday shield is required to
eliminate effects of static charge on the samples. A metal cage or a folded
piece of foil may serve as an effective shield.
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o A forced air drying oven with temperature control at 105 °C, ±2 °C.
o Cotton gloves and six sample holders to handle samples. Construct sample
holders as shown on page 6-16, Figure 6-7.
Conditioning
See Figure 6-4 on page 6-13 as a guide for the following procedure.
3. Divide each grade into two equal groups, one set will be conditioned to
ambient humidity, the other will be oven dried.
4. Mark half the samples of each grade “Dry” and the other half “Wet”.
5. Punch a hole in the upper left corner of all samples to accommodate hanging
the samples during conditioning, see Figure 6-4.
6. Using a bent paper clip, heavy wire, or similar material, hang the samples in a
clean and stable environment. Ideally a controlled laboratory but, an office
environment may be substituted.
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7. Allow the samples to condition for a minimum of four hours, twenty four
hours is optimum. Conditioning is quicker if a fan is used to circulate air
around the samples. Do not contaminate the samples during handling and
conditioning.
3. Place each sheet in an Aclar® bag. Seal the Aclar® bag using a heat sealer, or
tape it closed it if you plan to use the samples within a few hours. Bagged
samples will remain stable for several weeks.
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2. Create a sample holder / protector and place it in the drying oven set to 105
°C. See Creating a sample holder/protector in this chapter, on page 6-16. The
holder accommodates handling with less moisture pickup.
3. Place the samples to be dried in the sample holder. At least two hours is
required to bone dry the sample / holder combination at 105 °C.
Equation 2-11
5. After using the “Aclar® bag two point method worksheet” in Appendix A to
determine the percent moisture of the “Wet” samples, mark each “Wet”
sample with the calculated percent moisture. Use a label on the bag to mark
the sample; do not open the Aclar® bag. If readings will be taken in multi-
wavelength mode identify the target percent ash content.
6. After drying and weighing the “Dry” samples, return the samples to the drying
oven. Samples may be weighed in Aclar bags is the bag weight is properly
tared out. Samples are returned to the oven to remove any moisture picked up
in the weighing / handling process.
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7. Using Latex or cotton gloves and a sample protector (Figure 6-7 and Figure
6-6 below) remove each sheet in turn from the oven and immediately place the
sample in and Aclar® bag and seal the bag. These samples are labeled “0%
Moisture”.
When not in use, store bagged samples in the same room they were conditioned.
When properly stored and sealed ambient the percent is stable within ± 0.5% for
several weeks. If the bags were sealed by tape only, read them in the gauge within a
few hours after they were made. The samples are now ready to be measured in the
moisture using the sample check utility. See Perform a sample check on page 8-2
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Required materials
1. A temperature and humidity controlled laboratory
3. An analytical balance with capacity of at least 160 Grams, and a resolution of 0.5
milligrams. A Faraday-shield to eliminate the effect of static on samples. Either
a metal cage or a folded piece of heavy aluminum foil may serve as an effective
shield.
4. Four desiccator tanks large enough to hold at least three 200 X 200 mm samples
for each grade to be conditioned. Desiccator tanks may be constructed from 10-
gallon aquariums. See Desiccators on page 6-21.
5. Five conditioning racks, one in each desiccator, one used to condition samples in
the laboratory environment.
8. Cotton gloves and six sample holders to handle samples. Construct sample
holders as shown below, see page 6-20.
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Preparation procedure
TAPPI TIS 0810-01 has detailed descriptions of conditioning solutions and methods similar
to this procedure.
1. Cut 18 samples of each grade to be correlated 200 x 200 mm (8 x 8 inch).
3. Place the samples in a drying oven for 2 to 4 hours. The TAPPI (Technical Association
of the Pulp and Paper Industry) procedure for drying samples can be used to determine
the amount of time necessary, but 4 hours assures complete drying in most applications.
4. After drying use the sample holder and wear cotton gloves to weigh each sample.
Quickly place the sample in a plastic bag somewhat larger than the sample. An Aclar®
bag will work for this purpose. Press out the excess air and close the bag from the
environment. Fold the end over twice to prevent conditioning. Weigh the sample and
bag in the laboratory balance. It is important to get the most accurate measurement
possible. Record the weight of each sample along with its identification. Weigh and
record the weight of the plastic bag and tare the bag out.
5. Place three samples of each grade into the desiccator tanks and three samples into a
conditioning rack outside of the tanks, to condition in the laboratory environment. There
should be three samples of each grade left in the oven.
7. Using the oven sample holder, wearing cotton gloves, place the oven samples in Aclar®
bags, and seal the bags. These are the bone dry samples. Mark the bags 0.0% moisture.
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o Using the sample holder (see page 6-20) and wearing cotton gloves, quickly
place a sample in the Aclar® bag.
o Close the bag and fold the end over twice to prevent conditioning.
o Weigh the bag and sample, and record the weight, bag weight will be tared.
o Seal the bag. If the sample is to be used within one day, the bag may be
sealed by folding the end and using tape to maintain the fold. If the sample is
to be used for a longer period, up to one month, the bag should be sealed with
a heat sealer. It is best to store the bagged sample in its original desiccator.
9. Subtract the weight of the Aclar® bag from the weight of the bag and sample together
(tare) to obtain the wet weight of the sample.
10. The percent moisture of each sample is calculated. It is advised that the average of each
moisture group be used for correlation purposes rather than the individual sample
moisture.
11. Mark each bag with the percent moisture average for the respective group. The samples
are now ready to be measured in the moisture sensor. Procedure to measure Aclar® bag
samples can be found in the 1190 Sensor Procedures Manual 101766-011.
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Construction Procedures
1. Cut a large piece of file card stock as shown below or open a manila file folder and cut it
as shown below.
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o A 10 gallon aquarium.
o Units made of plastic (Plexiglas, etc.) and held together with adhesive are the
best choice as compared to units made of glass with metal frames.
o Gasket material 0.635 cm. (¼ inch) wide by 0.317 cm.(1/8 inch) thick. Door
gasket or weather stripping with an adhesive backing is very satisfactory. A
sufficient quantity to go around the entire perimeter of the top of the aquarium
one and one-half times is required.
o Metal door handles approximately 5 cm. (2 inches) long and 1.3 cm. (½ inch)
wide.
o Racks to hold the samples inside the desiccators. An additional rack for
holding samples in the laboratory environment may also be desired.
Construction Procedures (See Figure 6-10 on page 6-23)
o Apply a strip of the gasket material around the entire top rim of the aquarium.
Use extra adhesive if required to obtain a bond to the aquarium.
o Apply a strip of the gasket material across the width of the cut edges of the
two halves of glass. Use extra adhesive if required to obtain a bond to the
glass.
o Place the two pieces of glass on a flat surface with the gasketed edge of each
piece touching the other.
o Apply epoxy to the back of the continuous hinge and position the hinge on the
glass so that the center pin of the hinge is along the line where the two strips
of gasket material touch. Allow the epoxy to cure so that a good bond is
obtained between the hinge and glass.
o Take the two handles and epoxy one at each end of the glass to serve as lifting
handles.
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o 100 mm. (4 inch) plastic (ABS) cable Panduit about 50.8 cm. (20 inches) long.
o 50.8 mm. (2 inch) plastic (ABS) cable Panduit about 25.4 cm. (10 inches)
long.
Construction (refer to Figure 6-10 on page 6-23)
1. Cut the 101.6 mm. (4 inch) plastic cable Panduit so that its length is 25.4 mm.
(1 inch) shorter than the inside length of the aquarium.
2. Cut two 95.2 mm. (3.75 inch) lengths of the 50.8 mm. (2 inch) plastic cable
Panduit.
3. Using an adhesive, bond the flat side of the 50 mm. Panduit to the flat side of
the 10o mm Panduit at each end of the 100 mm. Panduit. This will serve as
the support feet for the 100 mm. Panduit.
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Silica Gel
No mixing is required. Pour enough silica gel into the conditioning tank so that the
bottom is covered 20 mm. (0.75 inch) deep. In a 10-gallon aquarium this requires
about 3 kg of silica gel.
NOTE: If the silica gel turns pink in color, it is saturated with moisture. An
overnight drying at 105 °C (221°F.) removes the moisture, allowing the silica gel to
be used again.
Salts
1. Bring about 2 liters of distilled water to a boil and dissolve as much of the
chosen salt in the water as possible. Do this by slowly by adding salt while
stirring the water until no more salt will dissolve (some solids remain).
2. Pour the remaining salt into the desiccator so that the bottom is covered 6 mm.
(0.75 inch) deep. This requires about 4.5 kg of sodium bromide or 3.0 kg of
ammonium sulfate for a 10-gallon aquarium.
3. Pour the hot salt solution slowly into the desiccator over the salts until it
contains about 25 mm. (1 inch) of salt / water solution.
4. Cover the desiccator tank and allow it to stand for 24 hours. An equilibrium
humidity condition is obtained. When using the desiccator, add salt or water
periodically as required to maintain about 13 mm. (0.5 inch) of water and 06
mm. (0.25 inch) of un-dissolved salts.
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Materials needed:
o A tape measure
Preparation:
1. The moisture profile is first examined to find a flat area; a sample should be taken
from that area.
2. Adjust / select the single point position to chosen area of the profile.
3. Find the distance from the closest edge of the process to the centerline of
measurement (usually marked on the head package), when the head package is in
single point.
4. Set the mini scan setting to 1.25. (See “Mini Scan for Calibrate Sample while in
Single Point on page 6-27.)
5. Print the correlation worksheet shown in- Single point moisture correlation
worksheet, Appendix B.
Procedure:
1. The scanner is placed in single point just before reel turn up.
3. When the Calibrate Sample LED goes out, flag the reel.
7. Make a mark on the reel using the distance measured from the edge of the process to
the centerline of the sensors. See Figure 6-11 on page 6-26
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discard the first layer of the sample and place the remaining layers in the plastic bag.
Squeeze the air from the bag and close tightly and secure using the rubber band.
Sample should contain enough layers so that the total weight is approximately 100
grams. See Figure 6-11 below.
9. Rotate the reel and cut another sample approximately 76 mm x 510 mm, (3 by
20 inches), several layers thick.
11. Place the samples in the drying oven. The oven should be 105 °C. Samples are dried
for four hours. Longer drying time is okay, over night is best.
12. Remove the samples from the oven, immediately placing each sample back its plastic
bag, secured with a rubber band.
13. Weigh the samples again while still in the bags. Again weight the bag and rubber
band after removing the sample. Make entries on the Appendix B worksheet.
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15. The average of the two tests is compared to the percent moisture from the Calibrate
Sample Report. If the difference between the two laboratory samples is greater than
0.25% moisture, the test is flawed and should not be used for correlation purposes.
Accuracy depends on:
o Scale accuracy
o Measurement area to template width difference
o Accuracy in placing the template in MD
o Profile deviation in template area
o Machine direction moisture variation
o Sample conditioning between sample gathering and the laboratory analysis
How it works
The variable Cal Sample Mini Scan is found in the Scanner Configuration under the
PCL tab (Position Control Logic). It determines how far the mini scan will deviate
from the single point position. The entry in Cal Sample Mini Scan is in customer
units of frame measurement. If the single point position is 102 inches and Cal
Sample Mini Scan is 3, the sensors will scan between 99 inches and 105 inches, for a
total measured cross direction area of 6 inches. The illustration below, Figure 6-13,
shows the Mini Scan Area. See the Network Platform Software Reference Manual
for details on changing configuration settings. If Cal Sample Mini Scan is zero, Mini
Scan is not activated.
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Use of an oscilloscope
a) Watch intermittent noise or other interference on raw sensor signals.
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Rewet
When rewet showers are proximate to the scanner (within 0.5 seconds of web travel),
correlation errors may occur. The best prevention is to have the shower 0.5 sec., or
more, from the head package. Use of surfactants added to the water and use of hot
water may reduce the problem (water is more quickly absorbed into the sheet). For
example, if a cold water shower is 0.25 seconds from the measurement, only ~60
percent of the added water is measured. If the water forms a transparent layer on the
web surface, a measurement error is expected. If the water is absorbed into the web
scattering matrix, the problem should not be noticed. Water layer induced correlation
errors are more severe for ReflectionPlus compared to HemiPlus; although HemiPlus
is not immune to error when a distinct water layer exists on the surface of the web.
Dirty window
The geometry is designed to be insensitive to dust on the window. However, a build-
up of a black material, such as graphite, or oily substances may cause measurement
error. Black build may cause a lower than normal reading. This problem is more
severe on light weight sheets (below 60 g/m²). The issue has been successfully
addressed by use of heated air wipes. Heated air keeps hydrocarbons from
condensing on the cool window.
Condensation on windows
If step-out or “drift” is noticed after the sensor has been off sheet for a while, often
the problem is condensation of water on sensor windows (or face-plate). Air wipe
adjustment may cure a condensation problem. If the condensation occurs inside the
sensor, then the sensor must be changed. Heated air wipes also reduce condensation
problems; their primary purpose is to keep water from dripping off of the sensor and
onto the process.
Grounding
Systematic step-out noticed in the profile is evaluated with the aid of an oscilloscope.
It is easy to observe the effects while scanning a fixed sample. Grounding problems
are difficult to troubleshoot. In HemiPlus, symptoms may only be present at specific
gain settings. This problem is noticeable on heavy weight processes using U frames.
Experimenting with signal and chassis grounds at the frame terminal strip may isolate
the problem. Occasionally the disturbances originate in the frame drive motor circuit.
Bypassing (disconnecting) the motor step-up transformer may help isolate the
problem and prolong motor life.
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Composition influence
HemiPlus is designed to have low sensitivity to web composition. However, operation
in 2-Filter mode allows increased sensitivity to sheet composition. In 2-Filter mode
changes in web specific scatter coefficient of 20 cm2/g cause errors of about 0.2%
moisture. Normal “in grade” variation of specific scatter coefficient in is less than 20
cm2/g. Heavy calendering or large changes in refining will cause changes greater than
20 cm2/g. In multi-wavelength mode HemPlus is not sensitive to specific scattering
coefficient changes.
Adding pigments having broadband optical absorption, such as carbon black, iron
oxide, or black liquor, cause substantial error when operating in 2-Filter mode. Error
in multi-wavelength mode for HemiPlus and ReflectionPlus is much smaller. In 2-
Filter mode the process always reads lower when dark pigment is used.
A source of dark pigment is recycled newsprint; the ink is generally full of carbon
black. If recycled newsprint is de-inked much less carbon black remains in the web.
However the efficacy of de-inking varies widely, leaving more or less carbon black in
the web. HemiPlus and ReflectionPlus running in multi-wavelength mode, has very
low sensitivity to carbon black. However, at the point the web looks very dark grey (>
0.2% carbon black by weight) errors may be noticed.
Insufficient cooling
At sites with very high sheet temperature and low flow from the liquid cooling unit
exists; the water delivered to cool to the sensor may not be stable. This may be seen
by monitoring the temperature of the return flow to the LCU. If sufficient flow rate
and constant water return temperature (±3°C) can not be maintained contact a
Measurement Specialist for help.
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7 Troubleshooting Procedures
This chapter contains the following main sections:
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o Signal lost at the ‘standard signal conditioning board’, or the ‘power signal
conditioning board’.
With a wet sample in the measurement plane, when the flag is inserted the water
absorption pulse should increase in amplitude. If there is no increase in the signals
when the flag is energized the flag is probably not being rotated in place. The flag
may also be viewed by looking through the sensor's window.
With the flag energized use the diagnostic card plugged into the carriage board power
diagnostic connector; verify 42 VDC across the solenoid that rotates the standardize
flag. Use the appropriate function drawing for diagnostic card pin numbers.
1. If 42 volts is present, check the continuity of the sensor pigtail and the
carriage board connectors between the diagnostic connector and the connector
which plugs into the sensor. On the pigtail, pin W is high and pin F is low.
2. If the pigtail and carriage board check ok, replace the sensor.
3. If 42 volts is not present at the carriage board, check for 42 volts at the ASPC
connector J24. If present, replace the power ribbon cable.
4. If 42 volts is not present at the end column board replace the Standard Signal
Conditioning Board or the Standard Power Conditioning Board.
5. If 42 volts does not come back replace the Modular power supplie.
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Network Platform Health Report will be zero. In many cases the lamp current will
also be zero. See Figure 7-3 below
1. If RPS is zero, and lamp current and voltage are zero, cycle the power on the
IR sensor by turning the circuit breaker for IR off, and then on again. If
operation is restored, the most probable cause is overheating of the IR sensor.
Check to ensure proper coolant flow and temperature. If coolant flow and
temperature are ok, the problem is in the safety circuit in the sensor. Replace
the sensor.
2. Check to see that 120 volts AC is present. Using the diagnostic connector and
the appropriate functional drawing, measure 120 VAC at the upper carriage
board power diagnostic connector. AC High and AC neutral. If 120 VAC is
not present, go to step 9.
3. If 120 VAC is present on the upper carriage board, it can also be checked on
pins K (high) and X (neutral) on the pigtail connector that plugs into the
source head. If the 120 is present at the carriage board, but not at the pigtail
connector, replace the pigtail.
4. If 120 VAC is present at the sensor and the lamp current is zero, change the
lamp or check to see that 12 VAC is present on the output of the IR
transformer located on the upper carriage board.
5. Check the ±15 volts to the source head. Using the diagnostic paddle and the
appropriate functional drawing, measure ±15 volts at the upper carriage board
power diagnostic port.
6. If ±15 volts are not present at the upper carriage board, check for ±15 at the
power ribbon cable connector at the ASCP, if it is present at the ASCP,
replace the power ribbon cable.
7. If ±15 volts is present at the upper carriage board, and is within specifications
(±0.2V & noiseless than 150 mV for plus and minus voltages), check for the
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logic stream at the signal diagnostic port on the upper carriage board. The
logic pulses should be 10 volts ±2.0 volts. See Figure on page 3-13.
8. If logic pulses are present at the upper carriage board, check to see if they are
also present at the ASPC diagnostic signal connector. If not, the signal ribbon
cable may be faulty, replace it per instructions in the appropriate Network
Platform Installation and Maintenance Manual.
9. If logic pulses are not present at the upper carriage board, the sensor is the
probable cause. First check the continuity of the pigtail and upper carriage
board before replacing the sensor. Check between pin N on the connector
which plugs into the source head and the appropriate pin on the diagnostic
connector. Appropriate pin on the diagnostic connector card and pin c (lower
case c) on the connector which plugs into the head. In both cases there should
be less than one ohm resistance. If the resistance is incorect replace the pigtail
or upper carriage board, which ever is faulty.
10. If head pulses are present and logic pulses are present at the ASPC, check the
health page pulse signal graph for pulse amplitude. If no pulses show on the
graph, use the Network Platform diagnostic tool to check the AI (analog input)
for head pulse amplitude.
11. If head pulse amplitude is not present with Network Platform diagnostic tool,
replace the ‘standard signal conditioning board’ or the ‘standard signal jumper
board’.
1. Check for 120 VAC at the power ribbon cable connector at the upper carriage
board. See the functional drawing for pin numbers. If 120 VAC is present, at
the power ribbon cable connector replace the power ribbon cable or upper
carriage board, which ever is faulty.
2. If 120 VAC is not present at the power ribbon cable connector, check for it at
the program jumpers shown on the functional drawing.
3. If 120 VAC is not present at the jumpers, check to see that 120 VAC is
present at ASPC and coming from the Sola isolation transformer. Use the
appropriate functional drawing for the scanner and sensor. If not present,
check the input voltage to the IR Sola isolation transformer. Also check the
fuse for the Sola. Replace the transformer if necessary.
4. If 120 VAC is present at the Sola, replace the Standard Signal Conditioning
Board.
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limit set for that counter. An error is generated and the measurement is set invalid.
The depiction below show’s how the limits affect the counters. See Figure 7-4 below.
Lo Mean VDC
Default 2.83 VDC A Low Default Limit 10
Minimum VDC
Default 0.1 VDC Missing Default Limit 10
Counter Reset Period
Default Time 45 Sec.
To allow for extremely large moisture and/or basis weight profiles, the counter limits,
available for gain logic are available on the ‘IR Sensor GAIN health page’, and they
may be increased. Figure 7-4 above
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1. Check the HemiPlus windows for oil, carbon black, or metal dust. A small amount
of these contaminates cause large variations in standardize ratios. This may also
cause calibration shift. If dark dirt buildup is found, first adjust the air wipe as
described in Coanda air wipes of this manual. If that is not successful, a heated air
wipe may alleviate the problem, see Part Numbers for information on heated air
wipe installation and kits.
4. Ratio out of limits can also be caused by an episode of overheating. The infrared
band-pass filters can be damaged by heat, resulting in a high standardize ratio. The
sensor needs to be replaced. For ReflectionPlus sensors, check the flag as described
below. If the flag does not energize during standardize then the ReflectionPlus will
very likely fail standardize, see ReflectionPlus flag malfunction on page 7-35.
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1. Check the ±15 VDC power supply for drift and noise. Use the diagnostic card
plugged into the lower carriage board diagnostic connector for power. Specs are
15 volts ±0.2 volts and noise less than 150 mV for both positive and negative 15
volts. Reference the functional drawing for card pin numbers.
2. Check the temperature of the coolant. The nominal temperature is 32 °C (90 °F),
Higher temperatures will increase sensor noise.
3. Verify ambient light sources are not getting to the detector. An easy check is to
tape over the carriage gap, or cover a reflection IR sensor with a sample holder
containing a heavy weight sample. Ambient light sources can be visible light or
infrared light from infrared dryers.
4. Check the stability of the lamp current and RPS on the sensor health pages.
5. There may be intermittently bad ribbon cables. See the SolutionsBank document,
‘Checking signal and power cables in SP1200, SP700, MP, and RSP’, document
number 914044G407936, for information on checking cables. This document is
effective for Smart Platform & Network Platform.
6. Check the Standard Signal Conditioning Board or the Stand Power Conditioning
Board for faults.
7. If none of the above checks show or correct the problem, replace the sensor.
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1. Check to see if lamp current is zero on the Service Work Station health page for
the IR sensor. If it is zero, see Logic stream malfunction on page 7-35 for more
on lamp current.
2. If the IR lamp current is correct, check for filter wheel rotation, shown as
RPS/Rotation on the IR sensor health page, it should show 50 or 60. If the
rotation is zero troubleshoot the lamp power safety circuit.
3. If RPS is correct, and the sensor is a HemiPlus, check the sensor’s gain control,
see page 7-37.
4. If head pulses (IR Signal) are not present when checking the gain control, but
lamp current is correct and RPS is correct, replace the IR sensor.
5. If sensor pulses are present and logic pulses are present at the ASPC, check the
health page IR pulse signal graph for pulse amplitude. If no pulses show on the
graph, use the Network Platform Diagnostic Tool to check the AI (analog inputs)
to verify pulse amplitude.
6. If proper head pulse amplitude is not present with Network Platform Diagnostic
Tool to, replace the Standard Signal Conditioning Board or the Stand Power
Conditioning Board.
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During measurement
If the alarms received indicate Fiber, Absorption, or Reference out of range is received during
measurement, but not during standardize, check the following:
1. Using the diagnostic paddle connector, and scanning the sensor, monitor the head
pulses (IR Signal) at the ASPC diagnostic connector for bottom signal. Use the
appropriate functional drawing to locate the correct pins on the diagnostic card.
If the signal is intermittent for any part of the scan, replace the lower signal
ribbon cable. As described in the Network Platform Installation and
Maintenance Manual. *
2. Using the diagnostic paddle connector, with the sensor being scanned monitor
the logic pulses at the ASPC diagnostic connector for top signal. See Figure on
page 3-13. and /or see page 2-4. If the logic pulses are intermitten at any portion
of the scan, replace the upper signal ribbon cable. As described in the Network
Platform Installation and Maintenance Manual.*
3. If logic and head pulses are present at the ASPC for the entire scan, check page 2
of the IR sensor health pages. Check the NP IR Health Report gain tab for low
or saturated head pulse counts. If several saturated or low pulses in the counters
and the process has very heavy or light basis weight streaks, or very wet or dry
streaks, the saturated or small counter limits can be increased for a wild process
see HemiPlus gain malfunction on page 7-37.
4. If the small count counter is exceeding the limit count the sensor is a HemiPlus,
and the process basis weight it 350 GSM or greater, the sensor is out of range for
multi-wavelength operation. Change to 2 filter mode, see page 1-8.
5. If the counts in the "saturated counts" counter are exceeding limits, check the
sensor windows for condensation. If condensation is present, install heated air
wipes. If condensation is not present, check the gain logic as described in this
chapter, see page 7-37.
*If the IR sensor is the only sensor on the scanner, or no other sensors use ±15 volts, such as
a Smart Basis Weight Sensor which uses ±12 volts, the problem may also be the power
ribbon cable.
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3. Manually change gain using the IRGAIN Select on the Network Platform IR
Health Report. See HemiPlus gain test, page 7-34. As the gain is changed, you
should be able to see the effect on the amplitude of each signal as long as the
signals are not saturated. If the signals respond properly, the system is able to
control the gain of the sensor, if not continue troubleshooting.
4. If the head pulses appear to be saturated on the health page, check the head pulse
amplitude with the Network Platform Diagnostic Utility.
2. Check the voltage for the increase and decrease signal; it should be approximately 10 to
12 volts DC. The signal originates in the sensor. If voltage is not present, verify
necessary voltage is present at the sensor. Also verify the increase or decrease signal isn't
shorted or an open circuit. See “Checking signal and power cables in SP1200, SP700,
MP, Refl. SP” document number 914044G407936, on the SolutionsBank for information
on testing ribbon cables in the Network Platform, Smart Platform, or Measurement
Platform.
3. Jumper the increase and decrease signal to simultaneously ground momentarily, one
second should be enough. This will set the sensor's gain to mid-gain. The head pulses
should appear saturated.
4. Jumper the decrease gain signal to ground momentarily several times until the head
pulses come out of saturation.
5. Jumper the increase signal to ground, and the head pulses should increase in amplitude
again.
6. If grounding the increase or the decrease signals cannot change the gain, the gain circuit
is faulty and the sensor must be replaced. If the gain can be controlled or changed by
grounding the increase or the decrease signals, the problem is in the system controlling
the sensor, test the Standard Signal Conditioning Board.
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8 How to
Chapter 6 contains the following main sections:
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Terms Definition
CHKSMP time Current Time (Based on 24 hour clock) and Date
FRAME Sample Check Frame Number (On printed reports)
MACHINE Customer’s Machine Number (On printed reports)
PROC MOIS % This reading uses the slope, and offset in the preliminary grade code file.
STD MOIS% Raw moisture reading before applying the grade code slope and offset.
IRGAIN Active preamp gain during sample check measurement. For HemiPlus only.
IR1 and IR2 Value ratios calculated during sample mode
OFFSET Preliminary product code file tuning factor for offset in percent moisture
SLOPE Preliminary product code file tuning factor for slope.
PRODUCT Preliminary Product Code ID
The ASH compensation value used in HemiPlus sensor. 4-Filter Mode
Mode Ash Compensation
ASH COMP
1 Manually entered % Ash
% ASH
2 Measurement ASH
3 Default Ash Comp
Weight compensation used for IR measurement (2-Filter Mode).
Mode Weight Compensation
WT COMP 1 Manually entered weight
2 Measurement weight
3 Default weight Comp
MODE Mode Specified on Sample Check Setup Page
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Procedure
Press the CALIBRATE SAMPLE pushbutton, a minimum of five seconds of data will
be collected after the light comes on. To extend the averaging continue to hold the
button; data collection stops when the button is released and lamp is extinguished
when released. The time for a quick button push can be extended by changing the
variable calSampMinTime in the Scanner Configuration. The time may be set from 5
to 100 seconds. See the Network Platform Software Reference Manual for details on
changing configuration settings.
Figure 8-3 below and Figure 8-36 below are examples of the Calibrate Sample
Reports, as shown on the NP IR Health Reports.
Figure 8-3 HemiPlus calibrate sample Figure 8-4 ReflectionPlus calibrate sample
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Terms Definition
CALSMP Time Current Time (Based on 24-hour clock) and Current Date
FRAME Sample Check Frame Number (Shown on printed reports)
MACHINE Customer’s Machine Number (Shown on printed reports)
PRODUCT Grade Code ID (Shown on printed reports)
This reading uses the slope, and offset in the current product code
Proc Moisture %
file.
Std Moist % Raw moisture reading before applying the product slope and offset.
IRGAIN Active preamp gain during calibrate sample. (for HemiPlus only)
IR1 and IR2 Value ratios calculated during sample mode
OFFSET Grade code file tuning factor for offset in percent moisture
SLOPE Grade code file tuning factor for slope.
ASH COMP
% ASH
The ASH compensation value used in 4-Filter mode.
WT COMP Weight compensation used for IR measurement in 2-Filter Mode
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1190/Nexus Systems
800xa Systems
See 800xA host documentation.
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Get Ash
Compensation for
HemiPlus Moisture
Internal Ash
Compensation?
No
Yes
Is
Ash Sensor
Measurement
Valid? No
Yes Is
Grade Code
Use Grade Code
Compensation
Ash Compensation
Zero? No
Use Active
Ash Compensation Yes
Use Default
Ash Compensation
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9 Configuration Items
This chapter contains listings of the configuration items for HemiPlus Moisture Sensor.
Default and example entries are show. See the Network Platform Software Reference Manual
for details on configuration.
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10 Part Numbers
Reference: Part Description Part Number
HemiPlus IR Sensor 072929-001 Kit*
ReflectionPlus Sensor 072044-001 Kit*
A Check Sample Holder for 1.25 inch pass 069884-204
line – ReflectionPlus
B Check Sample Holder for 0.25 inch pass 069884-201
line – HemiPlus
IR Lamp Replacement Kit 085870-001
Filament Transformer, 12v 128877-050
Glass check sample 33.0 g/m2 Dry 064608-001
Glass check sample 34.5 g/m2 Wet 064608-002
Glass check sample 112 g/m2 Dry 064608-005
Glass check sample 119 g/m2 Wet 064608-006
Glass check sample 188 g/m2 Dry 064608-007
Glass check sample 199 g/m2 Wet 064608-008
Glass check sample High Moisture for 069732-002
ReflectionPlus
Glass check sample High Moisture for 085870-001
ReflectionPlus
The Heated Air Wipe Kit NP1200 Top 126259-003
Heated Air Wipe Kit NP1200 Bottom 126259-004
Heated Air Wipe Kit NP700 Top 126259-005
Heated Air Wipe Kit NP700 Bottom 126259-006
Table 10-1 - Part numbers
A
B
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Grade ________________
1. Sample group “wet” weight after conditioning_______________________________
2. *Sample group “wet” count, number of sheets________________________________
3. *Sample group “wet” area in Meters (count * length * width) _______________________
4. * Sample group “wet” basis weight (weight in grams / area in meters2)____________
Grade ________________
1. Sample group “wet” weight after conditioning_______________________________
2. *Sample group “wet” count, number of sheets________________________________
3. *Sample group “wet” area in Meters (count * length * width) _______________________
4. * Sample group “wet” basis weight (weight in grams / area in meters2)____________
* Indicates steps needed only for samples measured with IR Sensors in two filter mode or
Microwave Moisture sensors.
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Date________________________________________
Time________________________________________
Single Point Position___________________________
Edge of Sheet to Sensor Center___________________
Time in oven__________________________________
Time out of oven__________________________________
Sample 1 Dry
Sample + Bag Weight ______________________
Bag Weight______________________________
Sample ID _______________________________
Sample 2 Dry
Sample + Bag Weight ______________________
Bag Weight______________________________
Sample ID _______________________________
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