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Network Platform

HemiPlus and ReflectionPlus


Sensor Manual

ABB
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.

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Document Version History



IR Sensor Technical Manual with Network Platform
Version Sections Changed by Sections Added by Sections Deleted by
Level Effective Date Revision Revision Revision

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

2 HARDWARE OVERVIEW ........................................................................ 2-1


2.1 Source ..........................................................................................................2-2
2.2 Detection ......................................................................................................2-4
2.3 Air Wipe........................................................................................................2-5

3 INSTALLATION PROCEDURES.............................................................. 3-7


3.1 HemiPlus alignment ....................................................................................3-8
3.2 ReflectionPlus alignment ...........................................................................3-9
3.3 Coanda air wipes.......................................................................................3-10
3.4 Power-up ....................................................................................................3-12
3.5 Raw signals................................................................................................3-13
3.6 Transfer constants ....................................................................................3-14
3.7 Compensating variables...........................................................................3-17
3.8 Standardize limits......................................................................................3-19

4 MEASUREMENT PROCESSES............................................................... 4-1


4.1 Algorithm .....................................................................................................4-2
4.2 Signal gain ...................................................................................................4-2
4.3 Standardize ..................................................................................................4-4
4.4 Calibration....................................................................................................4-5
4.5 Correlation ...................................................................................................4-6

5 MAINTENANCE PROCEDURES ............................................................. 5-1


5.1 Stability ........................................................................................................5-2
5.2 Preventive maintenance .............................................................................5-2
5.3 Liquid cooling unit ......................................................................................5-2
5.4 Source lamp.................................................................................................5-3

6 SENSOR VERIFICATION......................................................................... 6-7

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6.1 Overview ......................................................................................................6-8


6.2 Phase one ....................................................................................................6-9
6.3 Phase two ..................................................................................................6-11
6.4 Phase three................................................................................................6-29
6.5 Correlation problems................................................................................6-30

7 TROUBLESHOOTING PROCEDURES ................................................. 7-33


7.1 HemiPlus gain test ....................................................................................7-34
7.2 ReflectionPlus flag malfunction ..............................................................7-35
7.3 Logic stream malfunction ........................................................................7-35
7.4 HemiPlus gain malfunction ......................................................................7-37
7.5 Standardize ratio malfunction..................................................................7-39
7.6 Standardize noise malfunction ................................................................7-40
7.7 Signal range malfunction .........................................................................7-41
7.8 HemiPlus, gain out of range.....................................................................7-43

8 HOW TO................................................................................................... 8-1


Perform a sample check.....................................................................................8-2
8.1 Interpret sample check report....................................................................8-3
8.2 Perform a Calibrate Sample .......................................................................8-4
8.3 Interpret calibrate sample report ...............................................................8-5
8.4 Switch multi-wavelength & 2-Filter modes ...............................................8-6
8.5 Grade code dual function entries ..............................................................8-7

9 CONFIGURATION ITEMS ....................................................................... 9-1


9.1 Signal decomposition constants...............................................................9-2
9.2 HemiPlus multi-wavelength constants .....................................................9-3
9.3 HemiPlus 2-Filter constants.......................................................................9-3
9.4 HemiPlus signal limits ................................................................................9-3
9.5 HemiPlus standardize limits ......................................................................9-4
9.6 HemiPlus check sample limits...................................................................9-4
9.7 HemiPlus analog inputs .............................................................................9-4
9.8 HemiPlus logic inputs.................................................................................9-5
9.9 HemiPlus gain outputs ...............................................................................9-5

10 PART NUMBERS................................................................................... 10-1

APPENDIX A - ACLAR® BAG TWO POINT METHOD WORKSHEET ..............A-1

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APPENDIX B - SINGLE POINT MOISTURE CORRELATION WORKSHEET .. B-1

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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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Figure 9-2 Multi-wavelength constants ................................................................................. 9-3


Figure 9-3 2-Filter Constants ................................................................................................. 9-3
Figure 9-4 HemiPlus signal limits ......................................................................................... 9-3
Figure 9-5 HemiPlus standardize limits................................................................................. 9-4
Figure 9-6 HemiPlus check sample limits ............................................................................. 9-4
Figure 9-7 HemiPlus analog inputs........................................................................................ 9-4
Figure 9-8 HemiPlus logic inputs .......................................................................................... 9-5
Figure 9-9 HemiPlus gain outputs ......................................................................................... 9-5
Figure 10-1 Check sample holders ...................................................................................... 10-2

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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 Sensor, selected for the specific application

o Cooling Unit, for maintaining the desired sensor temperature

o Head package cabling to interface with the sensor

o End Column Hardware and Software, for processing the raw data into a
moisture measurement and controlling modes of operation

o Host Software, for display, report and interface to control applications.

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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

Figure 1-1 IR HemiPlus (top), ReflectionPlus (bottom)

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Key to functional diagram


A. Digital input for DDC (direct digital control) of gain applied to detector,
HemiPlus only

B. Digital input for DDC of gain applied to detector, HemiPlus only

C. Detector output analog signal with gain applied, HemiPlus & ReflectionPlus

D. Printed wring board, digital gain board, HemiPlus

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

G. Detector portion of polished spherical cavity, HemiPlus only

H. Lead salt detector on water-cooled heat sink, HemiPlus & ReflectionPlus

I. 120 VAC “protected” see output ‘Q’, HemiPlus & ReflectionPlus

J. Transformer, typical output 12 VAC, 18VAC possible, located in the scanner,


HemiPlus & ReflectionPlus

K. Low voltage AC supplied to source lamp, HemiPlus & ReflectionPlus

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

O. Motor to drive filter wheel. Synchronous and polarized to AC line frequency.


(3600 rpm at 60 Hz drive), HemiPlus & 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.

R. Logic output signal, used to synchronize demodulation of detector signals,


HemiPlus & ReflectionPlus.

S. 42 VDC to drive solenoid, ramping voltage, ReflectionPlus only

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T. Analog diagnostic, voltage proportional to analog pre-amp gain (not currently


used), HemiPlus only.

U. Over temperature sensor feeds PcBd “P” HemiPlus & ReflectionPlus.

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.

The response is normalized by a wavelength selected for minimal absorption in the


measured material. The measured material may be a mixture of different constituents
(cellulose, moisture, plastic, clay, etc). Wavelengths may be selected that coincide
with unique absorption bands for each material. For example, the absorption
coefficient spectra for water and cellulose are shown in Figure 1-2 below

Pure Cellulose and Water Absorption Coefficient Spectra


10000

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]

Figure 1-2 Infrared spectrum

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Water may be measured, independent of cellulose, by taking the ratio of two


wavelengths at approximately 1.8 and 1.95 microns, as shown by the arrows in the
Figure. In this case 1.8 microns is the reference wavelength for water [Rw] and 1.95
microns is the measurement (or ‘absorption’) wavelength for water [Mw]. The ratio
is expressed as:
Ratio = Mw / Rw
Equation 1-1

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

The transfer function


A plot demonstrating how water weight (in a paper web) influences Ratio, is shown in
the figure below.

WATER WEIGHT VERSUS RATIO


1.0
0.9
RATIO = Mw / Rw

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

WATER WEIGHT, G/M2

Ratio response to water weight

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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Both HemiPlus and ReflectionPlus features utilize up to four different wavelengths to


determine sheet percent moisture. Signals are normalized during off-sheet
standardization mode. A complex algorithm uses the normalization constants and
ratios formed when the sensor is on-line to compute percent moisture. In many cases
additional product code coefficients (unique to specific customer products) are
utilized by the algorithm to fine tune the on-line response so that each product
measures accurately.

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.

The optical cavity, HemiPlus


A five inch spherical diameter optical cavity surrounds the process containing most of
the radiation scattered by the paper web, see the Figure 1-1 on page 1-3figure on page
1-3. The web bisects the cavity; the beam is focused onto the web at the geometric
center of the cavity. When the web scatters radiation scatters in all directions the
optical cavity redirects energy back to the same spot on the web. The design is
optically efficient providing high signal to noise ratio. It compensates for scattering
differences in web and improves sensitivity on light weight sheets due to multiple
interactions between the beam and web. The design incorporates elements to reduce
errors caused by dirt build-up on the windows and pass-line deflection.

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.

Moisture and weight range


HemiPlus and ReflectionPlus moisture and basis weight ranges are shown in Table 1-1 -
HemiPlus ranges and Table 1-2 - ReflectionPlus ranges below. The selection of two or four
filter modes is made via the product code file.

HemiPlus Operation Ranges


4 Filter mode 2 Filter mode
Moisture Bone Dry Weight Moisture Bone Dry Weight
Rated Range 0-35% 8-350 g/m² 0-20% 40-500 g/m²
Effective Range 0-25% 15-335 g/m² 0-15% 50-450 g/m²
Table 1-1 - HemiPlus ranges
Note: Specifications apply to the effective range. The sensor may operate in the rated
range, but specifications do not apply.

ReflectionPlus Operation Ranges


4 Filter mode 2 Filter mode
Moisture Bone Dry Weight Moisture Bone Dry Weight
Rated Range 0-48% 10 g/m² Min 0-70% 10 g/m² Min
Effective Range 0-40% 18 g/m² Min 0-65% 18 g/m² Min
Table 1-2 - ReflectionPlus ranges
Note: Specifications apply to the Effective Range. The sensor may operate in the
rated range, but specifications do not apply.

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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.

Cooling block, and reflector


The lamp is mounted in a Rhodium plated cooling block, that be seen in the
functional drawings on page 1-3. This block is common between HemiPlus and
ReflectionPlus. Water is circulated through the cooling block; the water temperature
is controlled to 33 °C (90 °F) via the liquid cooling unit (LCU).

Figure 2-1 Source lamp power supply

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Lamp safety switch


In both ReflectionPlus and HemiPlus the source subassembly is protected by a safety
switch. Lamp power is latched off if the cooling block overheats or if the filter wheel
stops rotating. Radiation from the lamp will destroy infrared band-pass filters if the
filter wheel stops rotating. Cooling block temperature is sensed using a bimetallic
switch (thermostat) attached to the lamp cooling block. Filter wheel rotation is
sensed by internal electronics.

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.

Motor Driven Filter Wheel


The Motor Driven Filter Wheel shown in Figure 2-2 below contains the infrared
band-pass filters. The positioning of the filters and phasing of the filter wheel,
relative to the motor, are pre-set my ABB manufacturing. The motor rotates in phase
with the 120 VAC line. It rotates at 3600 RPM (Revolutions Per Minute) when line
frequency is 60 Hz and rotates at 3000 RPM when line frequency is 50 Hz

Figure 2-2 Basic filter wheel and logic stream

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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).

2.3 Air Wipe


The air wipe feature protects windows from excessive dirt buildup. For proper
operation, correct adjustment is required. The usefulness of air wipes is application
dependent. If the air is dirty or oily their use may be detrimental. A heated air wipe
kit is available (with installation instructions), see Part Numbers. Heated air is useful in
applications where condensation on the windows or top plate is a problem.

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3 Installation Procedures
This chapter contains the following main sections:

3.1 HemiPlus alignment....................................................................................3-8


3.2 ReflectionPlus alignment ...........................................................................3-9
3.3 Coanda air wipes.......................................................................................3-10
3.4 Power-up....................................................................................................3-12
3.5 Raw signals ...............................................................................................3-13
3.6 Transfer constants....................................................................................3-14
3.7 Compensating variables...........................................................................3-17
3.8 Standardize limits .....................................................................................3-19

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3.1 HemiPlus alignment

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

Figure 3-1 HemiPlus sensor alignment

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3.2 ReflectionPlus alignment


The alignment goal for ReflectionPlus, on any frame, is to obtain a 31.7 mm ±1.5 mm
(1.25 in. ± 0.0625 in.) pass-line (distance from process to sensor face-plate). The
face-plate should be parallel to the process within ± 1°. One degree tilt causes a 3.3
mm (0.125 in.) edge to edge misalignment across the face-plate of the sensor in the
machine direction. If ReflectionPlus is mounted on the same frame as a basis weight
sensor then:

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.

Figure 3-2 Alignment of the ReflectionPlus sensor


For a single sided scanner ReflectionPlus mounting verify the sensor face-plate is
31.75 mm ± 1.6 mm (1.25 inches ± 0.062 inches) from the nominal web pass-line.
Ensure the face-plate is parallel to the process sheet within 2 mm (0.08 inches) in
both the machine and cross-machine directions. See Figure 3-3 below.

Figure 3-3 alignment of the ReflectionPlus Sensor to the process


Sheet guides used with the ReflectionPlus on a reflection scanner control pass-line to
the proper 1.25 inches.

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3.3 Coanda air wipes


Coanda effect air wipes are typically installed on the upstream side of the sensor,
blowing down stream. However, if there is steam carried with the process air wipes
may blow upstream. Verify, using feeler gauge, that slot width is 0.13 mm (5 mils)
as shown in Figure 3-4 below. Adjust slot width, if required, using the following
procedure.
o Loosen retaining screws on air wipe. See Figure 3-5 below.
o Gently tap top of unit until top lower edge of slot contacts feeler gauge.
o Slide feeler gauge along slot, ensuring that top lower edge contacts feeler
gauge along entire length of slot. This ensures that slot edges are parallel.
o Secure retaining screws.
o Adjust air wipe regulator for 140 kPA (20 (psig)) at the frame junction box.
o Sprinkle a small amount of machine dust or similar material on IR sensor
window.
o Adjust air wipe regulator, while observing dust, to give maximum wiping
effect at IR sensor window

Figure 3-4 Air wipe slot


Feeler Gauge

Retaining Screws

Figure 3-5 Air wipe adjustments

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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

Figure 3-7 ReflectionPlus 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

Figure 3-8 Circuit breakers

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3.5 Raw signals


Verify logic signals (pulses) are present. Use an oscilloscope to view the Logic Pulses
using the diagnostic card plugged into carriage board, see Figure 3-9 below

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).

Figure 3-9 Measure pulses & logic stream

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3.6 Transfer constants


Transfer constants, generally called head constants, establish the base calibration and
linearity factors for the sensor. They allow for calibration transferability between
sensors. The numeric values for head constants are found on a tag attached to the
sensor. A sketch of a tag used on HemiPlus is shown in Figure 3-10 below. Constants
may also found in the factory calibration report or frame test report. Record these
values in the System Log Book for future reference. On HemiPlus and ReflectionPlus
there are two sets of constant that support two different algorithms. This allows the
sensor to run in “so called” 2 FILTER mode (called Hemi Constants below) mode or
multi-wavelength mode (called Hemi-Plus constants below). The mode is user
selective via the product code file. For application a guide line for each mode see
Table 1-1 on page 1-8 and Table 1-2 on page 1-8. For further typical values and a
short explanation of each constant, for HemiPlus and ReflectionPlus see Table 3-1
and Table 3-2on page 3-15.

Figure 3-10 HemiPlus head constant tag

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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HemiPlus Moisture Calibration Constants


Parameter Typical
4 Filter 2 Filter Function 4 Filter 2 Filter

A A1, A2 quadratic non-linear term 1.79855 0.0002577,


0.0004869
B B1, B2 quadratic linear term 9.557 0.0562, 0.0408
C C1, C2 quadratic offset term -.039 0.8281, 0.4221
CW moisture offset -0.0701
DELTA1 SDELTA water linearity -.017 6.00
DELTA2 fiber linearity -.066
KF1 Water normalize 525.988
KF2 Fiber normalize 544.998
WTBP1, weight break point 67.65
Table 3-1 - HemiPlus head constants

ReflectionPlus Moisture Calibration Constants


Parameter Typical
4 Filter 2 Filter Function 4 Filter 2 Filter
A A1, A2, A3 quadratic non-linear term 2.335 -0.0000070,
-0.0000671, 0
B B1, B2, B3 quadratic linear term 6.970 0.02972, 0.04010, 0
C C1, C2, C3 quadratic offset term 0.570 0.8281, 0.4221,
5.727
D1, D2 weight sensitive offset 0.00006, 0
CW1, CW2 moisture offset -0.0063, 0
DELTA1 SDELTA water linearity -0.368 -676
DELTA2 fiber linearity -0.186
KF1 KF Water flag normalize 1002 971
KF2 Fiber flag normalize 940
WTBP1, weight break points 112.4, 400
WTBP2
Table 3-2 - ReflectionPlus head constants

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Figure 3-11 NP health page - HemiPlus head constants

Figure 3-12 NP health page – ReflectionPlus head constants

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3.7 Compensating variables


HemiPlus and ReflectionPlus are compensated for web ash content when they are run
in multi-wavelength mode (which is the normal mode). If either sensor is run in the
“two-filter” mode then are compensated for basis weight. In each case, the
compensation may come from an on-line sensor located on the same frame. Or, the
compensating value may be a static value from the product code file; the value may
change from grade to grade. Finally, the compensating value may come from scanner
software if the compensating value in the product code file is “0”. The names of the
compensating value in scanner software are:

DefaultAshCompensation & DefaultWeightCompensation

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.

Figure 3-13 -Configuration for HemiPlus – default entries

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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Figure 3-14 Health report for HemiPlus – ‘Current’

Figure 3-15 Health report for ReflectionPlus – ‘Current’

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3.8 Standardize limits


Standardize limits are modified through the use of the health pages in the service
work station, see figures. Default nominal and range are usually correct for most
applications. In the examples below IR1 refers to the ratio for water weight signals
and IR2 is the ratio of fiber weight signals.
HemiPlus Standardize Limits for IR1 and IR2
Parameter Function Nominal Range
RAIR (Reference signal on Air gap reference signal 6.5 3.0
Air during Standardize)
AAIR(Absorption signal Air gap absorption signal 6.5 3.0
on Air during Standardize)
KC (Ratio of RAIR to Ratio on air gap 1.0000 0.3500
AAIR during Standardize)
SIGMAIR (Noise on KC Ratio noise on air gap 0.00005 0.00005
during Standardize) (reported as variance)
IRGAIN (Digital gain step Gain step at standardize (not 4 3
at Standardize) in db units)
Shown for IR1 but applies
to all signals
Full Scale average time Full scale accumulation time 15 --
sec., applies to all signals.
Table 3-3 - Standardize limits for HemiPlus

ReflectionPlus Standardize Limits for IR1 and IR2


Parameter Function Nominal Range
RAIR (Reference signal on Standardize reference signal, 6.5 2.5
internal flag during measured on internal standard
Standardize)
AAIR (Absorption signal Standardize absorption 6.5 2.5
on internal flag during signal, measured on the
Standardize) internal standard.
KC (Ratio of RAIR to Ratio of reference and 1.0000 0.3500
AAIR during Standardize) measure signal
SIGMAIR (Noise on KC Noise on the ratio 0.00005 0.00005
during Standardize) expressed as variance
Full Scale Avg Time SEC Full scale accumulation time 10 --
Applies to all signals.
Table 3-4 - ReflectionPlus standardize limits

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Figure 3-16 NP HemiPlus health report standardize limits

Figure 3-17 ReflectionPlus health report - standardize limits

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4 Measurement Processes
This chapter contains the following main sections:

4.1 Algorithm .....................................................................................................4-2


4.2 Signal gain ...................................................................................................4-2
4.3 Standardize..................................................................................................4-4
4.4 Calibration ...................................................................................................4-5
4.5 Correlation ...................................................................................................4-6

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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.

4.2 Signal gain


This section applies only to HemiPlus. ReflectionPlus gain processing is internal to
sensor hardware.

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.

None of the following applies to ReflectionPlus.

Gain changes are performed under the following circumstances:


o At Standardize the gain is set using “Signal Limits Hi” and “Signal Limits
Lo” (see Figure 3-16 on page 3-20).
o When the sensor comes on sheet the gain is set using “Hi Mean” and “Lo
Mean” (see Figure 7-1 on page 7-34).
o When a sample check is performed the gain is set using “Hi Mean” and “Lo
Mean” (see Figure 7-1 on page 7-34).
o During the on sheet measurement the gain may change to accommodate
process changes, see below for description.
The Standardize, Going on sheet and Sample check cases all uses the same strategy.
Gain is set to previously used gain for the same action, if the desired reference signal
is not achieved, the gain increases or decreases with one gain step. If desired
reference signal is still not achieved a full binary search is employed.

Gain counter logic (while scanning in NP and SP)


Four (4) signal limits can be configured for gain change when scanning see Figure 7-1 on
page 7-34:
a) Maximum VDC – This is the maximum allowed voltage for reference signal, values
higher than this are considered saturated.
b) Hi Mean VDC – This value is only used to set the gain when going on sheet, not
during scanning.
c) Lo Mean VDC – Reference pulses below this value are considered “Low”.

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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.

Figure 4-1 HemiPlus standardize results

Figure 4-2 ReflectionPlus standardize results


See Figure 3-16 on page 3-20 and Figure 3-17 on page 3-20 for an explanation of the
standardize results.

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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.

MOISTURE = (STD MOISTURE) * SLOPE + OFFSET


Equation 4-1
The ideal calibration is thus a slope of 1.0 and offset of 0.0. The sensor may be
delivered with product code constants, determined in ABB sensor laboratory or by a
predictive calibration program, based on the customer’s furnish information. Slope
and offset values that are significantly different from 1 and 0 may indicate an unusual
process furnish, operation near or past the operative limits, laboratory problems, or a
failing sensor. If correlation efforts yield slopes that are greater than 1.5 or less than
0.6 and / or offsets are outside the range of ±1.5% moisture, there is high likely hood
that something’s amiss.

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 data are accumulated throughout a range of moistures, and offset change is


necessary, use the Slope and Offset Adjustment procedure on page 4-6.

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:

New Slope = Old Slope * Lab/Gauge


Equation 4-2

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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.

Example, set-up and data entry


A real correlation example for a ReflectionPlus sensor follows. The user must be
familiar with Excel (or similar tools). The Excel Data Analysis tool must be loaded
for effective use. For Excel 2003, or earlier, view the tools menu to see if it is
available (see below). If Data Analysis is not available, select Add-Ins and add this
function to Excel.

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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Example, the regression


Select Data Analysis under Tools menu. Select Regression, as shown below.

Fill in the Regression form as shown in the example below.


o Input Y Range: enter the range of sensor data, col. F in the example.
o Input X Range: enter the range of laboratory data, col. E in the example.
o Select an empty area in your worksheet for the “Output Range”, this is where
the statistical output data will be printed.
o When the form is completed, push OK. The “SUMMARY OUTPUT” will
appear at your selected Output Range.

Slope only correlation, ‘Constant is Zero’


If data are clustered, or it appears there is insufficient range of moisture, select the
check box Constant is Zero. This will force the offset coefficient to be zero and allow
the user to derive the best slope to fit the available data. When few samples are used,
or data scatter is high, this is often the best choice. In this example we will not check
Constant is Zero, but later test that decision.

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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.

Example, preliminary Slope and Offset


We first compute a preliminary ‘Slope’ and ‘Offset’ based on the regression.
Slope = 1/ ‘X Variable 1’ = 1 / 1.052 = 0.951
Offset = - Intercept / ‘X Variable 1’ = -0.512 / 1.052 = -0.487

If Sensor data already have slope and offset


If the Sensor data in the regression had Slope =1 and Offset = 0 then the computed
‘Slope’ and ‘Offset’ (above) are the new product code file coefficients, call them
NewSlope and NewOffset. In this example the sensor has an “old” (existing) PCF
slope and offset applied of:

OldSlope = 1.033 and OldOffset = 0.220

We compute a NewSlope and NewOffset as follows:


NewSlope = Slope * OldSlope
Therefore: NewSlope = 0.951 * 1.033 = 0.982

NewOffset = Slope * OldOffset + Offset


Therefore: NewOffset = 0.951 * 0.22 + -0.487 = -0.278
In the example 0.982 and -0.278 are new product slope and offset, respectively.

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Confidence interval check


It is possible to use our statistical data to see if the new slope and offset are
statistically different from the old ones. Before calibration change decisions are made
it is worth while to ask “will I just be chasing the calibration? Are the changes
significant at a 95% confidence interval”?

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.

Offset only adjustment


Use the offset only correlation may apply to “dry” applications or when all data are
bunched. For our example, average all laboratory and all sensor data:
o AveLab = 12.35%M
o AveSens = 13.49%,
o AveLab - AveSens = – 1.15%M.
o NewOffest = OldOffset + (-1.15)

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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:

5.1 Stability ........................................................................................................5-2


5.2 Preventive maintenance .............................................................................5-2
5.3 Liquid cooling unit ......................................................................................5-2
5.4 Source lamp.................................................................................................5-3

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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.

5.2 Preventive maintenance


o Clean the windows of HemiPlus and ReflectionPlus sensors with window cleaner
containing ammonia using a clean lint-free cloth. Frequency of cleaning is
application dependent, typical is once each week to once each month.

o Do not use window cleaner on the GT caliper sensor planes.

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.

5.3 Liquid cooling unit


Refer to the preventive maintenance section of the Liquid Cooling Unit Reference Manual
101333-003.

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5.4 Source lamp


The time required to change the lamp, steps 5 through 15 of this procedure is less than
fifteen minutes, once the sensor is removed from the head carriage. The only tools
required are:

o Screwdriver for #8 slotted screws

o Needle-nose pliers or equivalent

o 3/32” Hex Head Driver

o Ohm meter or continuity tester

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.

2. Clean external surfaces, focus on the area around the port.

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.

4. Place the sensor in a clean area where nominal RH is 50% or less.

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

Figure 5-1 HemiPlus / ReflectionPlus Lamp port

Figure 5-2 Lamp block assembly

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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Figure 5-3 HemiPlus / ReflectionPlus Lamp

10. Remove the old lamp using the needle-nose pliers.

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.

Do NOT touch the Quartz Envelope with bare fingers!

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.

16. Return the sensor to the frame or scanning platform.

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6 Sensor Verification
This chapter contains the following main sections:

6.1 Overview ......................................................................................................6-8


6.2 Phase one ....................................................................................................6-9
6.3 Phase two ..................................................................................................6-11
6.4 Phase three................................................................................................6-29
6.5 Correlation problems................................................................................6-30

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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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6.2 Phase one


Repeatability
Repeatability is the closeness of agreement among a number of consecutive
measurements of the output for the same value of input under the same operating
conditions, approaching from the same direction, for full range traverses.
Repeatability is determined from the deviation values of a number of rapidly
consecutive measurements of the output with a check sample in the measurement gap.
A repeatability test should be run on each of the six glass check samples supplied
with the sensor. Data from this test will be used in subsequent tests.

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.

IR Moisture Sensor Verification


Stability Check

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

Figure 6-1 Check sample repeatability

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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.

Deviation = Ave. from repeatability minus individual readings over 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

Glass Sample Limits

Figure 6-2 Moisture sensor reproducibility graph

Moisture Verification
Sensor Reproducibility
7

6
Percent Moisture (Sensor)

0
0 1 2 3 4 5 6 7
Sensor Value Percent Moisture (Initial Test)

Figure 6-3 IR Moisture reproducibility XY graph

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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.

6.3 Phase two


In phase two we connect sensor capability to the customer’s process; laboratory
versus sensor correlation is established. For information regarding regression
techniques see Section 4.5, beginning on page 4-6.

Static versus dynamic influence factors


Aclar® bag methods are considered the most accurate method of obtaining
correlation. It has the advantage of using archived samples. With archived samples,
the correlation is performed without waiting until a specific grade is scheduled, which
is required in the dynamic method.

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.

A hallmark of ABB sensor designs is to reduce or eliminate static to dynamic


influence factors. However, thickness direction moisture gradient remains an
influence factor for ReflectionPlus sensors. The approach is inherently single sided.
Therefore, ReflectionPlus expects either a homogenous distribution of moisture or
expects the client desires to measure surface versus total moisture.

Aclar® bag two point correlation

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 laboratory that is temperature and humidity controlled to 23 °C and 50%


relative humidity, or at least a stable humidity while samples are conditioned.

o A forced air drying oven with temperature control at 105 °C, ±2 °C.

o 12 x 12 inch Aclar® bags, ABB part number 064703-001.

o A heat sealer to seal the Aclar® bags.

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.

1. Obtain, at least, 10 samples of each grade to be correlated. Samples should be


cut to 200 x 200 mm (8 x 8 inches). Exact dimension of the sample is not
important if the multi-wavelength mode is used for on-line measurement. If
two-filter mode is used then exact dimensions to determine the basis weight of
samples is required.

2. Mark each sample with a grade indicator.

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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Figure 6-4 Conditioning samples

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.

Prepare the wet samples


1. If samples are not measured in multi-wavelength mode, weigh the samples for
each grade marked “Wet” using a precision lab balance. Enter the weight in
the Aclar® bag two point method worksheet on page A-1, and calculate the
average basis weight for the sample group. Mark the samples with the
average basis weight.

2. If samples are measured in multi-wavelength mode (which is the typical


mode) record the target percent ash for each grade, mark the samples with the
ash content, for example see Figure 6-6 on page 6-15

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.

4. Set these “wet” samples aside.

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Figure 6-5 Bagged wet samples

Prepare the dry samples


1. It is assumed that all samples (marked wet and dry) are conditioned to the
same percent moisture. Use the worksheet “i- Aclar® bag two point method
worksheet on page A-1.

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.

4. If samples are not to be measured in multi-wavelength mode determine the


average Basis Weight for each grade group of “Dry” samples using the “-
Aclar® bag two point method worksheet” on page A-1.

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”.

Figure 6-6 Bagged dry samples

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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Creating a sample holder/protector

Figure 6-7 Sample holder

Figure 6-8 Sample in Aclar® bag

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Aclar® bag multi-point correlation


The multi-point method employs desiccator tanks with different solutions used to
achieve varying levels of relative humidity. Using this procedure requires six
samples at different moisture levels. When paper samples are placed in the
desiccators they condition to differing percent moisture levels that are consistent with
the relative humidity in each tank. The samples are cut 200 x 200 mm or 8 x 8
inches. Samples are bone dried and the weight of each is recorded. Three samples of
each grade are conditioned in each tank. The samples are weighed again and the
percent moisture of each sample computed. One set of three samples for each grade
are sealed in an Aclar® bag while bone dry. The others are sealed in an Aclar® bag to
retain the conditioned moisture.

Required materials
1. A temperature and humidity controlled laboratory

2. A forced air drying oven controlled at 105 °C ±2 °C.

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.

6. 12 x 12 inch Aclar® bags ABB part number 064703-001.

7. A heat sealer to seal the Aclar® bags.

8. Cotton gloves and six sample holders to handle samples. Construct sample
holders as shown below, see page 6-20.

9. 18 samples of each grade to be correlated are cut to 200 x 200 mm (8 x 8 inch).


Exact dimension of the sample is not important if the multi-wavelength mode is
used for on-line measurement. If two-filter mode is used then exact dimensions to
determine the basis weight of samples is required.

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Chemicals for desiccators


Select four from the list below. (See mixing procedures below.)
1. Silica gel desiccate, produces approximately 1 to 1.5% M in paper.
2. Lithium Chloride, produces approximately 2% to 4% M in paper.
3. Potassium acetate produces approximately 3% to 5% M in paper
4. Sodium Chloride produces approximately 6% moisture in paper
5. Sodium Bromide produces approximately 5 to 8% M in paper.
6. Potassium Nitrate produces approximately 8% M in paper.
7. Ammonium Sulfate produces approximately 8% to 10% M in paper.
8. Sodium Bromide produces approximately 10% M in paper
9. Copper Sulfate produces over 10% M in paper.
10. Ammonium Chloride produces approximately 12 to 14% M in paper.

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).

2. In a corner of each sample, identify the sample.

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.

6. Allow 12 to 24 hours for the samples to condition.

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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8. For each sample in the desiccator and laboratory:

o Weigh an Aclar® bag and record the weight.

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 of the Sample Protector


Item Required

o A large piece of file card stock or a manila file folder.

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.

2. Fold the sample protector in half along the fold line.

Figure 6-9 Sample holder / protector

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Desiccators for moisture correlation


Items required (per desiccator):

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 A piece of double strength, single pane glass or Plexiglas as large as the


outside dimensions of the top (or open part) of the aquarium.

o A continuous hinge as long as the width of the aquarium.

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 Quick drying plastic adhesive.

o Quick drying epoxy.

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 Cut the piece of glass or Plexiglas in half.

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.

o The conditioning tank is now complete and ready for chemicals

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Rack to hold the samples


A rack to hold the samples that are being conditioned can be constructed from
Panduit plastic cabinet cable trough. The desiccator will contain solution of water
and salts in approximately the first inch of the bottom of the desiccator. Any rack that
will hold the samples away from, and out of, the solution in the bottom of the
desiccator will work.

To construct the rack from Panduit


Materials needed:

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.

4. Place the Panduit into the aquarium.

5. Place the cover glass on top of the aquarium.

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Figure 6-10 Sample rack assembly

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Saturated Salt Solution Mixing Procedures

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.

5. Table of relative humidity and approximate sample moisture.

Table 6-1 - Conditioning salts

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Single Point Dynamic Sample Method


A sample is cut from the reel and its moisture is determined by the oven dry method.
A comparison of the laboratory moisture to on-line measured moisture is made, using
a report from the measurement system “Calibrate Sample” utility.

Materials needed:

o Two plastic bags of the appropriate size to hold a sample 3 inches by 20


inches (76 mm x 510 mm), several layers thick

o Rubber bands to seal the bags.

o A tape measure

o A knife to cut the samples

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.

2. Press the Calibrate Sample pushbutton on the frame control panel.

3. When the Calibrate Sample LED goes out, flag the reel.

4. Return the scanner to scan mode.

5. Collect the Calibrate Sample Report.

6. Slab the reel off to the flag.

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

8. Cut a sample approximately 76 mm x 510 mm (3 inches by 20 inches), several layers


thick, with the long dimension orientated in the machine direction. Immediately

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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.

Figure 6-11 Cutting a dynamic sample


10. Weigh each sample while in the bag on a precision balance. Remove the samples
from the bag, marking one sample “A” and the other “B”. Weigh the corresponding
bag with rubber band. Enter the weights in the worksheet printed from Appendix B.

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.

14. Calculate percent moisture using the Appendix B worksheet.

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Figure 6-12 Calculate percent moisture

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

Mini Scan for Calibrate Sample while in Single Point


The Mini Scan feature provides a feature that compensates for small measurement
area of some sensors when performing a single point calibrate sample. In order to
provide excellent streak resolution the measurement area of some sensors is as small
as 6.4 mm (0.25 inches). When performing sensor verification by single point sample
method, it is not practical to cut a sample as small as 6.4 mm in the cross machine
direction. The Mini Scan feature allows measurement of a larger cross direction area
during calibrate sample.

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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Figure 6-13 Mini scan setup

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6.4 Phase three


This phase provides continuing certification to assure the sensor remains capable of accurate
and reliable measurement for the life of the system. Check samples associated with the
sensor are measured on a continuing basis as a part of a preventive maintenance program. It is
expected that sampling of the process also is continued. The frequency of sampling and
check sample readings is determined per application and according to the customer’s needs.

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6.5 Correlation problems


A correlation problem is usually defined as, systematic disagreement between the on-
line sensor and laboratory values. A reasonable preventive maintenance plan usually
heads off this problem. Before investigating correlation problems always ensure the
calibration and stability of the sensor.

Check sample reading history helps partition problems:


a) On-line measurement problems, which shows up as check sample drift
or step out in the same direction as the correlation problem. Review
historic and current check sample data. More than one glass sample needs
to be reviewed. Glass samples may leak due to improper handling (or
manufacturing defects). If a check sample step-out is noticed be sure to
verify:
ƒ Sensor constants have not inadvertently changed
ƒ Windows are clean, see next page
ƒ The liquid cooling using temperature has not changed
ƒ No external condensation on windows, see next page
ƒ No internal condensation (sensor needs replaced)
b) Process changes, which may be a change of furnish, such as de-inked
recycle, or large filler changes or re-wet showers (see page 6-31). Evaluate
what, if any, process changes occurred consistent with the correlation
problem. See the section titled ‘Two point Aclar® bag two point
correlation’ on page 6-11 to verify static calibration for the grade in
question is correct.

c) Laboratory problems, a bias to the quality control laboratory (new


operator, scale, or bad sample handling methods). Experiments may be
designed to evaluate capability of procedures being used

Use of an oscilloscope
a) Watch intermittent noise or other interference on raw sensor signals.

b) Bright lights or infrared heaters may cause interference which may be


noticed as a calibration shift. On the oscilloscope, the optical interference
is usually manifest as 60 or 120 (or 50 or 100) Hz interference
superimposed on the sensor signals.

c) Bad grounding can have the same effect.

d) These sources may, or may not be noticed on check sample readings.

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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.

Operation at design limits


Operation of HemiPlus or ReflectionPlus at, or near, the design limits may reduce on-
line accuracy. This may include:
o Basis weight high or low range
o Percent moisture or water weight range, (no low limit, 0%M is okay)
o Sheet fillers or pigments
o Water layers on the web
o Environmental parameters
o On-sheet ambient temperature maximums
o Off-sheet ambient temperature maximums
o relative humidity
o Low or high frequency vibration or shock
o Bright lights, Sheet inspection system lights

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:

7.1 HemiPlus gain test ....................................................................................7-34


7.2 ReflectionPlus flag malfunction ..............................................................7-35
7.3 Logic stream malfunction ........................................................................7-35
7.4 HemiPlus gain malfunction ......................................................................7-37
7.5 Standardize ratio malfunction..................................................................7-39
7.6 Standardize noise malfunction ................................................................7-40
7.7 Signal range malfunction .........................................................................7-41
7.8 HemiPlus, gain out of range.....................................................................7-43

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7.1 HemiPlus gain test


Gain may be increased or decreased through the Health Pages using the options listed under
Gain Selections. See Figure 7-1 below and Figure 7-2 below. Resulting changes should be
seen in the graph of IR Pulse Signals.

Figure 7-1 NP HemiPlus health report - Gain selections

Figure 7-2 Manually selecting HemiPlus gain

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7.2 ReflectionPlus flag malfunction


With the sensor off sheet, insert and remove the ReflectionPlus IR flag using the
Scanner Diagnostic Tool. See the Network Platform Software Reference Manual. Use
a volt / ohm meter attached to the “IR Signal” output to determine if the voltage is
increasing or decreasing. An increase in voltage indicates the ReflectionPlus flag is in
place. A decrease in voltage indicates the ReflectionPlus flag is not in place.
If the flag does not respond, one of the following may be the cause:
o Electrical solenoid in the sensor not functioning, new sensor is required

o Signal lost at the ‘standard signal conditioning board’, or the ‘power signal
conditioning board’.

o Connection bad between the ASPC and the sensor.

o The 42 VDC power supply is not functioning

o The software is not sending the signal.

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.

7.3 Logic stream malfunction


Symptom: The sensor fails to measure and / or the RPS indicates Zero. Use the
appropriate functional drawing with this procedure. This failure can occur if the
sensor stops sending logic stream to the ASPC, see pages 2-4 and 3-13. RPS on the

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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

Figure 7-3 HemiPlus / ReflectionPlus health report – Inputs

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’.

120 VAC not present at carriage 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.

7.4 HemiPlus gain malfunction


In some applications the HemiPlus may not have sufficient range to cover signal
differences when extremely large basis weight or moisture profiles exist. When this
happens, the histogram error counter/counters receive enough counts to exceed the

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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.

IR Gain in the Network Platform


Histogram Counters

Saturated Default Limit 10


Maximum VDC Default 12 VDC

High Mean VDC Default 4.95 VDC

R Head Pulses Good

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.

Figure 7-4 HemiPlus gain histogram


A detailed description of the gain change criteria can be found in Signal gain .

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

Caution should be exercised, as increasing these limits could also cover


up a problem such as a bad cable in the scanner.

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7.5 Standardize ratio malfunction


HemiPlus or ReflectionPlus standardize ratio out of range indicates that the ratio of a
reference and measure signal are out of limits. Check the sensor windows for dirt or dust
(does not apply to ReflectionPlus). If dirt or dust is collecting on the windows adjust the air
wipes for optimum cleaning see Coanda air wipes on page 3-10. See if the HemiPlus
detector windows have accumulated dirt or condensation on the inside of the window. If
this is found, replace the sensor.

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.

2. Check for condensation on outside of the ReflectionPlus or HemiPlus windows. In


a high humidity application water will condense on the face-plate or sensor window.
Condensation may cause standardize failure and inaccurate measurement on
transmission sensors, and inaccurate measurement on reflection sensors. In both
cases the condensed water may drip on the process causing quality problems. Install
heated air wipes.

3. Contamination or condensation inside the sensor can cause intermittent standardize


failure. Unfortunately the contamination may not be visible from outside the sensor.
Condensation inside the sensor may be misdiagnosed as a temperature sensitivity.
In general, it will be the water absorption signal the is most influenced and this ratio
may be used to help troubleshoot the problem. Assume the sensor is cold (setting
off-sheet) and condensation may have occurred and influenced standardize. Then
the water weight ratio (KC1, AbsAir / RefAir) is low. After the sensor is on-sheet
and heating up due to the hot web; we may see that subsequent standardize values of
KC1 begin to increase as the internal condensation evaporates. Additionally,
sometimes SigmaIR1 (noise of KC1)is high if the standardize takes place while the
condensation is evaporating. If internal contamination / condensation is diagnosed,
the sensor must be replaced.

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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7.6 Standardize noise malfunction


This alarm indicates a variation in the ratio between the reference and measure signals
has a high variance during standardize.

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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7.7 Signal range malfunction


During standardize
If the alarms indicate Fiber, Absorption, or Reference out of range during standardize,
check the following:

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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7.8 HemiPlus, gain out of range


If the IR sensor fails standardize for out of gain range, check the gain circuit as
follows.

1. Take the scanner off sheet, so there is nothing in the gap.

2. Verify lamp current is approximately 1.0 ampere. If there is no lamp current


troubleshoot the lamp circuit.

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.

Using an oscilloscope to monitor the head pulses


1. Locate the increase and decrease signals to the sensor and the measurement head
pulses signal and monitor using the diagnostic paddle. Use the appropriate
functional drawing.

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:

Perform a sample check.....................................................................................8-2


8.1 Interpret sample check report....................................................................8-3
8.2 Perform a Calibrate Sample .......................................................................8-4
8.3 Interpret calibrate sample report ...............................................................8-5
8.4 Switch multi-wavelength & 2-Filter modes ...............................................8-6
8.5 Grade code dual function entries ..............................................................8-7

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Perform a sample check


Check sample set-up can be either through host system (1190 or 800xA) or through
SWS. Prior to performing a sample check, make sure the sensor windows are clean
and dry. Perform a standardize, then select the sample check setup from the Network
Platform Setup Page.

Multi-wavelength mode (a.k.a. Four-filter mode)


o Enter the ash compensation .
o Enter "1" or “4 filter” for sample mode.
Two-filter mode
o Enter the basis weight compensation for the sample being measured.
o Enter "2" or “2 filter” for sample mode.
Either mode
o Clean the IR sensor’s windows, and perform standardize.
o Insert the glass sample into the sample holder, label up and toward the handle.
o With the Network Platform in remote and off sheet, press the sample check
button on the end column control panel.
o Refer to the following figures Figure 8-1 below and for examples of the Sample
Check Reports shown on the NP IR Health Reports.

Figure 8-1 HemiPlus sample check

Figure 8-2 ReflectionPlus sample check

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8.1 Interpret sample check report

Table 8-1 - Definition of terms used in the sample check reports

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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8.2 Perform a Calibrate Sample


Calibrate sample samples sensor data and computes an average for comparison to
laboratory tests, usually for calibration purposes. A report can be automatically
printed upon the completion of the Calibrate Sample procedure. Calibrate sample is
used for collecting on-line measurements. It may be used while scanning or in single
point mode. The amount of averaging time is controlled by the length of time the
pushbutton is pressed or the cycle timer. The scanning frame must be in SINGLE
POINT or SCAN mode.

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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8.3 Interpret calibrate sample report


Table 8-2 - Definition of terms used in the Calibrate Sample Report

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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8.4 Switch multi-wavelength & 2-Filter modes


2 or 4 filter operation is determined by the Grade Code. In order to switch to a
different mode you must change to a Grade Code that is set up for the specific mode
you want to use.

1190/Nexus Systems

1. Select the Grade code setup page


2. Enable editing for grade codes
3. Select the Moisture grade group
4. Set the flag for 2 or 4 filter options.
5. Set grade code filter mode to 1 for 4-filter operation, 2 for 2-filter operation.
6. The entry for ash compensation scaling in four filter mode becomes moisture
linearization in two filter mode.
7. The entry for linearization should be 0
8. Save the grade group
9. Perform a grade change to a grade other than the present grade.
10. Perform another grade change back to the current grade.
11. The sensor should now be in the mode set in step 4.

800xa Systems
See 800xA host documentation.

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8.5 Grade code dual function entries


HemiPlus sensor grade code “2-filter linearization”
When using the 2-filter mode the “2-filter linearization” entry in the moisture group
code, should be zero. If this location is anything other than zero, that number will be
used instead of SDELTA for signal linearization (not recommended). This grade
code entry is sometimes referred to as “2-filter linearization / Ash scale factor” but no
longer used for “Ash scale factor”.

Basis Weight Comp/Ash Comp Entry


In 1190/Nexus the “basis weight comp/ash comp” entry also has a dual function.
When in 2-filter mode, the location is used for grade code basis weight compensation,
in 4-filter mode the location is used for ash compensation, unless active ash
measurement is available. The 800xA System has separate entries for Ash and Basis
Weight compensation. Either of these entries may be selected if the compensating
sensor, basis weight or ash, fails to provide a valid measurement (should not happen
automatically). If the “basis weight comp/ash comp” entry is zero, the corresponding
default compensation in the Network Platform Configuration File variable is used.
The flow chart shows the logic for obtaining ash compensation for the HemiPlus
sensor measurement.

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

Figure 8-5 - 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.

This chapter contains the following Figures:


9.1 Signal decomposition constants...............................................................9-2
9.2 HemiPlus multi-wavelength constants .....................................................9-3
9.3 HemiPlus 2-Filter constants.......................................................................9-3
9.4 HemiPlus signal limits ................................................................................9-3
9.5 HemiPlus standardize limits ......................................................................9-4
9.6 HemiPlus check sample limits...................................................................9-4
9.7 HemiPlus analog inputs .............................................................................9-4
9.8 HemiPlus logic inputs.................................................................................9-5
9.9 HemiPlus gain outputs ...............................................................................9-5

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9.1 Signal decomposition constants

Figure 9-1 HemiPlus decomposition constants

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9.2 HemiPlus multi-wavelength constants

Figure 9-2 Multi-wavelength constants

9.3 HemiPlus 2-Filter constants

Figure 9-3 2-Filter Constants

9.4 HemiPlus signal limits

Figure 9-4 HemiPlus signal limits

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9.5 HemiPlus standardize limits

Figure 9-5 HemiPlus standardize limits

9.6 HemiPlus check sample limits

Figure 9-6 HemiPlus check sample limits

9.7 HemiPlus analog inputs

Figure 9-7 HemiPlus analog inputs

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9.8 HemiPlus logic inputs

Figure 9-8 HemiPlus logic inputs

9.9 HemiPlus gain outputs

Figure 9-9 HemiPlus gain outputs

3BUS209548 9-5
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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

*Kit Part Number


This is the number used to order a particular sensor. It is not physically attached to the
modules. This is a “kit” number and the prefix is generally “AK” signifying a set of
“calibrated” parts.

A
B

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Figure 10-1 Check sample holders

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Appendix A - Aclar® bag two point method worksheet


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)____________

5. Sample group “dry” weight after conditioning_______________________________


6. Sample group “dry” weight after drying________________________________________
7. Sample group “dry”, weight difference after drying _____________________________
8. *Sample group “dry” area in Meters (count * length * width) _______________________
8. * Sample group “dry” basis weight after drying (weight in grams / area in meters2)__
9. Sample group “wet” percent moisture (step 7/ step 5) * 100_______________________

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)____________

5. Sample group “dry” weight after conditioning_______________________________


6. Sample group “dry” weight after drying________________________________________
7. Sample group “dry”, weight difference after drying _____________________________
8. *Sample group “dry” area in Meters (count * length * width) _______________________
8. * Sample group “dry” basis weight after drying (weight in grams / area in meters2)__
9. Sample group “wet” percent moisture (step 7/ step 5) * 100_______________________

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)____________

5. Sample group “dry” weight after conditioning_______________________________


6. Sample group “dry” weight after drying________________________________________
7. Sample group “dry”, weight difference after drying _____________________________
8. *Sample group “dry” area in Meters (count * length * width) _______________________
8. * Sample group “dry” basis weight after drying (weight in grams / area in meters2)__
9. Sample group “wet” percent moisture (step 7/ step 5) * 100_______________________

* Indicates steps needed only for samples measured with IR Sensors in two filter mode or
Microwave Moisture sensors.

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Appendix B - Single point moisture correlation worksheet

Date________________________________________
Time________________________________________
Single Point Position___________________________
Edge of Sheet to Sensor Center___________________
Time in oven__________________________________
Time out of oven__________________________________

Moisture Correlation Test Sample 1


Sample 1 Wet
Sample + Bag Weight _____________________
Bag Weight______________________________
Sample ID _______________________________

Sample 1 Dry
Sample + Bag Weight ______________________
Bag Weight______________________________
Sample ID _______________________________

Moisture Correlation Test Sample 2


Sample 2 Wet
Sample + Bag Weight _____________________
Bag Weight______________________________
Sample ID _______________________________

Sample 2 Dry
Sample + Bag Weight ______________________
Bag Weight______________________________
Sample ID _______________________________

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