Page 1 Precision Platform 4022 Scanner System Manual 6510020208...
Page 3 Precision Platform 4022 Scanner October, 2007...
Page 4 All information and specifications contained in this manual have been carefully researched and prepared according to the best efforts of Honeywell, and are believed to be true and correct as of the time of this printing. However, due to continued efforts in product improvement, we reserve the right to make changes at any time without notice.
Page 5: Table Of Contents
Audience .............................. iv About this manual ..........................iv Related reading ............................ v Conventions ............................v Honeywell, Vancouver operations part numbers................vi Figures in this manual........................vii Understanding the drawing package and part numbering system ........... vii 1. System Overview ..........................1-1 1.1.
Page 6 Radiation safety circuits..................2-27 2.14.2. Where to find information on radiation safety............ 2-27 2.14.2.1. Radiation safety training manual for customers.......... 2-27 2.14.2.2. Radiation safety training manual for Honeywell employees ....2-27 2.15. Scheduling Installation Personnel ................2-29 2.15.1. Scheduling installation personnel to set Precision Platform setup parameters ..........................
Page 7 Precision Platform 4022 Scanner Contents 3.1. Inspecting the Precision Platform on receipt ..............3-2 3.1.1. Receiving inspection ....................3-2 3.2. Receiving radioactive sources and radiation safety............3-2 3.2.1. Receiving radioactive sources .................. 3-3 3.2.2. Removing safety shields ................... 3-4 3.3. Moving the Precision Platform ....................
Page 8 Checking sensor stability ....................4-18 4.6.1. Stability and verification procedures ..............4-19 4.7. Reviewing Precision Platform configuration parameters..........4-20 5. Precision Platform 4022 Series Scanner Components.............. 5-1 5.1. Scanner, PMP and MxOpen application manager ............5-4 5.2. Precision Platform 4022 scanner frame................5-6 5.2.1.
Page 9 Precision Platform 4022 Scanner Contents 6.2. Cable End electrical assemblies.................... 6-5 6.2.1. AC Power distribution assembly................6-5 6.2.1.1. Current protection ....................6-6 6.2.1.2. Over-temperature protection ................6-7 6.2.2. AC Motor........................6-7 6.2.3. Encoder assembly....................... 6-7 6.2.4. Motor controller ......................6-7 6.2.4.1.
Page 10 Precision Platform 4022 Scanner Contents 7.2.3. Separating the wire calender scanner heads............7-5 7.3. Head removal and breakaway heads ................. 7-7 8. Preventive Maintenance Schedules..................... 8-1 8.1. Preventive maintenance tasks....................8-2 8.2. Maintaining a scanner logbook.................... 8-5 9. Scanner Maintenance ........................9-1 9.1.
Page 11 Precision Platform 4022 Scanner Contents 9.6.1. Inspecting the drive belts ..................9-18 9.6.2. Replacing the motor drive belt................9-19 9.6.3. Adjusting belt tension and head CD alignment ..........9-21 9.6.4. Adjusting head MD alignment and gap ............... 9-23 9.6.5. Replacing head drive belts..................9-24 9.6.6.
Page 12 Precision Platform 4022 Scanner Contents Storage, Transportation and Disposal ................10-1 10.1. Storage and transportation environment ..............10-1 10.2. Disposal ........................... 10-1 10.2.1. Solid materials ......................10-2 10.2.2. Disposal of radioactive sources ................10-2 10.3. Storing radioactive sources ..................10-2 Glossary ..........................
Page 13 Precision Platform 4022 Scanner Contents Figure 6-4 Termination Board ......................6-12 Figure 6-5 Termination Board Schematic 1 of 6................6-20 Figure 6-6 Termination Board Schematic 2 of 6................6-21 Figure 6-7 Termination Board Schematic 3 of 6................6-22 Figure 6-8 Termination Board Schematic 4 of 6................6-23 Figure 6-9 Termination Board Schematic 5 of 6................6-24 Figure 6-10 Termination Board Schematic 6 of 6................6-25 Figure 6-11 Logic PCB Assembly......................6-26...
Page 14 Precision Platform 4022 Scanner Contents Table 5-3 09716603 Shutter Status Satellite Labels and Lamps ............ 5-15 Table 5-4 09716703 Shutter Status Satellite Labels and Lamps ............ 5-16 Table 5-5 Sample and Reference Panel Switches................5-18 Table 5-6 Scan Control (Touch) Panel Switch Decoder LEDs ............5-19 Table 6-1 Summary of Major Parts used in Cable End assemblies..........
Page 15: Introduction
Introduction The purpose of this manual is to provide an explanation of the installation and maintenance of the Precision Platform 4022 Series Scanners. This manual documents the maintenance of: • Scanner Frame • Heads • Communications • Power Distribution Assembly •...
Page 16: Audience
Precision Platform 4022 Scanner Introduction Audience This manual is intended for use by engineers or process engineers and assumes that the reader has some knowledge of the operation of a paper machine and a basic understanding of mechanical, electrical and computer software concepts.
Page 17: Related Reading
6510020192 Da Vinci Operator Manual 6510020199 Honeywell Radiation Safety Training Manual 6510020197 Honeywell Radiation Safety Manual for Customers 6510020276 Precision Measurement Processor (PMP) Manual - Release 2008 Conventions The following conventions are used in this manual: Text may appear in uppercase or lowercase except as specified in these conventions.
Page 18 Precision Platform 4022 Scanner Introduction lowercase In an error message, words in lowercase are filenames or words that can vary. In a command line, words in lowercase indicate variable input. Type Type means to type the text on a keypad or keyboard. Press Press means to press a key or a button.
Page 19: Honeywell, Vancouver Operations Part Numbers
Sample part numbers are as follows: 6510020004 6510020048 Rev 02 The first two digits of the part number are the same for all Honeywell, Vancouver Operations products. The next four digits identify part type. Type numbers 1002 designates technical publications. The next four digits identify the manual.
Page 20: Understanding The Drawing Package And Part Numbering System
Understanding the drawing package and part numbering system Honeywell assigns a part number to every part and assembly. In the Table of Contents for the drawing package, there are several types of part numbers. Each section in that Table of Contents corresponds to an 09 model number.
Page 21 Da Vinci Precision Platform 4022 Scanner, model # 09402231. A set of specific documents and drawings is sent with each system when it is shipped from the factory. Extra sets can be ordered from Honeywell. p/n 6510020208 10/4/07...
Page 23: System Overview
1.1. Features and benefits 1.1.1. Precision Platform 4022 scanners The Precision Platform 4022 series scanners include a four sensor PrecisionPak sensor enclosure and a remote PMP, or a direct interface to existing MXOpen systems, depending on the exact model. All Precision Platform 4022 series scanners span the process with rigid I-beams, welded to end supports that provide a solid measurement platform.
Page 24: Data Sheet
Precision Platform 4022 Scanner System Overview 1.2. Data sheet Category Specification • Environmental Max. temp: 55ºC (130ºF) without Optional Air Purge Conditions at End • Max. temp: 94ºC (200ºF) with Optional Air Purge Supports • Environmental PPAK 4 - Max. temp: 100ºC (212ºF)* Conditions for Sensor •...
Page 25 System Overview Data sheet Category Specification • Passline angle 0 - 30˚ • Sensor Enclosure Wheels: 38.1 mm (1.5”) W, 31.75 mm (1.25”) diameter Hypalon surface (Head) Carriages precision-ground to +/- 25 µm (0.001”), 16 load-bearing wheels • Sensor Enclosure Precision Pak-4: 465 mm (18.3”) include air wipes (Head) MD Dimensions...
Page 26: Differences Between 4022 Series Scanner Models
Precision Platform 4022 Scanner System Overview 1.3. Differences between 4022 series scanner models Feature Model 4022-31 / 4022-40 4022-30 Remote PMP Existing MXOpen Interface Control/Interface • 600 mm (W) x 760 mm (H) x Remote PMP 210 mm (D) [23.62” (W) x enclosure 29.92”...
Page 27: Site Preparation
2. Site Preparation To provide the proper environment for installation of the Precision Platform, use the information in this chapter before the Precision Platform equipment arrives on site. Site preparation activities include: • Obtaining the latest scanner installation drawings • Choosing a scanner location •...
Page 28: Obtaining The Latest Scanner Installation Drawings
The latest drawing set is shipped with the system. All Honeywell Field Project Managers have direct internet access to sites where drawings are stored.
Page 29 Site Preparation Choosing a scanner location • if space is adequate for the scanner frame, passage of the sensor heads, beam cover removal, access door swing, and unhindered access to service personnel • the scanner environment temperature, humidity, and contaminants •...
Page 30: Allocating Space
These factors are described in Subsections 2.3.1 through 2.3.3. 2.3.1. Precision Platform dimensions To comply with the European Union’s CE safety standards, Honeywell requires 35 cm (14”) of clearance between the head sheet deflector or outboard sensors and the scanner’s vertical end support. This makes the...
Page 31: Precisionpak Head Dimensions
Precision Platform beam length is site dependent. The scanner is available in standard lengths between 4.6 and 8.5m (10 and 28ft). Any beam length over 8.5m (28ft) is not standard and requires Honeywell engineering assistance. The length at a particular site is a function of paper roll width, head and sensor configuration, and process and environment conditions.
Page 32: Clearance Requirements
Precision Platform 4022 Scanner Site Preparation 2.3.3. Clearance requirements Various types of clearance space must be provided: • Beam Cover Removal • Door swings at both ends of the scanner • Service access for the scanner and adjacent equipment • Roll removal and retract paths for adjacent rolls •...
Page 33: Building Mounting Pedestals
Site Preparation Building mounting pedestals Threading rope runs, belts or conveyors often create challenges for locating scanners. Often rope runs must be rerouted to allow space for scanners. Conveyors provide more complexity. They need interlocks to prevent the scanner from scanning while the conveyor is active, and to prevent the conveyor from inserting through the scanner before the heads are in the offsheet position.
Page 34 Do NOT plan to exceed a ±10° angle of tilt for the lifting cables or the scanner unless you have specifically consulted with Honeywell personnel about this issue. The supplied lifting eyes are rated only for a ±10° angle of tilt.
Page 35: Installing Cables
Site preparation includes installing power, PrecisionNet (Ethernet), and process I/O cables. Select conduits and trays for cables in accordance with the Honeywell guidelines for cable-shielding, as detailed in Subsections 2.6.1 and 2.6.2. Installation preparations must also conform to all local regulations.
Page 36: Installing Cable Trays
Precision Platform 4022 Scanner Site Preparation • Ensure that bends in the rigid conduit do not damage the conduit wall or reduce the internal diameter, as per NEC requirements. NEC further specifies that a run of conduit from outlet to outlet, from fitting to fitting, or from outlet to fitting must not contain the equivalent of four quarter bends (360 degrees total), including bends located immediately at the outlet or fitting.
Page 37 • Honeywell cables may be run in the same tray system as plant instrumentation or communication cables if cables do not produce radiated electrical interference, either continuously or of a pulsed nature (such as master time-clock system wiring).
Page 38: Providing A Safety Ground
49 in. 5 kV 800A 120 in. • Where it is necessary for trays carrying Honeywell cables to cross over power cabling, make the crossover directly across the cabling (not over the power source) and with as much spacing maintained as is possible.
Page 39: Power Quality
Site Preparation Providing the communications network 2.8.1. Power quality To guarantee reliable Precision Platform operation, provide computer- grade power that is free of voltage surges, spikes, and noise. If the plant is in an area that is prone to lightning, adequate measures must be taken during site preparation to ensure against lightning-caused damage to the equipment.
Page 40: Providing Low Pressure Purge Air
Blowers and motors Install a dustproof blower. It is also important to install a damper at the blower inlet or in the duct to control air flow. Table 2-3 lists the motors and blowers recommended by Honeywell. 2-14 10/4/07 p/n: 6510020208...
Page 41: Providing High Pressure Instrument Air
A furnace-type filter must be provided at the blower inlet with an area of at least 0.4 m (4 ft ). Larger filters are required for more dusty environments. Honeywell recommends disposable air filters, 61×61×10 cm (24×24×4 in). 2.11. Providing high pressure instrument air...
Page 42: Providing External Cooling Fluid
Site Preparation An air supply system must be set up during site preparation. The customer must supply the compressed air to Honeywell-supplied filter- regulators. A 1.27cm (0.5 in) minimum pipe must be run from the air compressor or local compressed air tap to within approximately 1.5m (5 ft) of the projected location of the cable end support.
Page 43: Head Air Temperature Control
Site Preparation Providing external cooling fluid temperature setpoint can be adjusted over a small range (10°) by adjusting a pot on the Temperature Control PCB. 2.12.1.2. Head air temperature control Air is blown continuously by two fans mounted on a water-to-air heat exchanger (radiator) to cool and circulate the air in the heads and around the sensors.
Page 44: Head Purge Air
Precision Platform 4022 Scanner Site Preparation 2.12.1.3. Head purge air When power to the system is off with the heads in the offsheet position, it is possible for internal pressure changes due to temperature variations inside the head to result in entry of moisture and mill air. To prevent this, an air purge fitting bleeds air into the head continuously, preventing entry of outside air.
Page 45: Pmp Electronics Enclosure Temperature Control With Coolant
The 4604-02 PMP (MSS) electronics enclosure has an optional Heat Exchanger. If the ambient environmental temperature at the location of the PMP enclosure exceeds 35° C (95° F), a Honeywell-designed heat exchanger and insulation kit is required. The PMP (MSS) electronics enclosure uses forced air circulation through a coolant-to-air heat exchanger to control the temperature of the air.
Page 46: Choosing A Head Cooling Configuration
Table 2-7 contains the guidelines for determining the cooling configuration appropriate for local conditions. Table 2-7 Configurations for Cooling Heads and PMP Enclosure Depending on Site and System Characteristics Coolant Potable Cooling Honeywell Supply Comments Water Configuration Part Number Temperature...
Page 47: Using Mill Water Or Other Potable-Quality Water In An Open-Loop System
Site Preparation Providing external cooling fluid Experience has shown that mill water is detrimental to the life of the heads unless it can be absolutely ensured that the incoming water supply is clean (free of mineral, biological, and particulate contaminants) and non- corrosive.
Page 48: Setting Up A Chiller Backed Up By An External Open Loop
If the mill water source does not satisfy the preceding specifications, one of the following must be installed: • A Honeywell water-to-water exchanger unit in the case where the ambient temperature around the scanner and heads does not exceed 75°C (170°F), the ambient temperature around the chiller does not exceed 57°C (135°F), and the mill water does not...
Page 49: Choosing The Chiller Location
Site Preparation Providing external cooling fluid • A 50/50 mix of water and glycol coolant • 2.7-4.1 bar (40-60 psig) pressure, 2–8 liters/min (0.5–2 gal/min) flow rate • coolant at 27°C (80°F) The following sections detail the basic site preparation requirements for chiller installation.
Page 50: Establishing A Backup System For The Chiller
Precision Platform 4022 Scanner Site Preparation 2.12.5.3. Establishing a backup system for the chiller Site preparation also includes providing protection against chiller failure by setting up a backup system of mill water (or other water source external to the scanner) in an external open loop to the cable end support. The backup system should drain and not return to the chiller reservoir or mill water source.
Page 51: Body And Condenser Fins
When the ambient temperature around the chiller exceeds 43°C (110°F) most chillers will show a dramatic reduction in cooling capacity. In such an environment, use the Honeywell 1-hp chiller. This chiller includes an extra fluid-cooled condenser that turns on automatically when the ambient temperature around the chiller reaches 43°C (110°F).
Page 52: Coolant Pump
Precision Platform 4022 Scanner Site Preparation 2.12.6.5. Coolant pump The coolant pump should have these characteristics: • Minimum capacity of 8 liters/min (2 gal/min) at 30 psig minimum pressure • Continuous operation (5-year life), even at a zero flow setting 2.12.6.6.
Page 53: Radiation Safety Circuits
Honeywell strongly recommends that become familiar with the information provided in the Radiation Safety Training Manual (Honeywell p/n 6510020197). A copy of the manual is shipped with each sensor that contains a radiation source. Direct questions regarding radiation safety to Radiological Operations. The main contact numbers for...
Page 54: Radiation Safety Training Manual For Honeywell Employees
U.S. and Canada at 866-811-0312. 2.14.2.2. Radiation safety training manual for Honeywell employees The Radiation Safety Training Manual (Honeywell p/n 6510020197) provides detailed information on the following topics: • Sensor shipment, receipt, and installation (including testing before use) •...
Page 55: Scheduling Installation Personnel
Scheduling installation personnel to set Precision Platform setup parameters The Da Vinci Application Server software includes parameters that control scanning operations. When a Precision Platform is shipped, these parameters are set to Honeywell defaults. These parameter settings can be 2-29 p/n 6510020208 10/4/07...
Page 56 Precision Platform 4022 Scanner Site Preparation customized for the local site. Site preparation should include scheduling software personnel to perform these configuration procedures. Direct questions regarding radiation safety to Radiological Operations. The main contact numbers for Radiological Operations are First level of support: •...
Page 57: Installation
3. Installation This chapter covers the installation of the Precision Platform and describes: • Inspecting the Precision Platform on receipt • Receiving Radioactive Sources and radiation safety • Storing the Precision Platform and radioactive sources after receipt • Preparing the mounting hardware •...
Page 58: Inspecting The Precision Platform On Receipt
Installation 3.1. Inspecting the Precision Platform on receipt 3.1.1. Receiving inspection Honeywell scanners are thoroughly tested and inspected, then carefully packed for shipment. All units should be unpacked with the care afforded any precision instrument. Before any item of hardware is unpacked, conduct a visual inspection and inventory of the shipment as it was received.
Page 59: Receiving Radioactive Sources
Do not move or handle a damaged shipping container or sensor head that is labeled as containing a radioactive source until you WARNING have discussed the situation with a member of the Honeywell radiation safety staff. If a container or sensor head marked as containing a radioactive source is seriously damaged, contact Honeywell Radiological Operations.
Page 60: Removing Safety Shields
This can happen on uneven floors if one side of the dolly wheels falls into a hole causing the scanner to twist. Contact Honeywell Engineering if the scanner has been twisted.
Page 61: Preparing To Lift The Precision Platform
±10° from the vertical, it is permissible to attach the scanner to the crane by means of the lifting eyebolts installed by Honeywell at the ends of the upper I-beam. See Figure 3-1.
Page 62 Do NOT plan to exceed a ±10° angle of tilt for the lifting cables or the scanner unless you have specifically consulted with Honeywell Process Solution personnel about this issue. The supplied lifting eyes are rated only for a ±10° angle of tilt.
Page 63: Lifting, Placing, Leveling And Bolting Down The Precision Platform
Installation Lifting, placing, leveling and bolting down the Precision Platform Figure 3-1 Lifting the 4022 Precision Platform 3.6. Lifting, placing, leveling and bolting down the Precision Platform 1. Lift the scanner from the shipping dollies and position it as directly above the mounting pedestals as possible.
Page 64: Preparing The Expansion Joint
Precision Platform 4022 Scanner Installation 4. Use a 3 or 4-ft (1m) vertical level to take level measurements against the sides of the upper and lower fiberglass tracks (offset spacers will be required to do this). Level the scanner with shims supplied in the installation kit as necessary.
Page 65: Cabling The Precision Platform
Installation Cabling the Precision Platform washer. The nylon bearing allows the scanner to slide or float on the pedestal and allows for thermal expansion. During shipping and installation, shipping bolts hold the joint together. After the scanner is installed and shimmed on the pedestals, remove the 3/8”-16 shipping bolts.
Page 66: Hooking Up Ac Power
Precision Platform 4022 Scanner Installation from the cable trays to the scanner. Use cable trays only for types of cable approved for tray installation. The terminal strip (TS1) and termination PCB inside the cable end support includes these connections: • Termination area for hooking up scanner and sensor AC power (220–240 VAC) 50/60 Hz •...
Page 67: Connecting Air Sources
If air is not supplied, a cover (Honeywell-supplied) must be used to fill the hole. The supply air ducting must always include a damper to reduce the air flow should condensation occur on the outside of the scanner.
Page 68 Precision Platform 4022 Scanner Installation area near the scanner where the supplied air filter regulators are to be mounted. Additional plumbing should bring the filtered and regulated air within a few feet of the scanner. Rubber hoses supplied in the installation kit should then be used to complete the connection to the scanner.
Page 69: Solutions For Condensation Problems
Installation Connecting external coolant fluid Figure 3-3 Air and Coolant Distribution at the PrecisionPak 3.8.3. Solutions for condensation problems If the purge air cools the beam too much and condensation forms on the scanner covers, reduce the air flow from the blower using the damper until the condensation is reduced to an acceptable level (non-dripping) or increase supply air temperature.
Page 70: Connecting External Cooling Fluid To The Precision Platform
1.5 m (5 ft) from the planned location for the cable end support. During installation, hoses from the Honeywell scanner installation kit can be used to attach the mill water open loop or the chiller closed loop to the hose barbs on the manifold, which is located near the bottom of the cable end support.
Page 71 Installation Connecting external coolant fluid 3. Run 12.7mm (1/2-inch) hose from the mill water supply and attach it to the mill water supply in and out connections on the exchanger unit. 4. Connect 220 VAC power to the plug, or connect it directly to the junction box in the exchanger unit.
Page 73: System Testing And Verification
Precision Platform is made operational. This test must be conducted by a person who is specifically licensed to perform it. In cases where Honeywell employees install the sensors, Honeywell Radiological Operations provides authorized employees who can perform P/N 6510020208...
Page 74: Testing The Precision Platform Operation
U.S. and Canada at 866-811-0312. Information on licensing and regulatory requirements, radioactive sources and safety is available in the Honeywell Radiation Safety Training Manual (p/n 6510020199). Failure to follow radiation safety procedures MAY cause exposure WARNING to hazardous levels of radiation.
Page 75: Starting And Stopping Precision Platform Head Movement
System Testing and Verification Testing the Precision Platform operation verifying the heads are aligned and the upper and lower main drive belt tensions are set equally. Testing includes verifying the scan, offsheet, and emergency stop buttons on the scanner and on the operator station function as well as the other buttons on the scanner.
Page 76: Figure 4-2 Sensor Head-To-End Support Caution Placard
Precision Platform 4022 Scanner System Testing and Verification A placard (Figure 4-2) is prominently displayed on the inside of the end support. Figure 4-2 Sensor Head-to-End Support Caution Placard At one end of the Precision Platform (normally the tending side of the machine), a Scan Control Panel is set in the scanner end support door, facing out.
Page 77: Figure 4-3 Belt-Pulley Pinch Point Caution Placard
System Testing and Verification Testing the Precision Platform operation Figure 4-3 Belt-Pulley Pinch Point Caution Placard To start and stop the Precision Platform on the operator's console (see Figure 4-4) and on a system with one scanner, select the SCAN (picture of a scanner with two green arrows) or the OFFSHEET (picture of a scanner with one red arrow) button both located in the Vertical Menu Bar.
Page 78: Observing The Precision Platform In Motion
Precision Platform 4022 Scanner System Testing and Verification Figure 4-5 Multi-scanner Control dialog box 4.2.2. Observing the Precision Platform in motion Once the Precision Platform hardware has been tested, test the scanning operation: 1. Set the heads to scan continuously. 2.
Page 79 System Testing and Verification Testing the Precision Platform operation scanner scans smoothly and accelerates and decelerates quickly without hunting for the required speed. 3. If the scanner does not scan, check for and correct the following possible problems: a. A crash switch on the scanner or any emergency stop switch at either end of the scanner is open b.
Page 80: Using The Motor Controller To Troubleshoot Scanning Operations
Precision Platform 4022 Scanner System Testing and Verification d. Repeat Step C while performing a scan in the opposite direction. Start this scan by pressing the OFF/REVERSE button on the cable end termination board. The speed of the scanner when in Scanner Shop Mode is set by a pot on the Frame Controller.
Page 81: Verifying Drive Motor Torque
System Testing and Verification Testing the Precision Platform operation 4. Confirm that the crash switch LED (DS21 cable end termination board) is green. If not, check that all crash switches are in the closed position and that both emergency stop switches (mushroom switches at each end) are in the out position.
Page 82: Verifying Torque Setting With Motor Controller Panel
Precision Platform 4022 Scanner System Testing and Verification Perform the drive motor torque test as far away from the limit switches as possible to prevent the heads from reaching and possibly passing the limit switches and striking the crash switches. It must be possible to stop the heads manually as they scan, so it may be necessary during installation to reduce the torque of the drive motor for safety reasons.
Page 83: Table 4-1 Motor Controller Settings
System Testing and Verification Testing the Precision Platform operation Table 4-1 Motor Controller Settings P/N 6580800429 4022-30, -31, -40 Parameter GMO P/N 08733705 (01)* (01) (01) (01) (01) (01) (02) (02) (0.0) (0.0) (0.0) 30.0 75.0 75.0 80.0 29-39 (0.0) (60.0) (200) (20.0)
Page 84: Verifying Main Drive Belt Tension
Precision Platform 4022 Scanner System Testing and Verification 4.2.6. Verifying main drive belt tension The sensor heads are attached to the head carriages and scan in unison. They are driven by the drive motor and pulled by the main drive belts. The drive belt tensions must be similar to ensure the heads scan in unison.
Page 85: Verifying Cross Direction And Machine Direction Head Alignment
1. Place two spacer bars between the heads (spacer bars are provided by Honeywell). The size of these spacer bars is determined by the system’s sensor gap. 2. Check the gap between the heads for either of the following conditions: •...
Page 86: Testing Operator Console Inputs To Scanning And Other Functions
Precision Platform 4022 Scanner System Testing and Verification • The vertical play between the spacer bars and the head exceeds 0.8 mm (1/32 inch) 3. If either condition exists, see Subsection 9.6.3 and Subsection 9.6.4 for head alignment procedures. 4.3. Testing operator console inputs to scanning and other functions Press Scan on the operator interface and observe the scanner status.
Page 87: Checking And Adjusting Head Cooling System
4.4. Checking and adjusting head cooling system The head temperature setpoint is set by Honeywell before the Precision Platform system is shipped. In most cases, the setpoint never requires adjusting, even during installation. Once the coolant and coolant drain is connected, the heads should re-establish this factory-set setpoint quickly.
Page 88: Adjusting Sheet Guide And Air Wipe Heat Levels
Precision Platform 4022 Scanner System Testing and Verification 4.5. Adjusting sheet guide and air wipe heat levels The sheet guides are heated and can be controlled to a constant temperature. This heat prevents water condensation on the guides and sensor windows as the heads move on and offsheet. Heat for the sheet guides is provided from two sources.
Page 89: Adjusting The Setpoint Of Air Wipe Heaters
For each head, the setpoint for the air wipe heater determines the heat level produced by the heater. The setpoint is set by Honeywell before the Precision Platform is shipped. Under most conditions, the setpoint will not require readjustment.
Page 90: Internal Head Air Pressure
Precision Platform 4022 Scanner System Testing and Verification 1. Measure the ambient temperature around the head while it is onsheet. Take the measurement 30 cm (1 ft) above or below the sheet and 60 cm (2 ft) in from the sheet edge. 2.
Page 91: Checking Sensor Stability
System Testing and Verification Checking sensor stability 4.6. Checking sensor stability System testing is completed by performing the following procedures to check sensor stability and calibration, to determine calibration constants for new product codes, and to compare onsheet sensor readings with lab measurements of sheet samples: •...
Page 92 Precision Platform 4022 Scanner System Testing and Verification b. Enter the number of seconds for moisture and opacity sensors (four seconds recommended). The read times reflect the values used to calibrate the listed sensors. Ensure that the correct calibration data is being called up. 2.
Page 93: Reviewing Precision Platform Configuration Parameters
System Testing and Verification Reviewing Precision Platform configuration parameters 4.7. Reviewing Precision Platform configuration parameters Once testing of the Precision Platform has been completed, review and record the scanner configuration parameters set in the Precision Platform software. 4-21 P/N 6510020208 10/4/07...
Page 95: Precision Platform 4022 Series Scanner Components
5. Precision Platform 4022 Series Scanner Components The Precision Platform 4022 Scanner, shown in Figure 5-1, has these components: • The scanner frame, which supports the heads as they scan • A pair of PrecisionPak4 heads that house the following elements: •...
Page 96 Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components • A Model 4604-02 Remote Precision Measurement Processor (PMP) for 4022-31 and 4022-40 models only, including: • A computer that acquires, processes, and transmits data between the scanner and the Da Vinci Server •...
Page 97: Figure 5-1 Precision Platform 4022-30/31/40 Scanner
Preci sion Platform 4022 Series Scanner Components Scanner, PMP and MxOpen application manager Figure 5-1 Precision Platform 4022-30/31/40 Scanner p/n 6510020208 10/4/07...
Page 98: Scanner, Pmp And Mxopen Application Manager
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components 5.1. Scanner, PMP and MxOpen application manager The Precision Platform Scanner connects to the Da Vinci Server and Global User Stations through the PMP or through the MxOpen Application Manager using the Scanner Support Processor. A typical configuration of the Precision Platform Scanner in the mill environment is shown in Figure 5-2.
Page 99: Precision Platform 4022 Scanner Frame
Precision Platform 4022 Series Scanner Components Precision Platform 4022 scanner frame Figure 5-3 Typical Configuration – 4022-30 Precision Platform Scanner with existing MXOpen system 5.2. Precision Platform 4022 scanner frame The Precision Platform 4022 Scanner frame consists of: • Two rigid horizontal beams with precision aligned tracks •...
Page 100: Beams
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components • A pair of power tracks with cable and hose connections for the sensor heads • Beam covers with optional seals to protect the beams, tracks, and power tracks from the environment The scanner air purge system for the cable end protects it from process and mill conditions related to temperature and contaminants.
Page 101: Cooling And Purging The Frame With Air
Precision Platform 4022 Series Scanner Components Precision Platform 4022 scanner frame is caused by varying ambient and process heat effects. The resulting physical stress can distort scanner frame dimensions and distort the sensor path. However, the expansion joint relieves these stresses.
Page 102: Head Drive System
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components 5.2.4. Head drive system Figure 5-4 shows the Precision Platform Scanner head drive system. The drive system consists of: • Upper and lower head carriages, support arms, and wheels. • Upper and lower fiberglass head carriage tracks.
Page 103: Head Movement Monitoring And Control
Precision Platform 4022 Series Scanner Components Precision Platform 4022 scanner frame 5.2.4.1. Head movement monitoring and control The scanner is equipped with various switches that monitor and control head movement. Table 5-1 lists the switches and their functions. These switches are mounted to the upper and lower beams.
Page 104: Crash Switches
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components 5.2.4.3. Limit switches A limit switch is located at each end of the upper beam, near the sheet edge. The motion controller is typically set to reverse the direction of the heads before they reach either switch.
Page 105: Emergency Stop Switches
Precision Platform 4022 Series Scanner Components End supports and operator controls 2. Move the crash switches 12.7 mm (0.50 in) from the wheel assemblies. Injury can occur. Ensure crash switches are set properly. Always ARNING stand clear of the traversing heads.
Page 106: Scan Control Panel
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components • Optional location for Sample/Reference switch. Figure 5-5 Distant end support 5.3.1.1. Scan control panel The scan control panel on the distant end support has buttons to control scanning functions and enable sensors. An LED to the left of each button lights to indicate that the button function is active.
Page 107: Figure 5-6 Scan Control Panel
Precision Platform 4022 Series Scanner Components End supports and operator controls the scan control panel will not include the X-ray button label and key switch. There is an optional alternate location for the scan control panel at the cable end of the scanner.
Page 108: Sensor Shutter Status Satellite Box
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components Button/Switch Description X-RAY POWER Switch to control X-ray sensor. Disables power to the ash source. Enables power to the ash source (after using RESET). RESET Resets the ash source This turns off power to the ash sensor, which in turn sends EMERGENCY OFF the heads offsheet.
Page 109: Cable End Support
Precision Platform 4022 Series Scanner Components End supports and operator controls Table 5-4 09716703 Shutter Status Satellite Labels and Lamps Status Label Description ISOTOPE SHUTTER OPEN Indicates that the shutter for the isotope source (Red light is on.) (basis weight) is open.
Page 110: Figure 5-7 Cable End Support
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components • Termination PCB that terminates all of the power track cables, scanner accessory cables and field signal wiring • AC Power Distribution Assembly • AC Motor Controller (this applies to the 4022-30 scanner only; the...
Page 111: Sample And Reference Panel
Precision Platform 4022 Series Scanner Components End supports and operator controls 5.3.2.1. Sample and reference panel The Sample and Reference Panel is located on the cable end support of the scanner. You can initiate samples and references from the rotary switch on this panel.
Page 112: Figure 5-8 Switch Decoder Board For Scan Control Panel
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components Figure 5-8 Switch Decoder Board for Scan Control Panel Each of the scan control (touch) panel switch decoder board light bars (DS1 through DS8) consists of four yellow LEDs in series. Each light bar corresponds to a panel button.
Page 113: Precisionpak Heads
Precision Platform 4022 Series Scanner Components PrecisionPak heads Light Bar Shutter Status Panel Button Not Used X-RAY POWER ON Not Used 5.4. PrecisionPak heads The name PrecisionPak reflects the fact that each head is an environmentally secure enclosure that houses and protects the sensors for measuring sheet characteristics.
Page 114: Outboard Heads
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components Figure 5-9 PrecisionPak4 Heads 5.4.2. Outboard heads Some sensors can not be mounted within the PrecisionPak4 heads and are always mounted outboard of the main sensor heads. These outboard heads are mounted to the outside edges of the sheet guides of the main heads and have separate environmental controls.
Page 115: Sensors
Precision Platform 4022 Series Scanner Components Head contents Figure 5-10 shows a typical head layout. Figure 5-10 Head Contents 5.5.1. Sensors The specific array of sensors found in each Precision Platform Scanner is site dependent. Most sensors can be mounted inside the heads, while others...
Page 116: Termination/Configuration Pcbs
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components in separate environmentally secure cases that are bolted to platforms attached to the sheet guides. The sensors available for the Precision Platform Scanner may include: • Air Gap Temperature • Ash •...
Page 117: Figure 5-11 Sensor Termination Pcbs
Precision Platform 4022 Series Scanner Components Head contents The Termination PCB (Figure 5-11), present in both heads, contains: • Head Termination Backplane • Power Supply/FVC • Sensor Configuration PCB Set (as required by the system) Figure 5-11 Sensor Termination PCBs...
Page 118: Environment Control Unit
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components 5.5.3. Environment Control Unit Each Environment Control Unit (ECU) includes heating elements, a coolant control solenoid valve, three thermistors, and three temperature controllers. These ECU components participate in controlling internal head temperature.
Page 119: System-Level Electronics And Connections
Precision Platform 4022 Series Scanner Components System-level electronics and connections Figure 5-12 Environmental Control Unit (ECU) 5.6. System-level electronics and connections The following subsections describe the system-level components used to route and process the sensor signals: • Routing and Processing •...
Page 120: Routing And Processing
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components Figure 5-13 provides a summary of the components. 5.6.1. Routing and processing The Precision Platform Scanner includes the following system-level components that either route or process signals to and from the sensors: •...
Page 121: Figure 5-13 System Level Electronics And Connections
Precision Platform 4022 Series Scanner Components System-level electronics and connections Figure 5-13 System Level Electronics and Connections • Precision Measurement Processor (PMP) – This applies to the 4022-31 and 4022-40 scanners only. Note that for 4022-30 scanners, analog signals are transferred directly from the Termination Board located in the scanner end to the SSP located 4022-31 and 4022-40 models only.
Page 122: Scanner Control Hardware Circuitry
Precision Platform 4022 Scanner Precision Platform 4022 Series Scanner Components in the MxOpen system. The PMP controls the flow of all data between the Da Vinci RAE Server and the 4022-31 and 4022-30 scanners. The PMP sends and receives signals to and from the...
Page 123: On-Screen Scanner Setup And Diagnostics
Precision Platform 4022 Series Scanner Components On-screen scanner setup and diagnostics 5.8. On-screen scanner setup and diagnostics The Da Vinci RAE Server provides the necessary tools to set up scanner motion control parameters within the MSS. These include: • Scan speed, acceleration, and deceleration •...
Page 124: Internal Environment Control For The Heads And Pmp Enclosure
Using a water-to-water heat exchanger cooling system (closed loop) If the ambient temperature around the scanner and heads is 66°C (150°F) or less, a Honeywell Water-to-Water Heat Exchanger unit can be used in a closed loop to cool the heads.
Page 125: Precisionpak Head Environment Control Devices
On-screen scanner setup and diagnostics A chiller in a closed-loop system can be used to supply coolant to the heads. One Honeywell chiller can service up to two scanners in parallel. Supplying the heads with chiller coolant requires connecting hoses from the chiller to supply and return fittings on the fluid manifold at the cable end support.
Page 127: Cable End Electrical Assemblies And Precision Measurement Processor
6. Cable End Electrical Assemblies and Precision Measurement Processor The Cable End electrical assemblies serve as the interface between the scanner and the Quality Control System. The 4022-31 and 4022-40 scanners also require a Precision Measurement Processor (PMP) with integral Measurement Sub System (MSS). The 4022-30 scanner is designed to interface directly to existing MXOpen systems and does not require a PMP.
Page 128: Cable End Electrical Overview
Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor This chapter is divided into the following main sections: • Cable End Electrical Assemblies • Cable End Electrical PCB Assemblies • Remote 4604-02 PMP • MSS Electronics • Miscellaneous Interlocks and Switches For more information on the end supports and electronics for the Precision Platform Scanner, see Chapter 5.
Page 129 Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical overview resides in a PMP (4022-31 and 4022-40) or in the scanner itself where there is no PMP (4022-30). The Encoder Assembly sends signals relating to scanner position and velocity back to the Quality Control System or PMP.
Page 130: Figure 6-1 Cable End Electrical Overview
Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Figure 6-1 Cable End Electrical Overview 10/18/07 p/n 6510020208...
Page 131: Cable End Electrical Assemblies
Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical assemblies Table 6-1 Summary of Major Parts used in Cable End assemblies Part Description Honeywell P/N Termination Board (all scanners) 05441900 PMP Logic PCB used with Termination 05442000 Board (all scanners)
Page 132: Current Protection
Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Figure 6-2 AC Power Distribution Assembly 6.2.1.1. Current protection Two circuit breakers on the AC Power Distribution Assembly provide current protection: • CB1: 10 amp – protects motor controller (4022-30 only). •...
Page 133: Over-Temperature Protection
Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical assemblies 6.2.1.2. Over-temperature protection The over-temperature protection uses two snap-action, bimetallic disc thermostat devices: one located in the upper left hand corner of the Termination PCB, and the other beside the motor controller (4022-30 only). When the temperature exceeds 66°C (150°F) for either thermostat, the four-pole contactor K1 disconnects both the motor controller and the primary of the 230/56 VAC transformer.
Page 134: Password Entry
Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor 6.2.4.1. Password entry Before any changes can be made, a password must be entered. Enter password by pressing Mode. The display will read 00. Use the up arrow to change the display to 225. Press Mode again. The display will now read P01 to indicate that parameter 01 can be edited.
Page 135: 230/56 Vac Heater Transformer
Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical assemblies Parameter 4022-30, -31 (01) (02) (02) (0.0) (0.0) (0.0) 28.0 75.0 75.0 80.0 29-39 (0.0) (60.0) (200) (20.0) (01) (225) (01) (01) * Values shown in parentheses are factory settings. 6.2.5.
Page 136: Cable End Electrical Pc Boards
Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Figure 6-3 56 VAC Heater Transformer 6.3. Cable End electrical PC boards The scanner Cable End (see Figure 6-1) also contains the Termination Board with Logic PCB. The Termination board provides connection points for all power tracks, safety interlocks and scanner motion control signals.
Page 137 Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical PC boards The Termination Board provides basic routing of the signals between the power tracks and the external PMP or MXOpen SSP. Signal conditioning and interfacing is done outside of the scanner. A number of sensor and head signals are used by the Logic PCB to generate interlock and motor control signals.
Page 138 Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Figure 6-4 Termination Board 6-12 10/18/07 p/n 6510020208...
Page 139: Termination Board Leds, Jumpers, Fuses
Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical PC boards 6.3.1.1. Termination board LEDs, jumpers, fuses Table 6-3 Termination Board LEDs Termination Board indicators (4022-30 and 4022-31) Upper power track health - Good Upper power track health – Bad Head over temperature Moisture edge detect Motor enable...
Page 140: Termination Board Connectors And Signals
Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Switches Termination Board (4022-30 and 4022-31) Up: Manual mode Down: Computer mode Computer mode: Scan Manual mode: Forward Computer mode: Offsheet Manual mode: Reverse Table 6-5 Termination Board Fuses Fuse Termination Board (4022-30 and 4022-31)
Page 141 Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical PC boards Terminal Termination Board (4022-30 and 4022-31) J9-8 56 VAC Sheet Guide Return Rad Lamps J10-1 X-ray power J10-2 X-ray lamp sense J10-3 X-ray ground J10-4 X-ray shutter J10-5 Red - J10-6...
Page 142 Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Terminal Termination Board (4022-30 and 4022-31) Sheet Guide Heater Control J27-1 24 VS J27-2 24 VS J27-3 S/G heater enable J27-4 Heater 230 VAC enable Position Encoder and Head-Split Clutch J29-1 Phase A + J29-2...
Page 143 Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical PC boards Terminal Termination Board (4022-30 and 4022-31) J30-35 Strength drive OUT J30-36 Strength enable C/I Drive End Accessories J31-1 Ash lamp 24 VE J31-2 Ash amber sense J31-3 24 VE return –...
Page 144 Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Terminal Termination Board (4022-30 and 4022-31) Scanner Switches J3-1 Lower DE crash switch IN J3-2 Lower DE crash switch OUT J3-3 Upper DE crash switch IN J3-4 Upper DE crash switch OUT J3-5 Lower CE crash switch IN J3-6...
Page 145 Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical PC boards Terminal Termination Board (4022-30 and 4022-31) TB2-3 24 VA return TB2-4 Int platform upper TB2-5 Int platform lower TB2-6 Ext platform upper TB2-7 Ext platform lower TB2-8 DC-DC converter upper TB2-9 Electric uni upper...
Page 146 Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Figure 6-5 Termination Board Schematic 1 of 6 6-20 10/18/07 p/n 6510020208...
Page 147 Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical PC boards Figure 6-6 Termination Board Schematic 2 of 6 6-21 p/n 6510020208 10/18/07...
Page 148 Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Figure 6-7 Termination Board Schematic 3 of 6 6-22 10/18/07 p/n 6510020208...
Page 149 Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical PC boards Figure 6-8 Termination Board Schematic 4 of 6 6-23 p/n 6510020208 10/18/07...
Page 150 Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Figure 6-9 Termination Board Schematic 5 of 6 6-24 10/18/07 p/n 6510020208...
Page 151 Cable End Electrical Assemblies and Precision Measurement Processor Cable End electrical PC boards Figure 6-10 Termination Board Schematic 6 of 6 6-25 p/n 6510020208 10/18/07...
Page 152: Logic Pcb
Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor 6.3.2. Logic PCB The Logic PCB plugs in to the Termination PCB. The Logic PCB houses most of the active components required to operate the scanner and to monitor certain conditions of the heads and the basis weight shutter.
Page 153: Remote 4604-02 Pmp
Cable End Electrical Assemblies and Precision Measurement Processor Remote 4604-02 PMP Table 6-7 Logic PCB Jumpers, LEDs, and Fuses Jumpers: Logic PCB (4022 -30, -31) A: MXOpen, B: Da Vinci A: MXOpen, B: Da Vinci Head Over Temp DISABLED (connect TB1-1 to TB1-2) Logic PCB Indicators: (4022 -30, -31)
Page 154 Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor For information on cable connections between scanner and PMP or MXOpen SSP, refer to the respective “I” drawings for 09402230, 09402231, 09402240. For an overview of scanner termination, refer to the drawing package for p/n 6580800670.
Page 155: Mss Electronics
Table 6-8 gives the standard assemblies used in the 4604-02 PMP. For detailed information, refer to Precision Measurement Processor (PMP) Manual, p/n 6510020276. Table 6-8 Assemblies used in 4604-02 PMP Part Description Honeywell P/N MSS Card Cage w/ 6 slot backplane 6580800556 FC Term Board Type II 05428901...
Page 156 Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Part Description Honeywell P/N Mfg Part Name Low Density PCI DAQ Card 6580500046 PCI-6013 (digital/analog) PCDAQ 05436600 PCI PCDAQ 05438200 DigiBoard 20000951 Digi Acceleport PC/4E 6 slot ISA backplane...
Page 157: Miscellaneous Interlocks, Switches And Accessories
Cable End Electrical Assemblies and Precision Measurement Processor Miscellaneous interlocks, switches and accessories 6.6. Miscellaneous interlocks, switches and accessories 6.6.1. Interlocks • Head split • Ash (X-ray source) 6.6.1.1. Head-split interlock The purpose of relay K6 on the Termination Board is to stop the scanner and close the shutters if the heads become separated or the basis weight receiver is removed.
Page 158: Computer/Manual Switch S1
Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor 6.6.2.1. Computer/Manual switch S1 In Computer mode, the MSS control algorithms handle the movement of the heads. On the Termination Board, S1 switches between Computer and Manual mode. In Manual mode, pushbuttons S2 and S3, or SCAN/OFFSHEET buttons control head movement.
Page 159: Sheet Guide Heater Circuitry
Cable End Electrical Assemblies and Precision Measurement Processor Miscellaneous interlocks, switches and accessories 6.6.3. Sheet guide heater circuitry In combination with the air wipe system in the heads and a thermistor in the sheet guides, the sheet guide heaters maintain the guides at a stable temperature.
Page 160: Setting The Voltage Threshold
Precision Platform 4022 Scanner Cable End Electrical Assemblies and Precision Measurement Processor Figure 6-13 Radiation Fault Protect PCB Assembly 6.6.4.2. Setting the voltage threshold The Radiation Fault/Protect board compares the analog output of the X- ray detector to a threshold voltage. Select the threshold by opening pin shunts on the board.
Page 161: Preventing False Triggering
Cable End Electrical Assemblies and Precision Measurement Processor Miscellaneous interlocks, switches and accessories Additionally, the detector voltage comparison output is logically ANDed with the X-ray shutter command signal. The logic tests for two source failure modes: • The conditions of the first source failure mode are a shutter-closed command and an above-threshold value for the signal.
Page 163: Precision Wire Calender 4022-40
7. Precision Wire Calender 4022-40 The Precision Platform 4022-40 Scanner, shown in Figure 7-1, is similar to the 4022-31 Scanner model. The similarities include: • Scanner Structural Frame Assembly. • Power Distribution and Electronics Assembly. • Termination PCB. • Remote MSS/PMP enclosure with AC motor controller. However, there are some key differences that make the 4022-40 Scanner unique for use specifically in Wire Calender applications.
Page 164: Precisionpak4 Head For Wire Calender
Precision Platform 4022 Scanner PrecisionPak4 head for wire calender • Precision Platform Wire Calender Scanner connects to an MXProLine Server. Figure 7-1 4022-40 Scanner with Remote PMP 7.1. PrecisionPak4 head for wire calender The 4022-40 Wire Calender Scanner features a unique sensor head that was developed especially for use in wire calendar applications.
Page 165: Wire Calender Head Gap Kit
Precision Wire Calender 4022-40 Ensuring radiation safety 7.1.2. Wire calender head gap kit The 4022-40 Wire Calendar Scanner comes standard with a 19mm (¾") head gap between the upper and lower heads. 7.1.3. Standardize shelf and sample paddle The 4022-40 Wire Calender Scanner includes a special standardization shelf and sample paddles for use in sensor calibration and standardization.
Page 166 Otherwise, operations of the type listed must be performed by authorized Honeywell employees or other appropriately-licensed individuals, or as described in the Customer Radiation Safety Training Manual p/n 6510020197.
Page 167: Wire Calender Headsplit Safety Interlocks
Precision Wire Calender 4022-40 Ensuring radiation safety Status Label Description X-RAY POWER ON Indicates that the upper and lower X-ray sources (Amber light is on.) have power. 7.2.2. Wire calender headsplit safety interlocks The wire calendar process material requires a special series of safety measures and Interlocks be present on the 4022-40 scanner that provides radiation safety protection.
Page 168 Precision Platform 4022 Scanner Ensuring radiation safety Because separating the sensor heads could put personnel at risk of exposure to the unshielded radiation beam, it is essential that you WARNING follow the Radiation Safety Procedures for head separation given in the Radiation Safety Training Manual p/n 6510020199. Radiation safety regulations in most countries require that the separation of source and receiver heads of sensors that use radioactive sources be performed only by persons who are specifically authorized to do such...
Page 169: Head Removal And Breakaway Heads
Precision Wire Calender 4022-40 Head removal and breakaway heads Figure 7-2 4022-40 Wire Calender Scanner Head Separation 7.3. Head removal and breakaway heads One feature of the 4022-40 Wire Calender Scanner model is that the upper and lower heads are attached to the scanner using specially designed brass breakaway screws.
Page 171: Preventive Maintenance Schedules
8. Preventive Maintenance Schedules This chapter deals with the recommended preventive maintenance and replacement schedules for the Precision Platform 4022 scanner. The maintenance of this scanner can be broken down into these areas of the scanner: • General Scanner Maintenance •...
Page 172: Preventive Maintenance Tasks
Precision Platform 4022 Scanner Preventive Maintenance Schedules 8.1. Preventive maintenance tasks The recommended preventive maintenance schedule and procedures for the scanner components are summarized in Table 8-1. This schedule is based on estimated life expectancies in a worst-case environment. Actual life expectancies may vary, depending on site location and scanner environment.
Page 173 Preventive Maintenance Schedules Preventive maintenance tasks Procedure Procedure Daily Weekly Months Years Details Scanner air purge air flow 9.2.5.1 Scanner air purge air inlet 9.2.5.2 filters POWER TRACKS Power track inspection 9.3.1.1 Power track adjustment 9.3.1.2 Upper and lower power 9.3.2 track replacement CARRIAGES, STATIC...
Page 174 Precision Platform 4022 Scanner Preventive Maintenance Schedules Procedure Procedure Daily Weekly Months Years Details Belt support bracket 9.6.7 adjustment HEAD SEPARATION CLUTCH Head separation clutch 9.7.1 maintenance Clutch pin replacement 9.7.2 MOTOR & ENCODER Head position encoder 9.8.1 inspection Head position encoder 9.8.1 replacement Motor inspection and...
Page 175: Maintaining A Scanner Logbook
Preventive Maintenance Schedules Maintaining a scanner logbook Procedure Procedure Daily Weekly Months Years Details LIQUID COOLING 9.10 SYSTEMS Open loop cooling system 9.10.1.1 maintenance Closed loop cooling system ∗ 9.10.1.2 maintenance ∗ Chiller maintenance 9.10.1.3 PMP ENCLOSURE 9.10 COOLING Leaking coolant in heat 9.10.1.4 exchanger drain Air flow from heat...
Page 176 Precision Platform 4022 Scanner Preventive Maintenance Schedules scanner upgrades, or similar information. Enter sensor variations or adjustments. Keep software changes in a separate book. This logbook is important as a means of informing future maintenance personnel of the changes that were made to the scanner and sensors, and that the scheduled maintenance was done.
Page 177: Scanner Maintenance
9. Scanner Maintenance This chapter contains procedures for maintaining these scanner components: • General maintenance tasks • Air system • Fluid Supply System • Power tracks • Carriages, Tracks, static drain and beam seals • Drive belt system • Head separation clutch •...
Page 178: General Maintenance Tasks
Check to make sure that the expansion joint bearing is assembled correctly, using Honeywell installation drawings as a reference. Also check that the two smaller shipping bolts between the ¾" mounting bolts in the bottom of the end support that hold the expansion joint together during scanner placement have been removed.
Page 179: Switches, Buttons, Lamps, And Fuses
Scanner Maintenance General maintenance tasks 9.1.4. Switches, buttons, lamps, and fuses • Inspect switches, buttons, lamps, and fuses for loose or corroded connections. Clean or replace any corroded connections. • If corrosion can be easily removed without damaging the part, then clean the part.
Page 180: Eliminating Condensation On Covers
Precision Platform 4022 Scanner Scanner Maintenance To remove sections of the beam cover: 1. If the optional Dirty Environment Seal kit is present, first remove the seal retainer extrusions from the upper and lower cable and distant end beam covers (total four covers, eight extrusions). These are removed by unscrewing the thumbscrews which fasten them to the covers.
Page 181: Air System
Scanner Maintenance Air system 9.2. Air system This section applies to both air purge and compressed air supply. See Section 2.10 and Section 2.11 for additional information. 9.2.1. Air pressures and flow • Inspect air supplies for correct pressure and flow as per the installation drawings.
Page 182: Power Tracks
Precision Platform 4022 Scanner Scanner Maintenance • Removing and replacing beam cover sections • Replacing beam cover seals (if installed) • Eliminating condensation on the beam covers 9.2.5.1. Checking air flow Check the scanner air purge daily (if it is used) by opening the cable end support doors and checking for air flow at the top of the end support.
Page 183: Inspection Of The Power Tracks
Scanner Maintenance Power tracks • Check dirt build up At the intervals shown in Chapter 8, use the procedure in Subsection 9.3.1.1 to maintain the power track in good condition: 9.3.1.1. Inspection of the power tracks 1. Scan the heads offsheet on the cable end of the scanner and turn off the Motor Power keyswitch.
Page 184: Adjustment Of The Power Tracks
Precision Platform 4022 Scanner Scanner Maintenance Hose and ribbon cable assemblies in the power track can be replaced independently. Hose assemblies typically wear out before ribbon cables. 7. Check the hose assembly. The hoses will be tight in the snaplinks and there will be hose dust where they rub against the snaplinks.
Page 185 Scanner Maintenance Power tracks 5. Reinstall the snap link covers and push the whole cable ribbon bundle so that it contacts the inside of the snap link covers at the power track bend 6. Mark the position of the edge of the metal snap link bracket on the top cable.
Page 186 Precision Platform 4022 Scanner Scanner Maintenance Figure 9-2 Cable Clamp Position Injury can occur. The head can move without warning. Keep hands, hair, and clothing clear of WARNING belts, pulleys, and other moving parts. Stand clear of moving heads. 8. Turn on the Motor Power keyswitch and make several scans in Shop mode.
Page 187: Replace Upper And Lower Power Track
Scanner Maintenance Power tracks 9.3.2. Replace upper and lower power track Life expectancy of the power tracks varies based on these factors: • Scan speed • Scanner environment • Scanner air purge • Regular Power track maintenance of the ribbon cable tension See the maintenance schedule in Chapter 8 for suggested maintenance tasks and their intervals.
Page 188: Carriages, Static Drain Wire And Tracks
Precision Platform 4022 Scanner Scanner Maintenance 7. If lengths are okay then disconnect the power tracks from the head carriages. This is done by removing the bolts connecting the vertical power track brackets to the head carriages. 8. Disconnect power track from the Cable end. 9.
Page 189 Scanner Maintenance Carriages, static drain wire and tracks 3. There are four wheel pad assemblies attached to the upper head carrier and four attached to the lower head carrier for a total of eight wheel pad assemblies. Remove the two 3/8"-16 fastening screws from any one of the eight wheel pad assemblies in order to remove the wheel pad.
Page 190: Static Eliminator Drain Wire
The drain lines are connected to ground at the cable end support. The drain lines should be checked for wear. If the drain lines need replacing, you need: • Assembly drawing (Honeywell p/n 6580800717A) • Cable clamps • Static line • Wire lugs •...
Page 191: Inspecting And Replacing The Static Drain Lines
Subsection 9.4.3.1 describes how to clean the tracks. If the tracks come out of alignment because of a wreck or some other cause, they will require realignment by a Honeywell factory technician. 9-15...
Page 192: Cleaning The Tracks
Precision Platform 4022 Scanner Scanner Maintenance DO NOT ATTEMPT TO ALIGN THE TRACKS. Special alignment AUTION tools are required to obtain proper alignment. 9.4.3.1. Cleaning the tracks 1. Scan the heads to the offsheet position at the cable end and turn off the Motor Power keyswitch (see Figure 9-9).
Page 193: Dust Wipers
Scanner Maintenance Beam Seals (Optional) 9.4.4. Dust wipers Inspect the dust wipers at both ends of the head carriage (four per carriage) for wear or excessive dirt. Replace any worn dust wiper assemblies or felt pads. Excessively worn or dirty dust brushes can damage the scanner tracks.
Page 194 Precision Platform 4022 Scanner Scanner Maintenance Use caution when removing the beam seals from the seal retainers. Ensure retainers are aligned and that there are no pinch points that may cause the beam WARNING seal to bind or otherwise not move freely. Pulling too hard on the seal could cause it to break and may result in injury.
Page 195: Drive Belt System
Scanner Maintenance Drive belt system 9.6. Drive belt system 9.6.1. Inspecting the drive belts Inspect the drive belts looking for • Excess wear on teeth or belt edges • Exposed fiber strands 9.6.2. Replacing the motor drive belt To replace the motor drive belt (see Figure 9-4): 1.
Page 196 Precision Platform 4022 Scanner Scanner Maintenance applied perpendicular against the belt. Tighten the motor bracket fastening bolts and recheck the belt tension. Readjust belt tension if necessary. 7. Move the encoder so that the pulley engages the motor belt and turns when the belt moves.
Page 197: Adjusting Belt Tension And Head Cd Alignment
Scanner Maintenance Drive belt system 9.6.3. Adjusting belt tension and head CD alignment Adjust the head drive belt tension under these conditions: • The heads do not hold the cross direction (CD) alignment. • The head drive belts have been replaced. •...
Page 198 Precision Platform 4022 Scanner Scanner Maintenance Figure 9-5 Head Drive Belt Tensiometer 5. Repeat steps 3 through 4 for the lower belt. Tension the lower belt as closely as possible to the same as the upper belt. 6. Check cross direction (CD) head alignment by inserting the head alignment pins in the holes provided at each end of the head sheet guides.
Page 199: Adjusting Head Md Alignment And Gap
13. Reinstall the beam covers as described in Subsection 9.1.7. 14. Run a profile correction for the sensors that need it (Refer to the Da Vinci System Installation and Setup Manual Honeywell p/n 46018200). 15. Record the maintenance in the scanner logbook.
Page 200: Replacing Head Drive Belts
Repeat the procedures if necessary to obtain a good alignment. 10. Remove the head alignment pins. 11. Run a profile correction for the sensors that need it (Refer to the Da Vinci System Installation and Setup Manual Honeywell p/n 46018200). 12. Record the maintenance in the scanner logbook.
Page 201 Scanner Maintenance Drive belt system Replace both belts (upper and lower) when either one requires replacement. To replace the head drive belts: 1. Send the heads offsheet to the cable end of the scanner. 2. Turn off the Motor Power keyswitch. To perform any maintenance, troubleshooting, or replacement of components, ensure that power is WARNING...
Page 202: Replacing Belt Idler Pulleys
13. Reinstall the beam covers as described in Subsection 9.1.7. 14. Run a profile correction for the sensors that need it. Refer to the Da Vinci System Installation and Setup Manual (Honeywell p/n 46018200). 15. Record the maintenance in the scanner logbook.
Page 203: Adjusting The Belt Support Brackets
8. Reinstall the beam covers as described in Subsection 9.1.7. 9. Run a profile correction for the sensors that need it. Refer to the Da Vinci System Installation and Setup Manual (Honeywell p/n 46018200). 10. Record the maintenance in the scanner logbook.
Page 204 Precision Platform 4022 Scanner Scanner Maintenance To perform any maintenance, troubleshooting, or replacement of components, ensure that power is WARNING disabled at the breaker. 2. Remove the covers as described in Subsection 9.1.7. 3. Check the belt tension and head alignment, as described in Subsection 9.6.3, and adjust if necessary.
Page 205: Head Separation Clutch
Scanner Maintenance Head Separation Clutch Figure 9-6 Adjusting the Belt Support Brackets 9.7. Head Separation Clutch This section describes clutch maintenance. This section is not applicable to the 4022-40 Wire Calender scanner model as there is no clutch present. See Chapter 7 for further details.
Page 206 Precision Platform 4022 Scanner Scanner Maintenance Figure 9-7 Clutch Assembly The clutch pins are worn and need replacing when the heads have a noticeable CD offset during a scan direction change. If pin wear is suspected, observe the relative movement of the two 2.8 inch drive pulleys in the cable end support during scan reversals.
Page 207: Clutch Pin Replacement
Scanner Maintenance Head Separation Clutch 9.7.2. Clutch pin replacement 9.7.2.1. Removing the Clutch Assembly Make sure there are spares for all of the items in this assembly before proceeding, especially the retaining rings, springs, Lubriplate and clutch pins (check the spare parts list and scanner assembly drawings).
Page 208: Clutch Reassembly
Precision Platform 4022 Scanner Scanner Maintenance 6. Check the pins mating surfaces where the pins seat in the inner 2.8 inch pulley. The seats can be polished, but not deformed or gouged. Replace the inner 2.8 inch pulley if worn. 9.7.2.3.
Page 209: Motor And Encoder
Scanner Maintenance Motor and Encoder 6. Run a profile correction for the sensors that need it (Refer to Da Vinci System Installation and Setup Manual, p/n 46018200). 7. Order items used from the spares inventory. 8. Record maintenance information in the scanner logbook. 9.8.
Page 210 Precision Platform 4022 Scanner Scanner Maintenance 3. Loosen the motor belt adjuster bolt. 4. Disconnect wires to the motor junction box. See Figure 9-8. 5. Remove motor from motor bracket. 6. If reusing motor pulley, remove from faulty motor and install on new motor.
Page 211: Limiting Drive Motor Torque
Scanner Maintenance Motor and Encoder Figure 9-8 Motor Wiring Details 9.8.4. Limiting drive motor torque The drive motor torque must be limited for safety reasons. When necessary, you must be able to stop the heads as they scan with your hands.
Page 212: Verifying Drive Motor Torque
Precision Platform 4022 Scanner Scanner Maintenance 9.8.5. Verifying drive motor torque 1. Place the scanner in Shop mode. The switch is on the Termination PCB in the cable end of the scanner. 2. Ensure that the heads are moving in a smooth and uniform manner.
Page 213: Adjusting Torque With Motor Controller Panel
Scanner Maintenance Motor and Encoder this current limit. It can be set anywhere between 30% and 180% of the rated maximum current. 3. Enter the password by pressing the Mode button. The display then reads 00. 4. Use the Up/Down Arrow buttons to change the display to 225 and press the Mode button.
Page 214: Heads And Sensors
Precision Platform 4022 Scanner Scanner Maintenance 2. Disconnect the leads to the motor controller. 3. Verify the new motor controller has the equivalent part number as the one being replaced. Different part numbers will have different default parameters depending on the scanner model. 4.
Page 215 Scanner Maintenance Heads and sensors Figure 9-7 shows the clutch and drive components. Authorized personnel should ensure that the radiation sources are in the shutter-closed position (refer to the instructions in the Radiation Safety Training Manual). Use this procedure to separate the sensor heads. To perform any maintenance, troubleshooting, or replacement of WARNING components, ensure that power is disabled at the breaker.
Page 216: Realigning The Heads After Clutch Separation
Precision Platform 4022 Scanner Scanner Maintenance Figure 9-9 Head Separation Clutch Controls 9.9.2. Realigning the heads after clutch separation 1. Manually pull the upper head over the lower head to align the heads (approximate alignment is OK). 2. Engage the clutch by turning the Head Split keyswitch off (see Figure 9-9).
Page 217: Head Removal And Installation
Scanner Maintenance Heads and sensors 9.9.3. Head removal and installation The heads may need to be removed for maintenance or replacement. This is a rare occurrence, and this procedure should be followed: 1. Scan the heads to the offsheet position at the cable end and turn off the Main Power switch (see Figure 9-9).
Page 218: Maintaining The Precisionpak Heads
Precision Platform 4022 Scanner Scanner Maintenance 10. If the heads need to be stored off the scanner, make arrangements with the customer for a safe, locked area where a nuclear source can be stored. Installing the head: 1. Install the head as described in the steps above, but in reverse order.
Page 219: Head Air Purge
Scanner Maintenance Heads and sensors To perform any maintenance, troubleshooting, or replacement of WARNING components, ensure that power is disabled at the breaker. The head covers must be reinstalled in the same locations from which they were removed. Make sure that the locations are marked on the interiors of the covers when they are removed.
Page 220 Precision Platform 4022 Scanner Scanner Maintenance • Check that the thumbscrew shut-off valve on the side of the air manifold is not closed for the air purge/gap temperature sensor hose. It should be opened four turns counterclockwise from the closed position. •...
Page 221 Scanner Maintenance Heads and sensors Figure 9-10 High Pressure Air Manifold 9-45 p/n 6510020208 10/18/07...
Page 222 Precision Platform 4022 Scanner Scanner Maintenance Figure 9-11 Low Pressure Air Manifold Figure 9-12 shows the ECU and the purge air location. 9-46 10/18/07 p/n: 6510020208...
Page 223: Maintaining Head Internal Temperatures
Scanner Maintenance Heads and sensors Figure 9-12 Head Air Purge 9.9.4.2. Maintaining head internal temperatures Check head temperatures daily on the User Station. Head internal temperatures are preset at the factory. This temperature should hold constant between 38°C (100°F) and 49°C (120°F), and, most importantly, vary less than ±1°C (1.8°F).
Page 224 Precision Platform 4022 Scanner Scanner Maintenance 2. Check that the ECU fan blades are turning and that air is flowing whenever the head covers are removed. 3. Check for coolant leaks whenever the head covers are removed. Do not open the head covers unless the humidity warning is on or other head maintenance is necessary.
Page 225: Setting Internal Head Temperature
Scanner Maintenance Heads and sensors head is one quart (about one liter) per minute. Most outboard sensors have their own solenoid temperature control circuits, so this is not an issue. However, some Gloss sensors may need a restrictor valve installed. 11.
Page 226: Sheet Guide Heaters
Precision Platform 4022 Scanner Scanner Maintenance Sensors may take an hour to stabilize before calibration can be performed. 6. To increase the head temperature, turn the trim heater knob clockwise one number at a time. To decrease the temperature, turn it counterclockwise.
Page 227: Air Wipe Heaters
The termination block is under one of the external head hose covers next to the sheet guide. It is very rare for a heater to fail. Notify Honeywell Customer Service if replacement is necessary.
Page 228: Maintaining The Water-To-Water Heat Exchanger Cooling System (Closed Loop)
Precision Platform 4022 Scanner Scanner Maintenance • Check the head temperatures on the User Station daily. Methods for correcting head temperature problems are described in Subsection 9.9.4.2. • Check the water pressure and flow rate daily. • Pressure: 2-4 Bar (30-60 psig) •...
Page 229: Maintaining The Chiller (Closed Loop)
9.10.1.3. Maintaining the chiller (closed loop) Procedures for maintaining a Honeywell chiller are supplied with the chiller documentation. For maintenance procedures for a non-Honeywell chiller, refer to the documentation provided by the chiller manufacturer.
Page 230: Radiation Safety
• Flush coolant and additive. 9.11. Radiation safety Perform required radiation safety tests on all nuclear and X-ray sensors as suggested in Honeywell Radiation Safety Manual p/n 6510020199. Replace radiation lamps as per the maintenance schedule in Chapter 8. 9-54 10/18/07...
Page 231: Storage, Transportation And Disposal
Reuse, recycle or dispose of all equipment in accordance with local environmental requirements or guidelines. This product may be returned to the Honeywell manufacturing location, and it will be disposed using environmentally friendly methods. Contact the factory for further details and instructions.
Page 232: Solid Materials
If storage will be for a period of weeks or months, arrangements often can be made to have Honeywell store the sensor. Contact Honeywell 10-2...
Page 233 Storage, Transportation and Disposal Storing radioactive sources Radiological Operations. The main contact numbers for Radiological Operations are First level of support: • The Americas, Asia Pacific and India are supported directly by Phoenix at 602-313-3330. • Europe, Middle East and Africa are supported by Waterford at + 353 (0) 51 372 151.
Page 235: Glossary
11. Glossary Actuator Mechanical or electronic device that performs the control action in a control loop. Back Side See Drive Side. The smallest measurement zone on the frame. Also called Bucket or Slice. Bucket See Bin. Cable End Location of the electronics and/or the entry point for communications and power on the scanner.
Page 236: System
The side of the paper machine where the main motor drives are located. Cabling is routed from this end. Also called Back Side. Foreign Controller The controller for a foreign non-Honeywell CD actuator, e.g., a Voith dilution profiling headbox. Front Side See Tending Side.
Page 237 Glossary Precision Measurement Processor The computer and I/O enclosure that supports the motion control of the sensor head and the raw processing of the sensor voltages. Also known as the MSS. Located in a separate remote enclosure. PrecisionPak A set of upper and lower heads mounted on the Precision Platform. The sensors are installed within the PrecisionPak, which travels back and forth on the rails of the Precision Platform.
Page 238 Precision Platform 4022 Scanner Glossary Sensor Processor A software program that takes one or many inputs from the PMP, converts those measurements to engineering units for measurement or measurement correction, performs automatic diagnostic tests, and reports on any alarm conditions. Sensor Set The term used in the Sensor Maintenance displays to describe a set of sensors working together on a scanner to perform one...
Page 239 Glossary Virtual Input/Output 11-5 p/n 6510020208 10/18/07...

This manual is also suitable for:

Precision platform 4022-31 Precision platform 4022-40 Precision platform 4022-30

Honeywell Precision Platform 4022 Series System Manual

Quick Links

Related Manuals for Honeywell Precision Platform 4022 Series

Summary of Contents for Honeywell Precision Platform 4022 Series