B Operating the AccuRay 1190

Supports software version AccuRay 1190 Release 7.0, Portal A, ESP330.0C

Block Diagram of the AccuRay 1190

State-of-the-Art Configuration
The AccuRay 1190 System is an implementation of the ABB Distributed Control System
for measurement and control on a paper machine. Unlike a conventional DCS, the
Accuray 1190 is not just hardware which the customer’s process control engineer must
program; the AccuRay 1190 process control programs and video displays are already
programed for the specific paper machine and are ready to function. Further, the AccuRay
1190 programming and video displays are easily customized “on site” and “on line.”

The AccuRay 1190 consists of:

• Control Electronics: MasterPiece
— ABB process control station and operating system
— AccuRay process control application programs
• Operator Station: Advant OS
— Advant OS hardware and operating system
— AccuRay video displays for the paper machine
• Measurement: Smart Platform
— AccuRay Smart Platform scanning frame
— AccuRay Smart measurement sensors
• Cross Direction Control
— AccuRay Smart Weight Profiler
— AccuRay Smart Calendar Profiler

Earlier configurations included:

• MasterView operator stations
• Programmable Microcomputer Modules
• First Site scanning frames

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 AccuRay 1190 Block Diagram

Master Bus 300 Distributed Control Network The MasterBus 300 network
connects the MaterPiece and
the Advant OS. The Advant
TCP/IP network has an additional TCP/IP net.

Printers connect to Advant.

A serial printer prints reports.
A parallel color printer prints
hardcopy of video displays; it
can be shared over TCP/IP net.
Advant OS

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The Smart Platform and the
Smart Weight Profiler connect
to the MasterPiece thru serial
links using 20 ma current loops.
They interface to MasterPiece
thru AccuRay Computer Processor
(ACP) cards.
MasterPiece Process I/O interfaces to the
stock valve and flow meter,
Printer tachometers, steam valve, etc.
C230 AccuRay Smart Platform Maintenance Course

Smart Platform
Smart Weight Profiler Process I/O

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 B - Operating the AccuRay 1190

An earlier AccuRay 1190 configuration

monitor

keyboard
MasterView

MasterBus

MasterPiece

Earlier configurations of the AccuRay 1190 used MasterView as the operator station.
Other earlier systems used Programmable Microprocessor Modules for scanning frame
and cross direction control; some systems used First Sight Technology which is the
predecessor of the Smart Platform scanning frame.

An IBM-compatible personal computer is used as a Smart Platform Work Station for

maintenance. Earlier AccuRay 1190 systems used this personal computer for an additional
function of a programming aid for the MasterPiece -- a MasterAid.
The Advant OS “on line” programming aid functions replace the MasterAid.

The Smart Platform, or any earlier type of scanning frame (PMM or FirstSight) and the
Smart Weight Profiler or Smart Calendar Profiler or earlier types of CD control (PMM)
interface to the MasterPiece through the AccuRay Computer Processor (ACP) card. An
ACP card can interface a maximum of two scanning frames. Programming is in PROM.
A different ACP card can interface two CD controls. A different program is in its PROM.

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 ACP cards interface Smart Platform to the MasterPiece via serial link.

Master Frame & Sensor serial

Piece
ACP
MP
computer

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serial
CD control

Smart Platform
ACP
Smart Weight Profiler
internal bus

Color control serial

C230 AccuRay Smart Platform Maintenance Course

ACP

ACP are slave CPUs.

MP computer reads
their memories.

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 B - Operating the AccuRay 1190

AccuRay 1190 Block Diagram (simplified for clarity)

Advant OS

MasterBus
MasterPiece

Smart Platform
serial
link

1190 uses distributed processing

net AccuRay 1190

computers &
Advant OS MP computer memories
memory
battery-backed
memory Smart Platform
BUS
hard disk battery-backed
memory

serial
ACP card
Master Smart
Aid memory Platform
386 Work
computer Station
Master Piece

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C230 AccuRay Smart Platform Maintenance Course

Booking List of PC Programs

PC1 ________________
PC2 ________________
PC3 ________________
PC4 ________________
PC5 ________________
PC6 ________________
PC7 ________________
PC8 ________________
PC9 ________________
PC10 System Initialize or Restart
PC11 Frame Control
PC12 PC13 Sensor Configuration
PC14 PC15 Measurement Overview
PC16 Measurement Status
PC17 Transfer Grade data to ACP card
PC18 Manual Grade Change
PC19 Grade Data Control
PC20 MIS Production Accumulator
PC21 Reel Report
PC22 Grade Report
PC23 Day/Shift Report
PC24 Roll/Set
PC25 Standardize and Sample Check History Accumulation
PC26 Standardize History Report
PC27 Sample Check History Report
PC28 Stdz, Calibrate Sample and Sample Check Reports
PC29-PC36 Composite Profiles from ACP
PC37 PC38 Single Scan Profiles
PC39 Interframe Measurement Data Transfer
PC40 PC41 Level 1 Actuator Control

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 B - Operating the AccuRay 1190

PC42 Simulator for MD Control

PC47 Speed Opt Control
PC48 Yankee Hood or OMC Startup
PC49 Cascade Weight or Crepe
PC50 Coordinated Dryer Control
PC51 Ply/Stock Loading Control
PC52 Dry Stock Control or Comp
PC53 Speed Change or OMC Speed
PC54 Scanning Control (BW, MO, etc.)
PC55 Headbox Control or Multiformer
PC56 Multiformer
PC57 PC58 AGC
PC59 Handles MV for Scanning Control
PC60 Simulator for CD Control
PC61 PC62 PC92 CD Initialization
PC63 Bias Profile
PC64 PC65 PC71 PC72 PC78 PC79 PC85 PC86 Actuator Operator Interface
PC66 PC73 PC80 PC87 Error Profiles Presentation
PC67 PC74 PC81 PC88 Actuator Bumptest Profiles
PC68 PC75 PC82 PC89 Actuator Windowing
PC69 PC76 PC83 PC90CD Tuning Parameters
PC70 PC77 PC84 PC91 Actuator Specific Op Interface
PC99 DIU Specific Interface

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C230 AccuRay Smart Platform Maintenance Course

Operating the AccuRay 1190

Smart Platform Pushbuttons

Backside HEOS FEOS

Forward
Off Sheet

Smart Platform must be in Remote

and On Sheet at the frame to scan.

Off Sheet On Sheet

Local Remote

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 B - Operating the AccuRay 1190

The Off Sheet pushbutton The On Sheet pushbutton

at the frame override. must be green in order for
everything and sends the AccuRay 1190 to
the head off sheet if the control the frame. The
frame is in Remote frame can scan only if
. On Sheet at the frame. The
If the frame is in Local, it frame will not standardize
moves only when jogged. automatically unless it is
Push either the JOG Fwd On Sheet at the frame.
or the Rev JOG button.

The 2 lights at the top are

Normal scanning uses
Off Sheet On Sheet the red Source Open light
AutomaticEdge of Sheet and green Source Closed.
but scan limits can be set
when AEOS is off. Jog Local Remote
to the desired scan limit Calibrate Sample reports
which must be within the the basis weight and
width of the widest sheet. moisture of the paper
If you pushed JOG Fwd, while the button is pressed.
then push the SET Fwd
Rev JOG Fwd If the Calibrate Sample
pushbutton; however, if button is pressed while the
you pushed Rev JOG, sheet is marked with a wax
Sample crayon, the paper can be
then push the Rev SET Check
pushbutton. cut out from the reel and
tested in the lab, then
Calibrate compared with the
Sample
The Standardize button Calibrate Sample Report.
flashes if a sensor has any Restart
problem. The LED lights LED
solid during standardize. Sample Check is done
Pressing the Standardize Standardize Off Sheet at the frame
pushbutton while to check the accuracy of
Off Sheet at the frame sensors by measuring
does “clean” standardize. standard samples.
Rev SET Fwd

After a Restart, you must first push Remote. Normal Operation Two green LEDs are on
The frame drives into the off sheet limit switch, for Remote and On Sheet at the frame. Only
then drives to the off sheet position and turns on then is the frame under the control of the 1190.
the Off Sheet LED. You then clean the heads of Pressing the Off Sheet button at the frame
any dirt, then push the On Sheet pushbutton. overrides and the frame goes off sheet, but it
will not standardize under 1190 control until it
The Restart LED flashes briefly for a restart of
is On Sheet at the frame. A sheet break causes
the AccuRay Smart Processing Center (ASPC)
Off Sheet at the frame. After the sheet break,
which is inside the frame’s end column.
the Backtender must push the On Sheet button.

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C230 AccuRay Smart Platform Maintenance Course

Frame control from the Advant OS

fixed display
Single Pt Off Sheet
CM#3 1995-01-24 13:00 Single Pt Off Sheet
WE3FC060 #7 MACH FLOW (MV > H2 95-01-24 12:20:00
Display Name and Description Here ? Standardize Scan

Off-Sheet
Frame
1 G
ProductionTons MD Control MV SP Standardize
Status New SETP Scan
Scan Reel 2395 Basis Weight 24.5 24.5 Auto 25.0
2 G
Grade 2395 Moisture 1 6.5 6.5 Auto 6.5
Single Point 3 G Dry Weight 1 22.9
Day 14.2
G Shift 1 14.2 Moisture 2 3.0 3.0 Auto 45.0
Standardize 4
Jet / Wire Ratio0.92 0.92 Bal
Global
Shift 2 12.8 Speed 504 500 Auto Scan by “pushing” the Scan “button”
Shift 3 0.0 Drystock
G
in the fixed display at the top right
Manual Grade Change On Grade Grade 3 Trey Trim 200.0 of any and every video page.
Auto Grade Change New Grade 3 Trey Reel # 5

M FRM1 Basis Weight P 44.16 M FRM1 Hemi+ Moisture P 4.00

45.17 High Resolution Profiles 4.1

44.16
To do a Frame Reload
4.01
or turn on or off AEOS
42.8 3.89
or to Clean Standardize,
first select the frame (Frame 1)
and then press D5 for Extend...
and press the D key.

Off Sheet Single Pt

? Scan Standardize
AP01FMOV11 Frame Overview

GLOBAL FRAME 1 FRAME 2 FRAME 3 FRAME 4

Description
Offsheet
Scan
Single Point
Standardize
Auto Edge of sheet
Independent
Local
Sheet Break
Current Head Position 282.22 68.25 57.00 56.92
Single Point Position 550 501
Comm Failure
Frame Service Check
Electrical Service Check
Measurement Service Check
Overtemp D 1 O ff s h e e t D 2 Scan D 3 S in g le P o in t D 4 S ta n d a r d iz e D 5 E x te n d .
Safety Interrupt
IR Cooling Flow
Auto Edge Alarm
Scan Limit AlarmD 6 D 7 S in g le P t P o s D8 D9 D 10
Sensor Alarm
FRAME 1
FRAME 2 S
FRAME 3 D1 D 2. D 3 A u to E d g e D4 D5
FRAME 4
Sample Check Setup
D 6 F r m R e lo a d D7 D 8 In d e p ./G lo b a l D 9 C l ean Stdz D 10
D1 Syst. Over. D2 Mach. Over. D3 Smart Plat. D4 Meas. Over. D5 Meas. Status

D6 Grade Data D7 D8 D9 SWP D10

Copyright © 1997, ABB Industrial Systems, Training Department

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 B - Operating the AccuRay 1190

Grade Change
Fram e
Off-Sheet Production Tons MD Control MV SP Status New SETP
1 G
Scan Reel 2395 Basis W eight 24.5 24.5 Auto 25.0
2 G
Grade 2395 Moisture 1 6.5 6.5 Auto 6.5
Single Point 3 G Dry Weight 1 22.9
Day 14.2
Moisture 2 3.0 3.0 Auto 45.0
Standardize 4 G Shift 1 14.2
Jet / Wire Ratio 0.92 0.92 Bal
Shift 2 12.8
Global Speed 504 500 Auto
G
Shift 3 0.0 Drystock

Grade 30 Litho Trim 20

GradeChange On Grade
New Reel #
Grade 20 Bond James

M FRM 1 Basis W eight P 44.16 M FRM1 Hem i+ M oisture P 4.0

45.17 High Resolution Profiles 4

44.16
4
42.8 3

To make a Grade Change:

• If not On Grade, click on the On Grade “pushbutton.”
• Select in the New Grade box and, on the keyboard, type the grade number.
• Click on the Manual Grade Change “pushbutton.”
• Finally, click on the On Grade “pushbutton.”
• Know that Grade Change forces a standardize.
The profiles of weight and moisture are displayed. Also see the profile pages.
The averages of weight and moisture are displayed. Also see the trend pages.

If the MasterPiece is restarted, then a Grade Change must be made and the date and time must be entered.

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C230 AccuRay Smart Platform Maintenance Course

Auto Control

Basis Weight Stock Flow

Level 2 Control Level 1 Control

Scanning Control Actuator Control
Example: “Basis Weight Reel” Example: “Stock Flow”
Measurement from Basis Weight Sensor Measurement from Flow Meter
Data Output to Stock Flow Set Point. Digital Output to Inc/Dec Stock Valve
Example: “Moisture Reel” Example: “Steam Pressure 1”
Measurement from Moisture Sensor Measurement from Analog Input
Dat Output to Steam Pressure 1 Set Point Analog Output to Steam Valve
Bal = Level 1 control not Auto Bal = actuator in Local
Man = Level 1 control in Auto Man = actuator in Remote
Auto = changes actuator set point Auto = set point can be changed
Ext 1 = not On Grade Ext 1 = set point from Level 2

Use trackball to select on control loop, then use Auto or Man push buttons on the keyboard.

Copyright © 1997, ABB Industrial Systems, Training Department

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 B - Operating the AccuRay 1190

Programming Aid

D1 D2 AdvaBuild D3 - D4 D5

Before activation of On-Line Builder

D6 OnLine D7 D8 D9 Password for User:
Enter D10onlineb
Builder
Password onlineb

OK Cancel Help

_
File Edit Action Help
Start Network address
Netw Node Desc Stop and network node

Paper Machine 11,12

System
Config

.
D2
D6
_ 11,12
On Line Builder = programming aid. Note: <Ctrl-B> replaces <Alt-B> and <Break>
To start it, first press System Config. Press <Ctrl-C> to terminate session
Next press <D2> AdvaBuild and then
<D6> On Line Builder. Type in the Target System Identity:
password, then select the net & node QAC280 SW*6.1/0
QMV280 SW*6.0/0
and pull down the Action menu to
click Start. It opens at system level * SLLEV PC
with * prompt, so you must type Loading existing map...done!
SLLEV PC to get the # prompt. #
To exit, first type TSESS and then
press <Ctrl-C>.
Master Aid = old programming aid.
See next page for how to start it.
To exit from it, you must type TSESS.

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C230 AccuRay Smart Platform Maintenance Course

MasterAid 220 Main Menu

1
C> MA220

2 Command Oriented Functions

Function Chart Editor

3
Project Setup Press Alt-B to activate MasterAi

Project Maintenance
4
Supported ABB Master Products
=============================
1. MasterAid 220
2. MasterPiece 200
3. MasterView 800
Select One: 2

Available Activities
===================== 5
Project Setup 1. MP 200 Programming
2. MP Programming via Network
. . . .
Master MA220 00,00 MasterAid itself Select One: 1
PM1 MV850 11,01 Operator Station 6
PM1 MP280 11,12 Paper Mach Command Processor Loading
=========================
7 Set correct target via <Alt-T>
. . . and type <CR>
8
Target System Identity
QAC280 SW*6.1/0
T
9 QMV280 SW*6.0/0
# TSESS
F2=Remove F3=Create Enter=select Esc PM1 MP280
exit

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 B - Operating the AccuRay 1190

MasterPiece restart

AUTO

INIT

DSPC MB MB
172H 175 175

172H

Auto Init = restart of MasterPiece.

Memory is battery backed, so even with power off, the software is ok.
Turning power on causes restart. To manually force a restart, put the
rotary switch into AUTO and press the pushbutton marked INIT.
See P- displayed during the self-test, then P1 which means that all is ok.

Clear Init erases the battery memory. This memory can be backed up on hard disk
If memory is erased, it must be reloaded of the Advant OS using Central Backup or
using the programming aid. it can be backed up on the hard disk of a
MasterAid.

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C230 AccuRay Smart Platform Maintenance Course

Smart Platform restart

Smart Platform
DOS
HealthPages ASPC
RemoteAccess
To restart
press RESET pushbutton.

SPWS
Application startup in progress. Wait!
DesqView menu EC
HOST COMMUNICATIONS SET FOR: 9600 baud ECF MPRC PSR
ECS sensor cards frame
card
If the HOST is down it will automatically download files
to the Smart Platform when it is started up.
ShortDiag
If the Host is already up, then request a manual reload
of this Smart Platform.
RESET
AVOS Shell
BANNER
$$

The Smart Platform Work Station (SPWS) is The electronics of the Smart Platform is in the
an IBM PC running DesqView multitasking. AccuRay Smart Processing Center (ASPC). The
Turning on power restarts DesqView and you CPU is on the microprocessor card (MPRC).
get the DesqView menu at top right of screen. Turning on power runs diagnostics and restarts.
Pressing the RESET pushbutton does the same.
On this menu, you only have to open the
Health Pages window.
During a Smart Platform restart, Health Pages
display the progress of the startup. When it is
ok, you see the “banner” as well as the
AccuRay Virtual Operating System (AVOS)
prompt which is: $$
AVOS is a subset of UNIX.
After restart is complete, you press <F7> to
get the Smart Platform Health Pages where
you can check the frame and all sensors.

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