Stressometer Flatness System With Standard Roll: User Manual

—
A B B M E A S U R E M E N T & A N A LY T I C S
Stressometer Flatness System

with Standard Roll
User Manual
3BSE076743R0101 en Rev B
Stressometer 8.3
USE OF SYMBOLS
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Information
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Tip
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NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment by ABB
AB. ABB AB assumes no responsibility for any errors that may appear in this document.
In no event shall ABB AB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising
from the use of this document, nor shall ABB AB be liable for incidental or consequential damages arising from use of any
software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB AB’s written permission, and the contents
thereof must not be imparted to a third party nor be used for any unauthorized purpose.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in accord-
ance with the terms of such license.
CE-marking
This product meets the requirements specified in the EMC directive 2014/30/EU and the Low Voltage Directive 2014/35/EU,
provided the installation is carried out in accordance with the instructions given in this manual.
© Copyright 2014- 2018 ABB. All rights reserved.

2 Table of Contents
1 System Description
1.1 Introduction.................................................................................................. 7
1.2 Cyber Security Disclaimer............................................................................. 7
1.3 Disposal and Recycling................................................................................. 7
1.3.1 Environmental Policy..................................................................................... 7
1.3.2 Recycling Electrical and Electronic Equipment, WEEE................................... 8
1.3.3 Recycling the Transport Material................................................................... 8
1.3.4 Disposal of the Product................................................................................. 8
1.4 Flatness System Overview............................................................................ 9
1.5 Flatness Functionality.................................................................................... 9
1.5.1 System Product Levels............................................................................... 10
1.5.2 Flatness Server Architecture (FSA).............................................................. 11
1.5.3 Software Description................................................................................... 11
1.6 Measuring Roll............................................................................................ 12
1.6.1 Mechanical Design...................................................................................... 12
1.7 Digital Transmission Unit - DTU................................................................... 14
1.7.1 Digital Transmission Unit............................................................................. 15
1.7.2 Pulse Encoder............................................................................................ 16
1.8 DTU Air Purge............................................................................................. 17
1.9 Digital Transmission System - DTS.............................................................. 19
1.9.1 DTS Signals................................................................................................ 19
1.9.2 DTS Tool..................................................................................................... 21
1.9.3 DTS main equipment.................................................................................. 31
1.10 Flatness System Cabinet............................................................................ 36
2 Installation
2.1 Introduction................................................................................................ 38
2.1.1 General....................................................................................................... 38
2.1.2 Safety Instructions...................................................................................... 38
2.1.3 General Installation Rules............................................................................ 39
2.1.4 References................................................................................................. 40
2.2 Installation of Measuring Roll....................................................................... 41
2.2.1 Delivery Check............................................................................................ 41
2.2.2 Storage....................................................................................................... 41
2.2.3 Unpacking.................................................................................................. 41
2.2.4 Mechanical Installation................................................................................ 42
2.3 Installation of Flatness System Cabinet....................................................... 53
2.3.1 Introduction................................................................................................ 53
2.3.2 Unpacking.................................................................................................. 53
2.3.3 Mechanical Installation................................................................................ 54
2.3.4 Electrical Installation.................................................................................... 56
2.4 Installation of Connection Unit DTS PFSC230............................................. 63
2.5 Installation of DTU Cover and Power and Media Converter Unit
PFSA185.................................................................................................... 63
2.6 Installation of DTU PFSA107....................................................................... 66
2.7 Installation of cable set between DTU and Connection Unit DTS
PFSC230.................................................................................................... 69
2.8 Stressometer Installation Checklist.............................................................. 71
2.9 Operation.................................................................................................... 73
2.9.1 Power On................................................................................................... 73
2.9.2 Start of Excitation........................................................................................ 73
3 System Check and Maintenance

3.1 Introduction................................................................................................ 74
3.1.1 Safety Instructions...................................................................................... 74
3.2 System Check Intervals............................................................................... 75
3.3 System Check of Measuring Roll................................................................ 76
3.3.1 Introduction................................................................................................ 76
3.3.2 Preparations............................................................................................... 77
3.3.3 Considerations during Bearing Status Check.............................................. 77
3.3.4 Visual Inspection......................................................................................... 78
3.3.5 Bearing Lubrication..................................................................................... 78
3.3.6 Drive Coupling Check................................................................................. 81
3.3.7 Calibration Verification Check of Measuring Roll.......................................... 81
3.4 System Check of Digital Transmission Unit.................................................. 83
3.4.1 Visual Inspection of DTU installation............................................................ 83
3.4.2 Spare Parts................................................................................................. 83
3.4.3 Pulse Encoder............................................................................................ 83
3.4.4 Maintenance using DTS Tool ...................................................................... 88
4 Repairs and Adjustments
4.1 Introduction................................................................................................ 97
4.2 Replacing Measuring Roll ........................................................................... 97
4.2.1 Removal of Measuring Roll.......................................................................... 97
4.2.2 Installation of Measuring Roll....................................................................... 98
4.2.3 Measuring Roll data update after installation............................................... 99
4.3 Regrinding Measuring Roll.......................................................................... 99
4.3.1 Introduction................................................................................................ 99
4.3.2 General Method 1..................................................................................... 100
4.3.3 General Method 2..................................................................................... 101
4.3.4 Repolishing of Wc/Co coated rolls............................................................ 102
4.4 Bearing Replacement............................................................................... 102
4.4.1 Removing Old Bearing.............................................................................. 102
4.4.2 Assembling New Bearing.......................................................................... 103
4.5 Replacing DTS equipment........................................................................ 104
4.5.1 Removal of DTU PFSA107........................................................................ 104
4.5.2 Removal of DTU Cover and Power and Media Converter Unit PFSA185... 106
4.5.3 Installation of Roll DC Supply Unit PFSA240............................................. 107
4.5.4 Removal of Roll DC Supply Unit PFSA240 ............................................... 107
4.5.5 Installation of Signal Control Unit PFSA287............................................... 108
4.5.6 Removal of Signal Control Unit PFSA287.................................................. 108
4.5.7 Removal of cables between DTU and Connection Unit DTS...................... 108
4.6 Replacing FC and Rack Mounted Boards................................................. 109
4.6.1 Replacing a Flatness computer, FC .......................................................... 109
4.6.2 Replacing Rack Mounted Boards.............................................................. 109
4.6.3 Replacing a Digital Signal Processing Board PFSK 151............................. 110
4.6.4 Replacing a Data Concentrator Board PFSK 152...................................... 111
4.6.5 Replacing a Microprocessor Board (MVME 3100)..................................... 111
4.7 Changing MVME 3100 Boot Line.............................................................. 111
4.8 Adjusting Software Parameters................................................................. 113
4.8.1 Manually Deactivating/Activating Sensors................................................. 113
4.9 Partly Covered Zone, Strip Stress Profile Display....................................... 114
4.9.1 Introduction.............................................................................................. 114
4.9.2 Minimum Coverage for Stress Calculation................................................. 115
4.9.3 Edge Zone Indication Limit........................................................................ 115
4.10 Edge Zone Compensation........................................................................ 115
5 Backup and Flash Handling
5.1 Introduction.............................................................................................. 117
5.2 Backup/Restore of the BM-part................................................................ 117
5.2.1 Folder Structure........................................................................................ 117
5.2.2 Saving Configuration to Flash.................................................................... 118
5.2.3 Making Backup......................................................................................... 119
5.2.4 Restoring Backup..................................................................................... 121
5.3 Backup and Restore of a FC or a Logger.................................................. 122
5.3.1 Backup/Restore Procedure....................................................................... 122
6 Fault Tracing
6.1 Fault Tracing During Rolling....................................................................... 125
6.2 Fault Tracing Without Rolling..................................................................... 126
6.3 Fault Tracing Displays............................................................................... 127
6.3.1 Engineer Display....................................................................................... 127
6.3.2 Rolling Status............................................................................................ 128
6.4 BM-part.................................................................................................... 129
6.4.1 Common Problem Areas........................................................................... 131
6.5 Operator Station....................................................................................... 131
6.5.1 Message "No network connection!".......................................................... 131
6.6 Fault Tracing the DTS................................................................................ 131
6.6.1 Event List.................................................................................................. 133
6.6.2 Ethernet Failure......................................................................................... 135
6.6.3 System Snapshot..................................................................................... 136
A Channel Calibration
B Roll Calibration Verification

B.1 Procedure................................................................................................. 140
B.2 Roll Calibration Force Diagram.................................................................. 143
Alphabetical index
Stressometer Flatness System with Standard Roll, User Manual
1.1 Introduction
The Stressometer Flatness System, is a high-quality measurement and control system used in cold
rolling mills and hot rolling aluminium mills to achieve precise and repeatable metal strip flatness. A
sensitive and specialized Measuring Roll measures the forces across the roll caused by the tension
distribution in the strip. Digital signal processors (DSPs) and embedded computers refine the
Measuring Roll signals into mill actuator commands, to achieve optimal strip flatness.
1.2 Cyber Security Disclaimer

This product has been designed to be connected and communicate data and information via a
network interface which should be connected to a secure network. It is the sole responsibility of
the person or entity responsible for network administration to ensure a secure connection to the
network and to take the necessary measures (such as, but not limited to, installation of firewalls,
application of authentication measures, encryption of data, installation of antivirus programs, etc.)
to protect the product and the network, its system and interface included, against any kind of
security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or
information. ABB is not liable for any such damages and/or losses.
1.3 Disposal and Recycling
1.3.1 Environmental Policy

ABB is committed to its environmental policy. We strive continuously to make our products envi-
ronmentally more sound by applying results obtained in recyclability and life cycle analyses. Prod-
ucts, manufacturing process as well as logistics have been designed taking into account the envi-
ronmental aspects.
Our environmental management system, certified to ISO 14001, is the tool for carrying out our
environmental policy. However it is on the customer’s responsibility to ensure that local legislation is
followed.
3BSE076743R0101 en Rev B 7
1.3.2 Recycling Electrical and Electronic Equipment, WEEE
The crossed – out wheeled bin symbol on the product(s) and / or accompanying documents
means that used electrical and electronic equipment (WEEE) should not be mixed with general
household waste.
If you wish to discard electrical and electronic equipment (EEE), in the European Union, please
contact your dealer or supplier for further information.
Outside of the European Union, contact your local authorities or dealer and ask for the correct
method of disposal.
Disposing of this product correctly will help save valuable resources and prevent any potential neg-
ative effects on human health and the environment, which could otherwise arise from inappropriate
waste handling.
1.3.3 Recycling the Transport Material

ABB designs all transport material to be recyclable where practical. The recycling of the transport
material depends on the material type and availability of local recycling programs.
After receiving the system into the site, the package and the transportation locking have to be
removed. Recycle the transport material according to local regulations.
1.3.4 Disposal of the Product

When the product is to be disposed, it should be dismantled and the components recycled
according to local regulations.
1.3.4.1 Dismantling and Recycling of the Product

Dismantle and recycle the components of the product according to local regulations.
CAUTION
Some of the components are heavy! The person who performs the dismantling of
the system must have the necessary knowledge and skills to handle heavy
components to avoid the risk of accidents and injury from occurring.
• Stressometer Roll: These parts are made of structural steel, which can be recycled accord-
ing to local instructions. All the auxiliary equipment, such as cabling must be removed before
recycling the material.
8 3BSE076743R0101 en Rev B
• Control Unit and Other Equipment: These parts include various circuit boards, electrical
components, voltage and current transformers, power cables, instrumentation wires, surge
arrestors and capacitors. See
1.3.2 Recycling Electrical and Electronic Equipment, WEEE.
1.4 Flatness System Overview
3 4
2
1
5
1 6
6 7
5
Figure 1. Example of a Flatness System
1. Roll Drive system (optional)

2. Millmate Strip Scanner; measures the position of the strip (strip center and edges). (optional)
3. Millmate Thickness Gauge; measures the thickness of the strip. (optional)
4. Spot Cooling system controls the Flatness Error. (optional)
5. Measuring Roll (Standard, Foil, Semi-Foil or Seamless), chapter 1.6 Measuring Roll.
6. Digital Transmission Unit 1.7 Digital Transmission Unit - DTU
7. Client computers with standard web browsers are used as operator stations.
8. Flatness System Cabinet (for housing the electronics) The cabinet contains power supplies,
excitation signalling for sensors, the digital electronics, network switches and connection
units, chapter 1.10 Flatness System Cabinet.
1.5 Flatness Functionality

The functionality of the system is divided into two parts: The Base Measurement System (BM-part)
and the Flatness-part.
The BM-part calculates force per zone vector of measured variables read from all sensors in the
Measuring Roll. The measurement extends over the entire width of the Measuring Roll, independ-
ent of the actual strip position. The BM-part uses an array of digital signal processors to compute
signals from each row of the measuring zones simultaneously, accurately and in a predictable time.
The Flatness-part uses the BM-part force vector together with other strip and operating conditions
to output a force or a flatness vector. This output is available via several TCP/IP based communica-
tion protocols.
3BSE076743R0101 en Rev B 9
Flatness System
Measuring Roll BM-part Flatness Client Computer

TCP/IP part TCP/IP
Figure 2. The two main parts of the Flatness System
In general, the Measuring Roll-related compensations are computed in the BM-part, while the
plant-related compensations and their models are performed in the processing part of the FC-part.
The interaction between users and the system is carried out by data servers. Thin-clients (standard
web browsers) are used as operator stations. All stations can work independently.
1.5.1 System Product Levels

The current release of the Flatness System has four different product levels (systems):
Force Measurement Measurement Flatness Flatness Error Flatness Control

Measuring Roll Calculation Calculation Calculation
Target Models Actuator Models

Strip edges + mechanical
Roll Plant Flatness actuators
position
Model Model - Control thermal
Model actuators
BM-part
FDMS
FMS
FEMS
FCS
Figure 3. Flatness Systems
The Force Distribution Measurement System (FDMS) uses the force output from the Base Measur-
ing part (BM-part) together with information on the position of the strip relative to the center of the
roll and relative to the roll measuring zones. It provides a distribution of force across the width of
the strip and compensates for partially covered zones, and for different zone widths on the roll.
• The FDMS performs the following operations:

— Measures the strip force with the measuring roll. Measured values BFU.
— Displays configuration data and values on the service HMI.
The Flatness Measurement System (FMS) uses the output from the FDMS to provide an absolute
value for flatness distribution across the width of the strip.
• The FMS performs the following operations:

— Recalculating the force to flatness.
— Displays configuration data and values on the HMI.
— Generates a compensated flatness value.
The Flatness Error Measurement System (FEMS) uses a target flatness model to compute a flat-
ness error across the strip width.
10 3BSE076743R0101 en Rev B
• The FEMS performs the following operations:

— Measures the strip force with the Measuring Roll.
— Displays configuration data and values on the HMI.
— Generates a compensated flatness value.
— Compensates measurement for misalignment and coiler deflection.
— Generates a Target Curve.
— Compensates the Target Curve for e.g coil crown build-up and coiler deflection.
— Subtracts the Measured Flatness from the Target Curve , to get the Flatness Error.
The Flatness Control System (FCS) uses actuator models (mechanical and thermal) to compute a
flatness correction signal to the actuators, based on the Flatness Error profile or reference signal.
Information
Each one of the systems above may have optional units such as loggers, special I/O, strip width
or position sensors.
1.5.2 Flatness Server Architecture (FSA)

A configured Flatness System provides the plant with all the strip flatness information that is
required. Such a configuration, adapted to the requirements of a specific plant, is called a Flatness
Server Architecture (FSA). A particular architecture optimizes the flatness measurement and control
of the existing mill actuators, the required strip quality and the production follow-up demands.
The Flatness System facilitates the integration and adaptation of the measurement and control
functions to external sensor and actuator units, to peer and superior plant control systems, as well
as to specialized statistical, logging, database and mathematical modeling tools. The FSA allows
integration of the Flatness System in plant-wide architectures such as ABB Industrial IT and a num-
ber of other established OEM-architectures.
Each delivery may be customized with its components and its options connected according to
customer needs. This is called an architecture configuration. All the configurations are implemented
by FSA-Objects which in their turn are connected to each other by an FSA-ADL script file
(ADL=Architecture Description Language). The software delivery is completely defined by its script
file.
The algorithms in FSA-Objects and the way FSA-Objects are connected require comprehensive
field experience, process knowledge and mathematical modeling gathered by ABB experts via the-
oretical research and a considerable number of implementations.
ABB may have several variants of FSA-Objects for the same function. For example there may be
several control algorithms for an FSA-Object intended for control. These FSA-Objects implement
both well-proven traditional algorithms that existed in earlier Flatness System versions, as well as
FSA-Objects implementing the latest results in modeling and process control. ABB continuously
develops, publishes or patents new applications via the design of new FSA-objects.
1.5.3 Software Description

The Flatness System applications are implemented as distinct software architecture configurations.
Each configuration forms a FSA. The architecture comprises all the software objects required for a
certain application, such as Cluster Mills or 4/6-High Mills.
3BSE076743R0101 en Rev B 11
The component objects as well as their connections are specified in a script file using an Architec-
ture Description Language(ADL). The FSA-Objects can have different levels and complex-
ity, e.g. utilities, communications, applications, measurement processing objects, mathematical
computation utilities, data storages, statistics, loggers, I/O drivers, flatness controllers.
The objects are stored in a library and a special architecture supervision unit, the FSA-Broker, acti-
vates and connects FSA-Objects according to the script. The FSA-Broker is a dynamic configura-
tion and supervision tool used for object-based products acting stand alone or in a system net-
work.
1.6 Measuring Roll
1. DTU
2. Bearing housing
3. Measuring Roll
4. Air purge unit
1.6.1 Mechanical Design

The Standard Measuring Roll has a steel core, with four axial grooves, in which the magnetoelastic
transducers are mounted. The roll is divided into 26 mm and/or 52 mm wide measuring zones,
each zone with four transducers placed at 90 degrees to each another as shown in Figure 4.
Transducer arrangement in Standard Measuring Roll page 12.
Figure 4. Transducer arrangement in Standard Measuring Roll
1. Transducers
2. Measurement zone
To ensure that each measurement zone is independent there are narrow gaps between the rings.
For a Standard Measuring Roll with a diameter of 313 mm the rings are 10 mm thick and are
dimensioned to permit regrind of the outside diameter of the Standard Measuring Roll without alter-
ing its properties.
12 3BSE076743R0101 en Rev B
1.6.1.1 Design and Electrical Operation of Transducers

The transducers are developed on the ABB Pressductor principle. Their low height is necessary to
ensure that the strength of the roll is not adversely affected. The construction of the transducer is
similar to that of a transformer. The core is made of a number of plates, stamped out from a metal
sheet, with suitable magnetic properties.
The magnetic coupling between the primary and the secondary windings will change under a
mechanical load. This change in output voltage is a measure of the applied force.
All transducers are connected in series on the primary side. On the secondary side, the four trans-
ducers that together form a measuring zone are connected in series. The connection of opposing
pairs register the changes in strip tension and also reduces to an insignificant level the effect of
temperature variations and centrifugal forces on the output signals.
1.6.1.2 Bearings and Seals

There are two types of bearing housing:
1. Bearing house for direct mounting on the Measuring Roll support.

2. Bearing cartridge for mounting in a bearing block.
The seals are of the labyrinth type, with anti-friction coating for high-temperature use as an option .
The seals can be used either with grease or oil lubrication, depending on the Measuring Roll
speed. The losses caused by friction in the seals are low, because there is no contact between the
surfaces in the seals.
Figure 5. Bearings with seals.
For a more detailed picture see 2.2.4.3 Mounting the Measuring Roll.
1. Labyrinth seals
CAUTION
The bearings must be installed carefully and accurately. Otherwise, the labyrinth seals might be
damaged and not work properly. For further information please refer to the Installation manual.
1.6.1.3 Air Purge

To improve the life time of cables and connections inside the Measuring Roll despite of high tem-
peratures, the system is normally equipped with an Air Purge system. The air pressure also pre-
vents cooling liquids and particles penetrating into the Measuring Roll.
3BSE076743R0101 en Rev B 13
The plant air system is connected via an air filter regulator (supplied by ABB) to a swivel on the
drive side of the Measuring Roll. Normally the air outflow is through the narrow gap between the
measuring zone rings. However, in some cases it can be necessary to have more air flow for cool-
ing. Four M6-bolts in the DTU side edge ring can then be removed to increase the air flow if strip
temperature exceeds 150°.
The air flow can also be adjusted for roll temperature by modifying the four M6-bolts with drilled
holes, contact ABB for advise.
CAUTION
Stressometer Roll and DTU require automatic air supply shut-off at mill fire warning.
3 4
2
5
6
Figure 6. Air Purge in Standard Measuring Roll
1. Air filter regulator

2. 4 M6-bolts to be removed if strip temperature >150°C
3. Air outlet
4. 5 m hose (included)
5. Fixed with hose clamps
6. Air purge unit
1.7 Digital Transmission Unit - DTU

The Digital Transmission Unit, DTU is used for power and signal transfer between the Measuring
Roll and the Measuring Electronics. The DTU connects to the Stressometer Cabinet with a system
of components, DTS- Digital Transmission System.
The DTS includes DTU, part of cabinet, wiring and air pressure/cooling system. It performs electri-
cal power and signal transformation/transmission as well as presentation, information and fault
tracing.
The DTU transfers power and measuring signals contact free to and from the Stressometer Roll.
This technique provides good signal quality, reliability and low maintenance cost.
There are two types of DTU.
14 3BSE076743R0101 en Rev B
• PFSA107-Z42 1-42 measuring zones, blue washer at the 100-pin connector.

• PFSA107-Z64 43 to 64 measuring zones, black washer at the 100-pin connector.
The exterior of the two are the same, except for the colour of the washer at the 100-pin connector.
A label plate is positioned on the DTU, it states:
• Type
• Part No
• Serial No
DTU Technical Data
Degree of protection (DTU cover) IP65
Number of measurement signals transmitted Up to 64

in parallel.
Operation temperature (ambient) +5 to + 70 deg C.
Storage temperature -25 to + 70 deg C.
Operation speed Up to 2400 rpm
Bump test 60068-2 10g
Vibration tolerance (recommended) < 2 mm/s at 10 to 200 Hz
Type of bearing Sealed hybrid deep groove
1.7.1 Digital Transmission Unit

The DTU structure consists of one stationary and one rotary part. The structural parts are built by
aluminium alloy. The two parts are built with high precision to provide the small air gaps necessary
for contact free power and signal transmission.
On the shaft flange end is the rotary transformer, one part in the stator housing and the other in the
rotor. The transformer supply the excitation current to the Stressometer Roll. The other side of the
DTU holds the capacitive link where measuring signals return from the roll.
Cooling air pass through the surfaces and enables cooling for the electronics inside the rotor.
3BSE076743R0101 en Rev B 15
Figure 7. Digital Transmission Unit
1.7.2 Pulse Encoder

The Pulse Encoder determines the angle position of the roll, counts the revolutions and detects the
rotation direction of the measuring roll. The Pulse Encoder is placed on the DTU stator and is con-
nected to the DTU shaft. The synchronization pulse is factory set and should not be adjusted. Each
channel is complementary, i.e. there are two output signals from each channel which means:
• A total of 3 signals and one excitation on 1024 pulse channels.

— Incr
— Incr 90
— Sync
• A balanced RS422 signal
The Pulse Encoder is connected to the Power and Media Converter Unit PFSA185 inside the DTU
Cover. The PFSA185 supplies the Pulse encoder with power. Measuring signals go through the
PFSA185 where they are converted to optical signals. The signals go in fiber optic cables through
the Connection Unit DTS PFSC230 to the Stressometer Cabinet.
To provide for customer connection, an auxiliary signal cable is connected from the PFSA185 to
the Connection Unit DTS PFSC230.
16 3BSE076743R0101 en Rev B
Figure 8. Pulse Encoder
1.8 DTU Air Purge

The DTU contains electronics and the clearance is tight between the moving parts. It is therefore
essential to have a protection for dirt and moisture ingress. The electronics also require cooling
for safe operation. An Air Purge system is therefore fitted to the DTU and the Power and Media
Converter Unit PFSA185.
The cooling system requires clean air without lubrication oil. If only lubricated air is available, addi-
tional filters are needed before the Filter Regulator unit.
Air enters the Air Purge Filter regulator unit which adjusts the air pressure and filters the air. The air
is connected to the DTU at the T-coupling in the bottom of the lower DTU Cover. The T-coupling
divides the air into two hoses.
One hose is connected to the top of the Power and Media Converter Unit PFSA185. The air is
released below the top plate and cools the mounting plate and as a result, the electronics inside.
The other hose is connected at the stator Cover (signal side) of the DTU. The air enters the DTU in
the gap between the Rotor and Protective tube. Air flows through the DTU and cools the stator
and rotor, and so the electronic boards. Cooling fins on the rotor covers improve the cooling. The
air flow is then released in the the other end of the stator housing. A part of the air flow escapes
through a hole in the lower part of the protection tube.
Air also enters the hollow DTU shaft and is released at holes in the shaft flange. The released
air escapes the DTU lower cover at the bottom drain holes and through the Stressometer shaft lab-
yrinth seal.
3BSE076743R0101 en Rev B 17
Figure 9. Air flow inside the DTU Cover
CAUTION
Stressometer Roll and DTU require automatic air supply shut-off at mill fire warning.
Pressurized air for cooling and purge
Return to outlet
The DTU Cover connection should be supplied with instrument air, or pressurized air as specified
below:
Particle size: ≤0.1 μm (acc. to ISO8573-1 class

1)
Oil contents: ≤0.01 ppm/weight air (acc. to

ISO8573-1 class 1)
Max consumption: 5 Ndm³/s (≈300 l/min)
Air Supply temperature +5 - +35 deg C.
18 3BSE076743R0101 en Rev B
Pressure at Air Purge Filter Regulator unit
Inlet pressure: Outlet pressure:
Max: The pressure at DTU Cover connection depends

1,6 MPa (16 bar) on the hose lenght. For the 25 m standard hose,
the pressure after the Filter Regulator Unit should
be at least 2 bar to obtain 0,5 bar at the DTU
Cover connection
Pressure at DTU Cover connection
Inlet pressure:
Min:
ambient ≤ 35°C 0.05 MPa (0,5 bar) or ambient
>35°C 0.1 MPa (1 bar)
Max:
0,3 MPa (3 bar)
1.9 Digital Transmission System - DTS
1.9.1 DTS Signals

The Digital Transmission System, DTS transfers power and measuring signals between the Stress-
ometer Cabinet and the Stressometer Roll.
The system consists of: Digital Transmission Unit PFSA107, (DTU), Power and Media Converter
Unit PFSA185 installed inside the DTU Cover, Connection Unit DTS PFSC230, Roll DC Sup-
ply Unit PFSA240 , Signal Control Unit PFSA287 and sections of the Stressometer Cabinet.
Included in the DTS is wiring of traditional copper leads, as well as fiber optic cables.
The type of power or measuring signal varies in different sections of the chain. Fiber optic
cables are used for measuring signals from the DTU cover to the Cabinet, to ensure that the high
quality measuring signal is fed without interference from the mill environment.
That is also the reason why the PFSA185 is placed inside the DTU Cover.
The DTU holds some electronic boards in the rotor. The parts that rotate are marked with a dashed
line.
3BSE076743R0101 en Rev B 19
Cabinet Measuring Roll
PFSA
7
240
3
PFSK DTU cover
151
(BMS)
DTU PFSA107 Stator
12 5
10
9
Encoder
4 8
Connection Unit DTU
DTS PFSC230 PFSA electronics
PFSA 185
11 13
287 6
Main 10 Rotor
Switch
1
Trans- EMI
former filter
2
Figure 10. DTS Signal chain
No Type Data From To
1 Mains power 98-518 V AC Mains Switch EMI Filter PFSA 145
2 Mains power 98-518 V AC EMI Filter PFSA 145 Transformer SLDF 181
3 Mains power 150 V AC Transformer SLDF 181 Roll DC Supply Unit

PFSA240
4 Power Supply 5-400 V DC Roll DC Supply Unit PFSA185 DC/AC converter

and 24V DC PFSA240
5 Transformer sup- AC 62,5 kHz PFSA185 DC/AC converter DTU Transformer, primary
ply side
6 Power transmis- AC,contact DTU Transformer, primary DTU Transformer, secon-

sion less,primary side dary side
7 Excitation cur- AC 1953 hz DTU electronics Measuring Roll

rent
8 Measuring signal Analog AC sig- Measuring Roll DTU electronics

nal
9 Signal transmis- Digital, contact Capacitive Link, rotor Capacitive Link, stator
sion free
10 Measured signal Digital Capacitive Link, stator Communication unit

PFSA185
11 Measured signal Optical Communication unit Signal Control Unit

PFSA185 PFSA287
12 Measured signal Analog Signal Control Unit PFSA287 BMS PFSK151
13 Encoder output Angle Encoder unit PFSA185 (BMS)
20 3BSE076743R0101 en Rev B
1.9.2 DTS Tool
1.9.2.1 Description
1.9.2.1.1 Menus and Functions

The DTS Tool makes it possible to fault trace the DTS system in case of disturbances or errors.
This document describes the tool and how it shall be used to fulfil the purposes below:
• To diagnose errors within the DTS.

• To discover circumstances (to high ambient temperature, cable break in installation etc.) that
can cause the DTS to require attention.
• To generate a dump file containing debug information that support engineers at ABB Force
Measurement can use to further identify the status of the DTS.
The DTS Tool is a PC-program that is used for supervision and fault tracing of one or two DTS.
DTU # 2
PFSA287 # 2
FC
Computer
DTS # 2
DTS
Tool
DTS # 1
DTU # 1
PFSA287 #1
Figure 11. DTS Tool connected to DTS
The DTS Tool is normally installed in the Stressometer Flatness computer, FC.
The physical connection between DTS Tool and the Signal Control Unit PFSA287 is Ethernet and
the communication protocol is built upon UDP/IP.
One PFSA287 shall not be simultaneously connected to more than one DTS Tool.
Menu Header
The Menu header contains five combined button/indications.
3BSE076743R0101 en Rev B 21
Figure 12. Menu header
1. Menu Selector:
Opens a dialog to select which menu that shall be shown. It also indicates which DTS the
current menu shows information about or from, and what the name is for that menu. This
picture displays the menu System Overview for the DTS with name DTSName1, see 1.9.2.3
HMI Settings for information about setting name for a DTS)
2. Events Button:
This button is a shortcut to the Event list menu.
3. System Status indicator:
The indicator displays the status of the system in text and colour and provides information
of communication between DTS and DTS Tool. The indicator is also a shortcut to the Sys-
tem Overview menu. See 1.9.2.5.1 Operations/System Overview for a more detailed
description of the indicator.
4. User selection: Opens a dialog to change user. It also shows the current user.
1.9.2.2 Start-up and Log-in
1.9.2.2.1 Starting the program

The DTS Tool is started from the start menu of the Stressometer or from a shortcut on the desk-
top.
After start up and logg in the as appropriate user (see 1.9.2.2.2 Logging in/Changing User) the
program shows the overview menu for the selected DTS, see 1.9.2.3 HMI Settings for information
on how to select start menu).
1.9.2.2.2 Logging in/Changing User

At start up the DTS Tool tries to log in with the same user level as it had when the program were
shut down last time. If that user level requires a password (see 1.9.2.3.2 Users tab) the login dialog
below is shown, otherwise the program will start automatically.
Figure 13. Login dialog
22 3BSE076743R0101 en Rev B
It is also possible to log in as another user by clicking the USER button (1) (see picture below) on
the upper right side of the menu and select login as another user. The current user is indicated as
seen on the indication (2).
Figure 14. Changing User
1.9.2.2.3 Menus for different users

The menus available for the different roles are shown in the menu navigation dialog in the figures
below.
Figure 15. Menu for Operator
Figure 16. Menu for system engineer
Reset of password:
3BSE076743R0101 en Rev B 23
In the configuration file ApplicationSettings.xml (located at D:\Stressometer\DTS Tool\Application-

Data or in the ProgramDataFolder/ABB Stressometer/DTS Tool 2.0/ (depending on installation type
and version) there are 2 settings for each user that can be manually edited. Password is stored in
plain text and can be changed by editing in the file (useful for example if the password is forgotten
or lost).
<Setting Key="ABB.Cga.Hmi.Framework.Services.Users.Operator.Password" Type="Sys-

tem.String" Description="User password" Value="" />
<Setting Key="ABB.Cga.Hmi.Framework.Services.Users.Operator.IsPasswordRequired"
Type="System.Boolean" Description="Decides if password is required for the user"
Value="False" />
<Setting Key="ABB.Cga.Hmi.Framework.Services.Users.System Engineer.Password" Type="Sys-
tem.String" Description="User password" Value="stress" />
<Setting Key="ABB.Cga.Hmi.Framework.Services.Users.System Engineer.IsPasswordRequired"
Type="System.Boolean" Description="Decides if password is required for the user" Value="True" />
CAUTION
Close the DTS Tool (by clicking on the cross in the upper right corner of the program window)
before editing the ApplicationSettings.xml file.
1.9.2.3 HMI Settings
1.9.2.3.1 Presentation tab

The DTS Tool provides the possibility to customize some presentation aspects. These aspects and
their default settings are shown in the figure below.
Figure 17. Dialog for customizing presentation
1. Use dark theme:

Clicking this check box makes the HMI change to a darker look suitable to darker surround-
ings. Default setting is not checked
2. Use fullscreen: This setting makes the DTS Tool window fill the entire screen.
3. Language: To select the presentation language from a list of available languages. Default lan-
guage is English.
24 3BSE076743R0101 en Rev B
4. Select unit profile: Changes the presentation unit set-up between SI and US units. For exam-
ple is the temperature presented in degrees Fahrenheit instead of Celsius when selecting the
US unit set-up.
5. Start-up display: The DTS Tool can at start-up show the System Overview menu for either
the first or the second DTS. The selection of which unit to show is done here. See also chap-
ter 1.9.2.5.3 Settings for information on how to set user-friendly names for a DTS.
6. Show DTSName1 and DTSName2: In cases where only one DTS exists it possible to “hide”
the menus for a DTS by clicking on the toggle buttons. If the button is “ON” then menus for
the DTS are shown, otherwise they are not.
7. DTS Name 1, DTS Name 2: User-friendly names that are used in the DTS Tool when pre-
senting information associated with a specific DTS. For example, a suitable name could be
Entry side or Exit side.
1.9.2.3.2 Users tab

There are two user levels, Operator (1) and System Engineer (2). See figure below.
Default settings for System Engineer are:
• Password required
• Password is at delivery set to "stress"
Default setting for Operator is:
• No password required
The Dialog for customizing DTS Tool password and user settings is shown in the figure
below.
Figure 18. Dialog for customizing password
1. Operator
2. System Engineer
3. User role
4. User role, current
5. Require password
3BSE076743R0101 en Rev B 25
6. Old password field

7. New password field
8. Change password button
1.9.2.4 Events
Status changes in faults and warnings that are presented in the Overview menu ( Figure 19. Sys-
tem Overview menu as seen by the operator page 27) are stored in an Event list. The purpose of
the Event list is to help fault tracing the DTS by showing how faults and warnings have performed
in the past. The Event list is stored in the Signal Control Unit PFSA287 and not in the DTS Tool. To
show the Event list, press the Event button on the Menu header or the Event button in the dialog
for operator, see Chapter 6.6 Fault Tracing the DTS for a detailed description of the Event list.
1.9.2.5 Menus for each DTS

Each DTU is represented by an identical set of menus, see Figure 15. Menu for Operator page
23 and Figure 16. Menu for system engineer page 23. To show menus for a specific DTS, click on
the DTS name in the left column (1) of the menu selection dialogue. This will display categories for
that DTS (2). The categories for the Service Engineer are: Operations, Service and Settings.
1.9.2.5.1 Operations/System Overview

Status of the different sections in the selected DTS subsystem is presented in the System Over-
view menu as shown in the picture below.
Changes in the alarms and warnings that are presented in the overview menu are stored in the
Event list.
26 3BSE076743R0101 en Rev B
Figure 19. System Overview menu as seen by the operator
Binary indicators show their status by using one or more colours as described in the table below.
Binary Indi- Status-Meaning

cator
Status: Normal
Grey Meaning: Requires no action, the system is OK or status can not be decided.
Warning
Meaning: The system is functional but requires an action at the next controlled
Orange stop in order to prevent an error to occur.
Alarm/Error
Red Meaning: Requires an immediate action to make the system functional again.
Measured value indicators show their status by using one or more colours as described in the table
below.
3BSE076743R0101 en Rev B 27
Value Indicator Status- Meaning
Status: Normal
Meaning: Requires no action, the system is OK or status can not be decided.
Warning
Meaning: The system is functional but requires an action at the next control-
led stop in order to prevent an error to occur.
Alarm/Error
Meaning: Requires an immediate action to make the system functional again.
See 6.6 Fault Tracing the DTS for a detailed description on how to use the overview menu during
fault tracing.
1.9.2.5.2 Service/Maintenance
Information about the Maintenance menu is found in 3.4.4 Maintenance using DTS Tool .
1.9.2.5.3 Settings
1.9.2.5.3.1 IP address tab

At installation of a Signal Control Unit PFSA287, It is necessary to enter communication settings.
The IP address is stored in the PFSA287. These settings are shown in the figure below.
Figure 20. IP Address tab in Settings menu
1. System Status indicator
DTS connection
28 3BSE076743R0101 en Rev B
2. PFSA287 IP Address field

3. Communication toggle button
IP address changing
4. New address combo box

5. Change button
6. Save in flash
IP address scanning
7. Available PFSA287s combo box
The communication settings are:

- IP Address (2)
The IP address of the PFSA287 in the DTS.
- Communication.
The Communication toggle button (3) can be either ON or OFF. When in ON state the data com-
munication service in DTS Tool is running and tries to establish contact with the PFSA287. In the
OFF state no communication takes place at all. If communication is successfully established- OK is
indicated in the System status indicator (1).
CAUTION
The Communication toggle button preserves its state between restarts of the DTS Tool program.
It shall normally be in the ON state.
Changing and scanning of IP Addresses.
In some cases there could be more than one DTS/Roll in a mill (entry/exit for example). These DTS
must have different IP addresses. it is possible to change IP address of a connected PFSA287 and
also to scan the local network for PFSA287 units with unknown addresses.
All PFSA287 shall as a standard have an IP address in the range 10.71.7.1 – 10.71.7.9.
If the standard IP address range does not fulfil requirements from the customer, it is possible to
add custom IP addresses by adding a file called CustomIpAddresses.txt in the application data
folder (D:\Stressometer\DTS Tool\ApplicationData\), but that shall be avoided as far as possible.
An example of how such a file can look like is shown in figure below.
Figure 21. Customizing the range of IP addresses
3BSE076743R0101 en Rev B 29
Extending the IP addresses as described above means that it is possible to set an IP address
within the extended range and also that a PFSA287 that has an address in the extended range will
be discovered during a scanning for available PFSA287s.
Scanning for avalible PFSA287s:

In order to find the IP address of a PFSA287, connect the PFSA287 to the FC and press the
Combo box as shown below.
A list of available PFSA287s shows up in the ComboBox.
Changing IP address for a PFSA287:

If the system has two PFSA287s- disconnect the PFSA287 which IP-address is not to be
changed.
1. Make sure that System status indicator (1) indicates OK. See Figure 20. IP Address tab in
Settings menu page 28.
2. Enter the IP address of the PFS A287 that shall receive a new IP address in the DTS CON-
NECTION: PFSA287 IP Address field (2) (if the address is unknown, scan for available
PFSA287s as described above)
3. Select a new IP address in the New Address Combo box (4) and press the Change button
(5). The address has now been changed (and System Status indictor (1) will indicate NO
CONNECTION within 10 seconds).
4. Turn communication OFF (3).
5. Enter the new address in the DTS CONNECTION: IP Address field (4).
6. Turn communication ON (3)
7. When communication has been established, press the “Save in flash button” (6) so the new
IP address becomes permanently stored in the flash memory.
8. The new address has now been successfully set.
1.9.2.5.3.2 About tab

The about tab shows software versions and the license condition.
Figure 22. About tab in Settings menu
About
30 3BSE076743R0101 en Rev B
1. License
Software versions
2. DTS Tool field

3. PFSA287 Firmware field
4. PFSA185 Firmware field
By pressing the license button (1) the dialog below shows version, copyright and license condi-
tions.
Figure 23. License and copyright conditions
1.9.3 DTS main equipment
1.9.3.1 Roll DC Supply Unit PFSA240

The Roll DC Supply Unit PFSA 240 is placed on top shelf in the Stressometer cabinet. It is a box
construction with ventilation grid at the bottom and top, to provide cooling for generated heat. The
PFSA240 converts the mills main power 50 or 60 Hz to DC. It has functions such as:
• Adjusting the voltage to the specific Stressometer Roll requirement.

• Reducing ripple voltage.
• Pulse-widht modulation and filtering
• Status monitoring
• Start sequence control
• Generation of internal supply and reference power
For more information about status indications see 6.4 BM-part.
3BSE076743R0101 en Rev B 31
X1 PFSA240
DC OUT
+
! 0-400 V
Max 3,2A
-
Danger !
Disconnect supply and leave
for 10 minutes before working
on this equipment
1
2 POWER
DC OUTPUT
Roll Excitation Unit WARNING
ALARM
X2
MAINS
3
100 -240 V X3
45 -65 Hz L1 CONTROL
1300 W L2/N
Figure 24. Roll DC Supply Unit PFSA240
1. X1-DC Out
2. Status indicators
3. X2- Mains power
4. X3-Control
1.9.3.2 Connection Unit DTS PFSC230

The Connetion unit DTS PFSC230 is used as a connection point for the copper and fiber optic
cables between the Stressometer Cabinet and the DTU Cover. The Connection unit makes it easier
to replace cables close to the DTU, if needed.
For information of cables to and from the PFSC230 see 2.3.4.4 Measuring Roll Cables. For instruc-
tions how to replace cables between the PFSC230 and the DTU Cover, see 4.5.7 Removal of
cables between DTU and Connection Unit DTS.
Figure 25. Connection Unit DTS PFSC230
32 3BSE076743R0101 en Rev B
1.9.3.3 DTU Cover

The DTU cover is made as sections, upper and lower. It is made of 3 mm sheets with thicker mate-
rial at the sealing surfaces and the bearing house flange.
Two dowel pins in the lower cover connects to the upper and the halves are fastened to each other
with a set of screws. A seal between the covers prevents fluid and dirt to enter, and air pressure to
escape the cover.
The lower cover holds two horizontally mounted mounting brackets for the Power and Media Con-
verter unit PFSA185. At front is the bracket for the DTU vibration damper. It also acts as a rotation
stop for the DTU.
The bottom slopes 1º towards the rear, this leads any fluids that enter the cover toward the two
drain holes.
Forward of the drain holes are three connection holes. One for a 2 inch standard adapter protective
hose for the electric cables, one for a ½ inch air coupling for the Air purge and one for an additional
air coupling.
To assist splitting the cover, there are two extra threaded blind holes in the front of the lower cover.
Two mounting screws can be inserted from below and be used to force the covers apart, as the
upper cover do not have holes at this position.
5
1
6
3
10
11
12
Figure 26. DTU Cover
1. Rotation stop and bracket for vibration damper

2. Upper Cover dowel pin (in lower cover)
3. Blind hole for separating covers
4. Upper Cover
5. Screw
6. Seal
7. Strain relief connector
8. Lower Cover
9. Bracket for PFSA185
3BSE076743R0101 en Rev B 33
10. Air Purge T-coupling

11. Drain hole
12. Protection hose connection
1.9.3.4 Power and Media Converter Unit PFSA185

The Power and Media Converter Unit PFSA185 is placed inside the DTU Cover. Roll excita-
tion power is in the unit converted from DC to AC and measuring signals are converted from digital
to optical.
The unit is placed on the two brackets close to the DTU to avoid electrical disturbance of measur-
ing signals. Cables to the DTU and Connection Unit DTS/Stressometer Cabinet connect to
the upper side.
Attached to the unit is a top plate that is mounted to the unit with a slot. The top plate a has cou-
pling that connects to Air Purge.
1
2
3
4
5
8
9
Figure 27. Power and Media Converter Unit PFSA185
1. X4- Roll excitation power to DTU

2. Air Purge connection
3. X1- Measuring signals from DTU
4. X5- Pulse Encoder to/from DTU
5. X3- Roll DC power from Cabinet
6. X7- Low voltage and status signals to Cabinet
7. X2- Pulse Encoder, auxiliary cable
8. X10- Measuring signals, optical
1.9.3.5 Signal Contol Unit PFSA287

The Signal Control Unit PFSA287 is the interface between signals that come from the DTU capaci-
tive link and go to the processing system BMS. The PFSA287 checks the signals for transmission
errors, transforms them from digital to analog and distributes them to the BMS system. The unit is
placed on the right side in the Stressometer Cabinet.
34 3BSE076743R0101 en Rev B
1
2 3
4 5 6 7 8 9 10
Figure 28. Signal Control Unit PFSA287
1. BMS, Force signals- Analog output

2. Distributed I/O
3. Pulse Encoder to BMS
4. X3- Control PFSA240
5. X6- Ethernet Communication
6. X1- Optical transmission
7. X2- Optical transmission
8. X7- Carrier
9. X5- Digital I/O
10. X4- Power 24V
3BSE076743R0101 en Rev B 35
1.10 Flatness System Cabinet
3 11
12
5
13
6
7 14
15
8
10
Figure 29. Flatness System cabinet
1. Roll DC Supply Unit PFSA240, Roll A

2. Fan unit
3. BM-part (Base Measurement part)
4. Keyboard and monitor
5. Flatness Computer FC
6. LAN swith and fiber optic transceiver
7. I/O
8. Main switch S1
9. Mains filter
10. Mains transformer
11. Signal Control Unit PFSA287. Roll B
12. Signal Control Unit PFSA287, Roll A
13. Connection box, fiber optic customer connection
14. Connection box, fiber optic to DTU and PFSA287
15. Terminal for low voltage/Status
36 3BSE076743R0101 en Rev B
For further information about these units please refer to the delivery documentation.
3BSE076743R0101 en Rev B 37
2 Installation
2 Installation
2.1 Introduction
2.1.1 General
This manual describes the installation of the Stressometer system. The system includes:
a. Base Measurement System (BM-part) including:

• Measuring Roll with bearings
• Digital Transmission Unit (DTU)
• Air regulators and filters
• Electronics in the Flatness System cabinet
• Cables for system-internal connections
b. Flatness Computer (Flatness-part) in the Flatness System cabinet
2.1.2 Safety Instructions

It is important that the following instructions are followed when operating the system in order to
minimize the risk of personnel injury and equipment damage. Any local statutory regulations, if
stricter than the following, are to take precedence.
2.1.2.1 Personal Safety

The following rules must be observed:
• Use only approved hoisting equipment when lifting cabinets.

• A protective ground wire (≥ 50 mm² copper lead) must be connected before applying the
mains voltage to the cabinet.
• Work with great care when the mains voltage is applied to the system. The voltage in the
cabinet can cause injury and may be lethal.
• Only authorized service personnel are allowed access to the cabinet.
• Personnel working with service and maintenance must know how to switch off the mains
power supply to the Flatness System equipment.
• Process technicians must be present when testing and operating the process objects and all
service personnel must be informed when performing test runs.
• Never change “System mode” without knowing what happens in the system with a mode
change.
• When subsections of the process have been checked and a test run has been performed,
interlocking chains and similar must be checked by an authorized person.
38 3BSE076743R0101 en Rev B
2 Installation
DANGER
Never look directly at the end of an installed fiber optic cable or connector because a laser
source emitting invisible light may be present. Exposure can cause permanent eye damage.
ELECTRICAL
Before any work on the DTU, PFSA185 or PFSA240, the mains power must have been off for 10
minutes.
2.1.2.2 Equipment Safety

• Electronic devices are sensitive to Electro Static Discharge (ESD) effect. A warning label is
attached to the system to draw attention to possible damage by ESD, see Figure 30. Warn-
ing label for ESD page 39. To avoid causing accidental damage while handling circuit
boards, it is recommended to wear a wrist strap earthed to the chassis. The wrist strap must
have a built-in protective resistor. Antistatic bags must be used to store and transport the
circuit boards.
• Avoid ESD by grounding both yourself and the tools before handling circuit boards and other
parts of the equipment.
• Never press the system Reset or Abort buttons without knowing the consequences of an ini-
tialization in the system.
• Use the grounded wrist strap installed in the cabinet when handling parts of the system.
• Handle the circuit boards carefully, particularly those containing MOS-components that can
be damaged by static electricity discharges. Note the warning label on the circuit boards.
• Always store circuit boards in envelopes of conductive plastic when not installed in the Flat-
ness System cabinet.
• Use, as far as possible, the grounded wrist strap when handling boards which are not stored
in envelopes of conductive plastic. This gives optimum protection against static electricity
discharges.
• Always switch off the voltage before extracting a board that cannot be replaced under
power. Wait for the capacitors to discharge.
• Before electrical welding is performed near the Flatness System, switch off the mains supply
voltage to the system and pull out all boards at least 20 mm.
• To ensure good electrical grounding of the board fronts tighten the screws at the top and
bottom of the front plate.
Figure 30. Warning label for ESD
2.1.3 General Installation Rules

Modern electronic control systems may be sensitive to different types of interference. The Stress-
ometer is a modular system that can be put together in different ways. Therefore it is important
to select the correct units and connect them in the correct way to reduce the sensitivity to interfer-
ence.
3BSE076743R0101 en Rev B 39
2 Installation
This manual is written to make the system configuration easier and for satisfying the legal require-
ments in EMC Directive 2014/30/EU.
The signal processing electronics in the system is normally grounded to the chassis and all interfer-
ence suppression of external signals refers to the chassis. For galvanic isolated units a capacitive
coupling to ground is normally provided.
Apply the following rules:
• For interference-free operation it is important that the installation is made in such a way that
good grounding arrangements is maintained for interference suppression.
• If a Stressometer system, where all hardware is approved, is sensitive to interference this
may be due to incorrect grounding or routing of the wiring. In this case the installation must
be checked, preferably by means of an interference test before other measurements are
taken.
• The potential of the installation ground must be stable and well defined, even in the event of
ground faults in low- and high-voltage equipment or lightning strikes.
• All components must be connected directly to the chassis with short wires. The best techni-
que to ensure a good electrical contact is to use thread cutting screws or standard threaded
screws. Special measures must be taken in cabinets other than ABB MNS series.
• Parts of cabinets or enclosures that are used as a reference ground (chassis) must have
good and permanent electrical bonding. Painted or anodized parts must also have good
ground bonding. This can be achieved by scraping the surfaces or using thread-cutting
screws. In aluminium the only way to achieve bonding is with thread-cutting screws.
• The grounding system connected to the Flatness System cabinet must be connected to the
mill stand ground system.
2.1.4 References
The following additional information is also available:
For the Measuring Roll:
• Assembly drawings (in Binder B2)

• Dimension drawings (in Binder B2)
• Circuit diagrams (in Binder B2)
• Alignment procedure for the couplings (in Binder B2)
• Instructions packed together with the couplings
• Delivery certificate
For the Flatness System cabinet:
• Installation drawings (in Binder B2)

• Circuit diagrams (in Binder B2)
• Interconnection tables (in Binder B2)
• Connection documents for site preparation and installation of electrical equipment (in Binder
B2)
• Environmental specifications
• Description of the LAN switch
• Technical Reference Manual
Optional equipment is described in separate manuals, for example:
• ABB drive system

• Cooling system
40 3BSE076743R0101 en Rev B
2 Installation
2.2 Installation of Measuring Roll
2.2.1 Delivery Check

At delivery check the following:
• Check the equipment delivery against ordering documents, shipping lists and other relevant
transportation documents, to ensure that everything has arrived at the installation site.
• Check for transportation damages, broken seals, etc. and report as soon as possible any
possible damage and/or missing parts, both to the transportation company and ABB, to
avoid delays in the commissioning.
• If the equipment will not be installed at once, follow the directions for storage given in the
following chapter.
2.2.2 Storage
Normally the Measuring Roll and accessories are packed in several crates. The Measuring Roll is
treated to prevent corrosion and the cylindrical surface is supported inside the crate.
If the Measuring Roll is not installed immediately, store it under dry and dust-free conditions at
a steady temperature.
2.2.3 Unpacking
When unpacking it is very important to take the following precautions:
The Measuring Roll must not be lifted from the crate by the lifting eyes of the bearing housings.
OK! Not OK!
Figure 31. Lifting the Measuring Roll.
Take extreme care when unpacking the Measuring Roll to ensure that the precision ground roll sur-
face is not damaged.
• Do not lift the Measuring Roll with a magnetic crane. If a magnetic device is applied to the
Measuring Roll surface, the Measuring Roll might be damaged.
• Keep the corrosion protection and the paper around the roll surface intact for as long as
possible when installing the Measuring Roll. The corrosion protection can be removed with
Kerosene.
3BSE076743R0101 en Rev B 41
2 Installation
Tip
The Measuring Roll is normally shipped in a wooden crate. After installation keep the crate for
future use.
2.2.4 Mechanical Installation
2.2.4.1 Mounting the Measuring Roll Support

The Measuring Roll is normally located between the roll gap and the coiler. See Figure 32. Location
of Measuring Roll in Rolling Mill. page 42
B
2
B 3 3
2
A A
Figure 32. Location of Measuring Roll in Rolling Mill.
1. Coiler
2. Measuring Roll
3. Work Roll (Roll gap)
The Measuring Roll is positioned so that the wrap angle never exceeds the limits stated in the
Delivery certificate. Distance B (Measuring Roll to coiler) must be larger than the maximum strip
width. Other distances may only be used if indicated on an ABB drawing or after consultation with
ABB.
The center position of the Measuring Roll surface must have a tolerance of ± 1 mm in relationship
to the mill center, unless otherwise specified, see Figure 33. Center position on the Measuring Roll
page 42. Consider the temperature expansion coefficient for the Measuring Roll.
The center line of the Rolling-mill can be fixed by the work-roll position or in the mill-stand settled
middle position.
Measuring Roll
Work Roll
+
_1 mm
Figure 33. Center position on the Measuring Roll
42 3BSE076743R0101 en Rev B
2 Installation
Information
If the design of the Measuring Roll support is not included in ABB’s scope of supply, the following
rules apply:
• The roll support shall be designed to deflect less than 0.1 mm in any direction when the
maximum radial force is applied to the Measuring Roll.
• The roll support shall be designed rigid enough to prevent excessive vibrations.
2.2.4.2 Roll Mounting Surface requirements
0,07 0,1/1000 mm Horizontal line

0,4/1000 mm Roll axial direction
Ra 3,2
Figure 34. Mounting surfaces requirement for Stressometer Roll
Tolerances are for both sides. The size of the area for the mounting surface depends on the size of
bearing block, bearing house and/or support plates.
2.2.4.3 Mounting the Measuring Roll

ABB AB drawings required:
Assembly drawings.
Dimension print.
These drawings are in Binder B of the delivered documentation.
The Measuring Roll (without the DTU and DTU cover) is delivered with bearings mounted.
A Measuring Roll equipped with standard bearing housings can be mounted directly in its position
in the rolling mill, while a Measuring Roll with cartridge bearings requires that special bearing
blocks are installed before the Measuring Roll is lifted into position.
Ensure that the bearing centre distance is in accordance with the roll dimension drawing. A devia-
tion of ± 1 mm is allowed.
When the Measuring Roll has been aligned (Dowel pins positioning is preferred) as described
in 2.2.4.4 Horizontal Alignment and in 2.2.4.5 Vertical Alignment, it must be bolted tightly with cor-
rect torque.
Ensure that the labyrinth seals are not in contact with each other. See the customer assembly
drawing 3BSXxxxxxxD281.
The labyrinth seals of the bearing house or cartridge must have a space (x) of 0.4-0.9 mm, see
Figure 35. Alignment of bearing houses page 44. The space can, for example, be checked by a
feeler gauge.
Labyrinth sealing with anti-friction coating (oil-circulation and speed ≥ 1700 rpm) must have a
space (X) of 0.2 - 0.6 mm. At measuring with e.g. a feeler gauge no damage on the anti-fric-
tion coated labyrinths.
3BSE076743R0101 en Rev B 43
2 Installation
Proceed as follows:
• Check the clearance of the labyrinth seals.

• Realign the bearing housings if there is any interference.
• Run the roll for approximately 30 minutes. Increase the speed in steps during this time, up to
the nominal operation speed.
• Check the labyrinth seals again for roll torque.
• Fix the bearing housings with dowel pins and torque the bolts to correct torque.
CAUTION
The bearings must be installed carefully and accurately. Otherwise, the labyrinth seals might be
damaged and will not work properly. Remember to protect the shaft end surface during
mounting.
Figure 35. Alignment of bearing houses
2.2.4.4 Horizontal Alignment
L1
L2
Work Roll
Measuring Roll
Figure 36. Horizontal alignment of Measuring Roll
44 3BSE076743R0101 en Rev B
2 Installation
Ensure that the Measuring Roll is parallel to the rolling mill with an accuracy of ΔL = L1 - L2.
A = Maximum possible measuring width on the Measuring Roll
A ≥ 1400 = → ΔL ≤ 0.1 mm
600 < A < 1400 = → ΔL = 0.007% of A ( A = 1000 → ΔL = 0,07 mm )
A ≤ 600 = → ΔL ≤ 0.04 mm
Fix the work roll to its rolling position. It may be necessary to wedge the work roll chocks against
the stand which they rest on during rolling. If the clearance between the work roll chocks and pads
is less than 0.1 mm, it is not necessary to use wedging.
Tip
If there are reference surfaces on the mill posts use these or use the work roll as reference.
2.2.4.5 Vertical Alignment
Figure 37. Vertical alignment of Measuring Roll..
A ≥ 1400 = → ΔV ≤ 0.1 mm
600 < A < 1400 = → ΔV = 0.007% of A ( A = 1000 → ΔV = 0,07 mm )
A ≤ 600 = → ΔV ≤ 0.04 mm
If there are reference surfaces (normally included) on the mill stand, use these to check that the
stand is vertical. If no reference surfaces are available, set the Measuring Roll in relation to the hori-
zontal line.
Use shim plates to correct vertical alignment errors. The shim plates shall be installed between the
upper pressure plate and the bearing housing. Use as thick (and few) shim plates as possible. The
shim plate can be made from steel, stainless steel or brass. It is recommended to use a large shim
plate that covers the entire base of the Measuring Roll bearing housing. This is required if shimming
is done when having a Tensiometer load cell under the bearing housing. It is recommended to have
the shim plates prefabricated to reduce the installation time.
Use as thick shim plates as possible. Grind as necessary.

Install shim plates between between pressure/adapter plates and bearing housing.
3BSE076743R0101 en Rev B 45
2 Installation
Tip
A suitable tool for the alignment of the Measuring Roll and other deflector rolls is a levelling tool
with 0.02 mm/m between the scale marks.
2.2.4.6 Alignment of Measuring Roll versus Mandrel
Picture B Picture A
E E
D
Figure 38. Alignment of measuring roll versus mandrel
1. Measuring roll
2. Mandrel
Picture A:
ΔD max = 0.1 mm across the entire width A
Picture B:
ΔE max = 0.1 mm across the entire width A measured on Mandrel segment
The Mandrel normally adopts a completely different position when it is unloaded (without support).
It is therefore very difficult to measure the position of the Mandrel. The Mandrel support provides
both rigidity and the possibility of making adjustments.
A Mandrel that is misaligned during rolling will result in a skewed flatness presentation. The magni-
tude of the skewed flatness depends on the magnitude of the alignment fault.
The same limitations apply to the shape of sleeves.
When the Mandrel is loaded with tension from zero to maximum coil diameter the recommenda-
tion is that the parallel centre movement is < 2 mm under load and ΔD and ΔE are still within the
tolerances in Figure 38. Alignment of measuring roll versus mandrel page 46.
46 3BSE076743R0101 en Rev B
2 Installation
1 < 2 mm
2
Figure 39. Horizontal alignment
1. Measuring roll
2. Mandrel
3 4 5
1 6
B
C
Figure 40. Alignment of Measuring Roll versus Mandrel
1. Work roll
2. Rolling direction
3. Rolling gap
4. Deflector roll 1 before Measuring roll
5. Measuring roll
6. Deflector roll 2 after Measuring roll
7. Mandrel
The Deflector roll must be fixed and rigidly mounted. The distances B and C must be within 50% of
the maximum possible measuring width on the Measuring Roll.
A = maximum possible measuring width on the Measuring Roll
A ≥ 1400 = → ΔB(ΔC) ≤ 0.050 mm
A < 1400 = → ΔB(ΔC) ≤ 0.0035% of A ( A=1000 → ΔB(ΔC)= 0,035 mm )
A ≤ 600 = → ΔB(ΔC) ≤ 0.020 mm
Vertical alignment of Deflector Roll
Use the Measuring Roll as a reference. The highest end on the Measuring Roll must be the highest
also on the Deflector Roll.
A = maximum possible measuring width on the Measuring Roll

A ≥ 1400 = → ΔV Deflector roll ≤ 0.042 mm
A < 1400 = → ΔV Deflector roll ≤ 0.003% of A ( A=1000 → ΔV = 0,03 mm )
A ≤ 600 = → ΔV Deflector roll ≤ 0.018 mm
3BSE076743R0101 en Rev B 47
2 Installation
2.2.4.6.1 Recommended Installation Arrangement

Deflector Rolls between the stand and the Measuring Roll and/or the Mandrel should be aligned in
the same way as the Measuring Roll. The alignment can be performed in relation to the Measuring
Roll. It is important to take into consideration the compounding effect of several tolerances.
A simple rule is when the distance between the deflector roll and the Measuring Roll decreases,
the tolerance will also decrease.
• Where there are movable Deflector Rolls (for example through hydraulic cylinders) next to the
Measuring Roll, mechanical stops must be arranged for them. This mechanical stop must be
used by the Deflector Roll during operation or otherwise it will not be possible to align them
correctly.
• The minimum hold down force is 10 kN on each side.
• If the Deflector Rolls are considered not rigid enough, consult ABB.
For an alternative method of alignment using piano wire, contact ABB for document: Alignment of
Stressometer roll 3BSE068912.
2.2.4.7 Tighten the Measurement Roll

• When the Measuring Roll has been aligned according to above, bolt it tightly.
• Use lubricated bolts according to ISO 898/1 (the same grease type can be used for the
bearing lubrication, see 3.3.5 Bearing Lubrication).
Table 1 Tightening torque for mounting bolts on bearing equipment
Dimension Tightening torque
M12 136 Nm, property class 12.9
The recommended active length of the bolt thread lead is min 1.5 times the outer thread diameter.
2.2.4.8 Measuring Roll Drive

When a constant strip speed is established in the mill, the Measuring Roll is normally driven by the
friction force between the strip and the roll surface. If the strip slides over the Measuring Roll (which
may cause scratches on the strip surface) it needs to be driven, particularly during acceleration and
deceleration. The roll also needs to be driven during the verification/calibration check.
The need for a drive is determined at the time of ordering, and is stated in the Delivery Certificate.
This also indicates whether ABB is supplying the drive system. A suitable drive system consists of
an AC motor together with a standard AC motor drive system.
48 3BSE076743R0101 en Rev B
2 Installation
In addition to the necessary basic drive control system the control equipment for the drive must
include the following function groups:
• Loss compensation. The drive motor needs extra current to compensate for bearing and
friction losses.
• Compensation for moment of inertia (acceleration boost). The drive motor requires extra cur-
rent on acceleration. When the compensation is correctly set, the drive follows each speed
change without slipping.
• Speed control with soft torque. Due to friction the roll follows the strip speed at constant
rotation speed. A dead band in the speed control system prevents slipping between roll and
strip even if the speed reference is not precisely set.
2.2.4.9 Couplings
In all applications with strip tension loadcells is the minimum requirement a dual coupling, and a
CVD coupling is strongly recommended.
In applications without strip tension (pillow block) loadcells, a single coupling can be used but is
not recommended. Contact ABB.
Also see the instructions packed together with any coupling.
Figure 41. Stressometer Measuring Roll Drive
1. Measuring roll
2. CVD Dual coupling
3. Motor
2.2.4.9.1 Coupling alignment procedure

Alignment of dual coupling shaft
• Constant velocity shaft (CVD-type) maximum α ≤ 10° /coupling (To be used as first choice).
recommended α = 1 - 5°.
• Universal joint coupling,
Recommended α = 1 - 5°.
• Double gear coupling with shaft maximum α ≤ 1.0° /coupling.
recommended α = 0.2 - 0.3°.
CAUTION
The thermal expansion affects must be addressed in coupling selection and mounting of the drive
shaft.
Alignment of single coupling unit
Concentric alignment (also called offset alignment or parallel offset) is the relationship between the
shaft axes in terms of vertical and horizontal displacements of the axis of one shaft from the axis of
the other shaft.
3BSE076743R0101 en Rev B 49
2 Installation
X= Horizontal offset
Shaft ”A” Y= Vertical Offset
Shaft A= Motor shaft
Shaft B= Drive shaft
X
Shaft ”B”
End view
To determine relative angular shaft positions of driving and driven machines, measure at four points
the space between the shaft ends. Choose the largest (a) and smallest (b) dimensions.
Shaft ”A”
a
Y
α D
X
ft ”B” b
End view
Horizontal Offset 57.3 (a-b)

Vertical Offset α o=--------------
aft A =Motor shaft D
aft B =Drive shaft
CAUTION
The thermal expansion affects must be addressed in coupling selection and mounting of the drive
shaft.
CAUTION
Any stiff or single coupling must be approved by ABB.
(General requirements: offset < 0,05 mm. α < 0,5 °)
2.2.4.10 Drive Shaft with Air Purge System

The air purge system consists of an air regulator that is connected to the common plant air supply.
The air regulator supplies the Measuring Roll through an air swivel connection that is attached to
the drive shaft delivered with the Measuring Roll. The hose from the air regulator is attached to the
swivel connector in such a way that it also acts as a rotational stop. See dimension drawing Binder
B2.
Air is used for two reasons:
a. To avoid cooling liquid and unwanted particles running through the steel ring slots into the
measuring transducers.
b. To act as a cooling media for strip temperature above 150ºC.
Prepare the Measuring Roll as follows:
50 3BSE076743R0101 en Rev B
2 Installation
• If strip temperature is above 150ºC, remove four M6 bolts attached to the edge ring on the
DTU side. This will increase the air flow through the Measuring Roll without affecting the
DTU. Four of the eight M6 bolts are normally already removed before delivery.
The air flow can be further adjusted for roll temperature by modifying the M6-bolts using dril-
led holes, contact ABB for advise.
• Check that the seal is mounted between the drive shaft and the Measuring Roll shaft end.
• It may not be possible to use air purging. Contact ABB to determine this.
• Check that the protection bolt, mounted in the centre hole of the shaft, has been removed.
• The air supply to air regulator must be dimensioned according to the following technical
data:
a. Minimum initial (before filter) air pressure: 0.2 MPa (2 bar)
b. Normal air flow at 0.4 bar (M6 on edge ring mounted): n × 0.35 Ndm³/s * (where n =
no. of measuring zones).
c. Maximum air flow at 1 bar (M6 on edge ring dismounted): n × 0.55+11 Ndm³/s *
(where n = no. of measuring zones).
d. Particle size, maximum: 5 μm (ISO 8573-1 class 3)
e. Oil contents, maximum: 1.0 ppm/weight air (ISO 8573-1 class 3) (1.0 mg/Nm³ air)
f. Rel. humidity, maximum: 50% at 20ºC *) 1Ndm³ = 1dm3 at 0ºC and 760 mmHg. The
air pressure inside the Measuring Roll shall not exceed 0.1 MPa (1 bar).
Information
In old pneumatic systems it may be necessary to install additional filters in front of the ABB filters.
2.2.4.11 Bearing and Lubrication

Two types of Measuring Roll bearings exist; bearing housing and cartridge.
1
2
1
3
3
9
3
8
6
5 7
4
3
Figure 42. Bearing housing and cartridge with bearing block
There are grease nipple inlets in the bearings to allow connection to the lubrication system.
3BSE076743R0101 en Rev B 51
2 Installation
1. Inlet: Bearing house (Qty 1, G 3/8")

Cartridge (Qty 2, G¼")
• Grease
• Oil circulation
• Oil-mist
• Oil-air (only permitted after contact with ABB)
2. Spare grease inlet (Qty 2, G ¼")

3. Vibration measurement nipple thread. Shock pulse or acceleration meter.
Bearing house (Qty 2, M8)
Cartridge (Qty 2, M8)
4. Outlet: (some can be used for temperature measuring Qty 4, G 3/4")
• Grease
• Oil-circulation (mostly total drain)
5. Outlet: (only to be used in special cases, Qty 2, G ¼")

6. Outlet: (for clean-out of lubrication, Qty 2, G 3/8")
7. Outlet: (for grease, oil circulation and oil-mist. Qty 2, G ¾")
Note: Bearing house and cartridge have for oil-mist only one outlet. The outlet has a G ¾"
plug with a Ø 7± 1 mm hole (pos 4 or pos 7).
8. Outlet: (spare for grease and oil-mist (Qty 2, G ½")
9. Access hole: (for temperature measuring, Qty 1, Hole Ø 6,5 G ¼")
Information
The nipple may be replaced by a supply pipe for automatic lubrication.
If the grease inlet is connected to the center of the bearing then the outlet may be positioned on
either side. If not, the inlet and outlet must be positioned on opposite sides. In cases where grease
lubrication is proposed, remove the plugs from the grease outlet.
When using oil-mist or oil-circulation lubrication, the connection should be to the middle of the
bearing housing and at the side on the cartridge. Both connections lubricate directly inside the
bearing.
Oil-circulation is normally used with total drain. A small quantity of oil can come out between the
seals at speeds > 800 rpm. At speeds ≥ 1700 rpm labyrinths must have anti-friction coating as an
extra seal. Labyrinths with anti-friction coating have other tolerances, see chapter 2.2.4.3 Mounting
the Measuring Roll. Oil-bath is not to recommended.
If a data plate with oil data is fixed on the bearing housing this indicates that the bearing is pre-
lubricated. Similarly a data plate with grease data indicates that the bearing housings or cartridge
bearings are charged with lubricating grease before delivery. See 3.3.5.4 Determine Lubricant for
correct quality.
Check that used grease is possible to mix with pre-lubricated grease (see data plate on the bearing
equipment).
Re-lubrication must be done when commissioning a new or repaired Measuring Roll.
Rotate Measuring Roll at low speed and lubricate 200g to each bearing house.
If the quantity of grease used for lubrication exceeds this amount then grease can leak into the
inside of the DTU Cover.
If grease lubrication is changed to oil lubrication or other grease type that is not mixable with pre-
lubricated, proceed as follows:
52 3BSE076743R0101 en Rev B
2 Installation
1. Remove the grease from the bearing housings.
• Remove the DTU and grease flange from the bearing house.
• Protect the 100-pin connector hole.
• Open the outlet and total drain (lower thread holes) see Figure 42. Bearing housing
and cartridge with bearing block page 51.
• Remove the lubrication nipple from cover.
• When using pressurized air, use clean air from the air-pressure system to blow out
most of the grease. When blowing rotate the Measuring Roll approx. 60 rpm.
2. Fill the bearing house with solvent, approximately 0.3 liter (for example hydraulic oil 15-20
cSt at 40ºC) and run the Measuring Roll for a few minutes at a moderate speed (200 rpm)
until most of the grease has been dissolved.
• Use clean pressurized air at the lubrication hole to remove the remaining grease/
solvent.
• While rotating the labyrinths small quantities of oil can leak. It may be necessary to
repeat this procedure 2-3 times.
3. Fill the bearing house with solvent approx. 0.7 liter (for example hydraulic oil 15 - 20 cSt at
40ºC) and run the Measuring Roll for a few minutes at a moderate speed (200 rpm) until
most of the grease has been dissolved. Drain the solvent completely.
4. It may be necessary to repeat this 2-3 times.
5. The bearing housing can now be connected to the lubrication system. See the instructions in
3.3.5 Bearing Lubrication, for oil grade and quantity.
6. Change the lubrication data plate.
7. To connect a temperature transmitter electrically, see the Circuit Diagram.
8. In some cases it may be necessary to measure the bearing temperature. If help is needed,
contact ABB.
2.3 Installation of Flatness System Cabinet
2.3.1 Introduction
The cabinets are delivered equipped from ABB.
2.3.2 Unpacking
The control cabinets are packed in a manner appropriate to the means of transport. When unpack-
ing it is important to take the following precautions:
• If the packaging is opened for a delivery check, it should be resealed if the cabinets are not
to be installed immediately.
• Avoid fixing labels on painted surfaces. If these remain in place too long, the surface can be
damaged.
• If the cabinet is not installed immediately upon delivery, it should be stored in a dry and dust-
free storage place (see the Environmental Specifications). The plastic wrapping should be left
in place to protect the cabinet.
3BSE076743R0101 en Rev B 53
2 Installation
• If a cabinet is equipped with a heating element, this should be activated as soon as possible
after the cabinet is unpacked to prevent corrosion.
• Handle the cabinets with care when loading or moving. A fork-lift truck is usually the most
suitable means of transportation.
• If the cabinets must be moved with a travelling crane:
1. Ensure that the cabinets are fitted with lifting eyes.
2. Fix the lifting slings with shackles to the lifting eyes.
3. Adjust the length of the slings so that the angle between the slings does not exceed
60 degrees.
Figure 43. Lifting a cabinet with a travelling crane.
2.3.3 Mechanical Installation
2.3.3.1 Check Free Space around the Cabinet

• There must be at least 150 mm of free space above the cabinet.
• If hinged frames or front doors of end cabinets are to be open fully without touching adjacent
walls, the distance from the hinge side of hinged frames must be at least 500 mm and at
least as big as the width of the cabinet (half the width if double door) as the door can be
opened 180 degrees.
• The free space in front of the cabinet should be equal to the width of the door plus aisle
width or min 1200 mm.
• The minimum permissible distance between the back of the cabinet and the wall and
between the end panels and the wall is 100 mm.
• The distance between the sides must be at least 40 mm. Stressometer mounted in a Flat-
ness System cabinet can be set up side by side with other cabinet types, but the side plates
must not be removed. Where several electronics cabinets of the same type, related to one
controller with I/O, are to be set up in the same row, however it is permissible to remove the
side plates between the cabinets.
2.3.3.2 Erect Cabinets

• The floor should be flat and suitable for a number of cabinets to be erected and bolted
together without any additional work. If the floor is not sufficiently flat, the cabinet frame base
may be skewed, making it difficult to open and close the doors.
• When being erected, cabinets may have to be be adjusted relative the floor by inserting
spacers etc. between the bottom cover and the ground.
• If a number of cabinets are to be bolted together, each cabinet must be adjusted before
mounting.
54 3BSE076743R0101 en Rev B
2 Installation
2.3.3.3 Bolt Cabinets to the Floor

• Cabinets should be bolted to the floor through the holes in the angle bracket.
• If the cabinet is fitted with a plinth, the plinth’s corner piece must be bolted firmly to the floor.
The hole of the corner piece is D=14 mm.
• Free-standing cabinets, and the first (left hand) in a row of cabinets, should be bolted to the
floor with four bolts, one at each corner. The other cabinets in the row should be fixed with
two bolts.
• When drilling into concrete, do not allow drilling dust to penetrate the equipment in the cabi-
nets.
2.3.3.4 Position and Connect External Cables

• The cabinets can be provided with cable attachment strips for routing external cables.
• The cable attachment strips have holes for securing cables with bunching straps. Bunching
strap attachments can be fastened with a 6 mm self-tapping screw.
• If the equipment cabinet is fitted with an anchor rail along the bottom of the side, then route
cables using cable holders.
• If a 120x60 mm cable duct is chosen, cables can be routed in this.
• If cable duct on the rear mounting plate is chosen, cable cores between different group lev-
els in the cabinet can be routed in this.
• All incoming cables must be screened.
Connection
• The cables should be stripped immediately before the level of the terminals of each group.
• Cable cores should be run as conveniently as possible from where they are stripped to the
connection point and be fixed to the cabinet frame with bunching straps if necessary.
• Vertical bar has M5 holes and horizontal earthing bars can be fitted with single-screw clamps
for up to 10 mm².
• Wires over 10 mm² should be fitted with cable shoes and connected under the clamps.
EMC connection
• The cables should be stripped at the EMC inlet so that the screen is uncovered.
• Secure the cables with bunching straps and the EMC seal is tightened.
• Route the cables to respective terminals. The cable screens should be connected to the ver-
tical earth bar or to the chassis. The stripped screen length must not exceed 50 mm.
1. EMC gasket
2. Cable screen
3BSE076743R0101 en Rev B 55
2 Installation
EMC connection Stripping
• The cable cores should be stripped depending on the terminal to which they are to be con-
nected.
— If the stripped length is too short, the cable insulation may become trapped under the
terminal clamp and cause a bad contact, or the stripped end will not be correctly fixed
to the terminal.
— If the stripped core length is too long, there is risk of shorting the adjacent cable core.
Cable cover plates
The enclosed torx key is intended for the cable cover plates.
2.3.3.5 Complete Mechanical Installation

Before the cabinet is connected to the power supply following steps must be taken:
1. Remove cut-off wire ends, waste cable sheaths, etc.

2. Clean off any grease or dirt.
3. Check that there are no tools or installation equipment left in the cabinet.
4. Vacuum clean the cabinet.
2.3.4 Electrical Installation
2.3.4.1 General Rules

• Maintenance in the cabinet is only allowed if the protective ESD wrist strap is used.
• To reduce interference, adjacent cabinets belonging to the same system must have a perma-
nent electrical connection and must be connected using a copper bar (PE).
• The connection units contain interference suppression circuits. For this reason, it is extremely
important that incoming external cabling and cabling between connection units and I/O
boards are routed on separate sides of the cabinet in accordance with the instructions in
2.3.4.3.5 Installation of I/O Cables from WAGO I/O.
• Cables to and from connection units must never be incorporated in the same cable har-
ness, because this will affect the interference-suppression function of the connection
units. For example, in cabinets with the frame hinged on the left, incoming external cabling
should be routed on the right-hand side of the cabinet.
The signal processing electronics in the Flatness System cabinet equipment is normally
chassis grounded and all suppression of external signal noise must use the chassis as a ref-
erence ground. If this requirement is not met, the system will be sensitive to high-frequency
interference and primarily interference from unsuppressed relays, contactors and the dis-
charge of static electricity.
• If a Flatness System remains sensitive to interference of this type, and all of the hardware is
approved, the reason could be an incorrectly grounded system or a part or cable that is
incorrectly located. In such cases the installation must be checked, most suitably with an
interference test, before starting any other activity.
• The potential of the chassis ground must be stable and well defined even in the event of a
ground-fault in the low or high voltage equipment or in the event of a strike of lightning.
— Interference suppression circuits are mounted on the cables.
— Bars are located on the right hand side of the cabinet for the fix of incoming cables.
— In double cabinets external cables are routed in the left hand cabinet on the left hand
wall, see 2.3.4.3.5 Installation of I/O Cables from WAGO I/O .
56 3BSE076743R0101 en Rev B
2 Installation
• All I/O-cables to/from the Flatness System cabinet must be screened. Exceptions are fiber
optic and mains supply cables.
• I/O cable with cable shoe terminated screen must be grounded to the copper bar with short-
est possible length and must be grounded with its screen through the adjustable cable
clamp, see 2.3.4.3.5 Installation of I/O Cables from WAGO I/O.
• Grounding wires must be as short as possible.
• Unconnected conductors must be connected to ground.
2.3.4.2 Network Setup

TP (RJ45) is used for all communication links inside the cabinet. Fiber optic is used for communi-
cation links to and from the cabinet. On the LAN switch there are two 100Base-FX standard out-
puts for the user.
The image below shows a typical TCP/IP connection for the Flatness System with the Flatness
Computer (FC).
Figure 44. TCP/IP connection
1. 100 Base-FX
CAUTION
Do not exceed minimum bend radius of fiber optic cable.
The installation of the fiber optic cable should follow the cable manufacture specifications, and
should be performed by a qualified installation engineer. Be careful that the minimum bend radius
of the fiber optic cable is not exceeded.
3BSE076743R0101 en Rev B 57
2 Installation
2.3.4.3 Cable Routing to the Cabinet

When routing field cables belonging to Flatness Systems a number of restrictions apply:
• Communication cables, used for communication without modems, and zone measuring sig-
nal cables must be routed at least 100 mm away from all other cables, including Flatness
Systems cables.
• Flatness Systems cables must be kept away from other non-Flatness System cables, by at
least 100 mm and at least 300 mm from mains supply cables. See Figure 45. Cable routing
outside and inside Flatness System cabinet page 58.
• Fiber optic cables are used for all communication links outside the Flatness System cabinet.
Connection Units,
Main Units,
Modems, Switches,
Field part Hub,
Cabinet part
Non ABB cables

300 mm Mains supply cables 50mm
100 mm signal cables
-Supply cables
-Communication cables between
modems
-Process I/O cables (AI/AO/DI/DO)
-Video cables 50mm
-External backup
-Roll DC supply cables
100mm
50mm
-Process I/O cables (AI/AO/DI/DO)

-24 V cables with screen
100mm
All communication cables for

communication without modem
50mm
100mm
Other cables
Non ABB cables 50mm

300 mm Mains supply cables
100 mm signal cables
-Other local supplies (VEXT, etc.)
50mm
- Roll DC supply cables
Figure 45. Cable routing outside and inside Flatness System cabinet
2.3.4.3.1 Installation of Low voltage and Status cables to DTU

Remove the cable sheath from the adjustable cable clamps to the end of the cable, inside the cab-
inet. Connect cables to terminal and neutral bar.
1. Remove the cable sheath from the adjustable cable clamps to the end of the cable
2. Connect the cables to the terminal.
3. Connect the braiding screen to the earth bar with the cable clamp.
58 3BSE076743R0101 en Rev B
2 Installation
Roll A Roll B
X1 X2
2.3.4.3.2 Installation of Signal Cables from DTU (Roll)

1. Insert the optic cables in the connection box.
2. Connect the cables to the stressometer side.
3. Tighten the strain relief connectors.
Roll A Roll B
3BSE076743R0101 en Rev B 59
2 Installation
2.3.4.3.3 Installation of Supply Cable to DTU (Roll)
Remove the cable sheath from the adjustable cable clamps to the top of the cable support.
2.3.4.3.4 Installation of Mains cable to Cabinet/PFSA 145
60 3BSE076743R0101 en Rev B
2 Installation
2.3.4.3.5 Installation of I/O Cables from WAGO I/O
+ + + +
_ _ _ _
s s s s
1 2 3 4
Figure 46. Installation of I/O cables.
1. Cable with sheath.

2. Bend the cable and make a cut.
3. Pull out the wires.
4. Remove the cable sheath in a length from the adjustable cable clamps to the very end of the
cable.
5. Connect the cable and the cable sheat as shown in Figure 46. Installation of I/O cables.
page 61.
2.3.4.4 Measuring Roll Cables

All Measuring Roll cables that are required are delivered by ABB, with a length as given in the order
specification.
Three types of cables go from the Stressometer Cabinet to PFSA185/Measuring Roll.
• Signal and pulse encoder cables. (Fiber optic type).

• Low voltage and status cables.
• High voltage DC supply roll excitation cables
The cables from the Cabinet are connected to the Connection Unit DTS PFSC230 near the DTU/
Stressometer Roll. The Connection Unit DTS have connectors for the signal cables and screw ter-
minals for Low voltage DC/Status and Roll excitation cables. The cables are from the Connection
Unit DTS to the DTU Cover routed in a kerosene proof protection hose.
3BSE076743R0101 en Rev B 61
2 Installation
Signals cables come with connectors. Low voltage/status cables and Roll excitation cables come
with connectors on the PFSA185 side.
A draw tape is positioned in the protection hose for eventual installation of a new cable.
An adjusting cable with a loop is protruding from the end. The cable is for adjusting the position
of the multi cable grommet.
To avoid damage to the connectors, cable routing between the Cabinet and PFSC230 Connection
Unit DTS must begin at the PFSC230 end. The other end must be suitably protected during rout-
ing of the cables. Special care must be taken when routing the fiber optic cables.
Connection to the cabinet of the excitation cables is made through screw terminals on the supply
terminal block PFSC 123. The screen must be connected to the earth bar by a cable no longer
than 5 cm.
The Low voltage/status cables connect to the terminal block. The Signal and Pulse Encoder cables
connect in the Connection box.
2.3.4.5 Grounding of Cabinet Components

All cabinet components must be bonded together with high quality and permanent ground con-
nections. The connections should preferably be made with thread-cutting screws. When thread-
cutting screws are used on painted components, the paint must be scraped off under the head of
the screw and the nut. The surface must be smeared with conducting grease.
In the cabinets, there is a horizontal grounding bar [PE] (5 x 30 mm copper for example) at the bot-
tom for protective grounding, and a vertical grounding bar (3 x 12 mm copper for example) on the
side where the external cabling enters. The screen of the external cabling should be connected to
the bar as described above. The vertical grounding bar should be grounded to the chassis in at
least 5 points and be bonded to the horizontal grounding bar through a 10 mm² yellow/green cop-
per conductor (protective function).
2.3.4.6 Grounding of Units

In the same way as mounting rails, all units such as subracks, power supply units and terminal rails
must be bonded to the chassis frame using approved mounting screws or short connecting wires,
max. 50 mm long, on both sides of the unit.
Other units must be correctly grounded, using for example max 50 mm long connections to the
chassis plate or to the copper grounding bar. In ABB cabinets, all these connections must be
made with tapered self tapping screws.
Information
Incorrectly mounted units give very poor protection against high-frequency interference and ESD.
2.3.4.7 Connection of Mains Voltage Supply

A connection terminal block on the mains filter unit PFSA 145 is located in the cabinet at the bot-
tom of the rear wall.
The length of the mains cable within the cabinet must be kept as short as possible; EMC consider-
ations. For connection details, see Circuit Diagram.
Mains voltage line-phase: 98-298 V AC. (Selectable see Circuit Diagram)

Mains voltage phase-phase: 98-518 V AC (Selectable see Circuit Diagram)
Mains power: Max 3 kVA (depends on system configuration)
Rated insulation voltage (RIV): 518 V AC, overvoltage category 3.
Rated frequency: 50-60 Hz.
62 3BSE076743R0101 en Rev B
2 Installation
The system may only be used with IT- networks with ground fault detection for phase to phase vol-
tages above 300 V
• The mains connection must be permanent.

• The incoming mains voltage must be provided with fuses and means outside the cabinet for
disconnection. The fuse size depends on mains voltage. Maximum fuse size is 32 A.
• Because of high current leakage in the protective ground the mains must not be connected
to the cabinet, unless the protective ground has been connected.
• Flatness System cabinets supplied with mains must always be provided with a protective
ground.
• The configuration is grounded at the same point with a ≥50 mm² copper lead.
• When several cabinets are used, each cabinet should have its own supply from the distribu-
tion unit.
2.3.4.8 Wall Socket

Certain products include a grounded wall socket to which servicing aid may be connected. The
220 V wall socket is supplied by the mains transformer.
2.4 Installation of Connection Unit DTS PFSC230

When routing field cables belonging to Flatness Systems a number of restrictions apply:
• Communication cables, used for communication without modems, must be routed at least
100 mm away from all other cables, including Flatness Systems cables.
• Flatness Systems cables must be kept away from other non-Flatness System cables, by at
least 100 mm and at least 300 mm from mains supply cables.
• Fiber optic cables are used for all communication links outside the Flatness System cabinet.
Place the Connection unit DTS PFSC230 at a suitable place from the Stressometer Roll/DTU. The
standard length of the cable from the Connection Unit DTS to the DTU is 25 m.
1. Mount the Connection unit DTS PFSC230 at a suitable place from the Stressometer Roll/
DTU. The standard length of the cable from the Connection Unit DTS to the DTU is 25 m
2. Connect a protective ground wire between the PFSC230 structure and mill structure
or ground point if the mounting itself does not provide protective ground.
To connect the cable to the DTU, see 2.7 Installation of cable set between DTU and Connection
Unit DTS PFSC230.
2.5 Installation of DTU Cover and Power and Media

Converter Unit PFSA185
ELECTRICAL
minutes.
3BSE076743R0101 en Rev B 63
2 Installation
1. Make sure that the Mains power has been switched off for 10 minutes and that DTU Air
Purge supply is off.
2. Mount the DTU lower Cover to the bearing house by connecting it to the flange so that the
cover hangs down approximately 2° as shown in position A, see Figure 48. Installation of
DTU Covers page 65.
3. Install the Power and Media Converter Unit PFSA185 (4) to the brackets in the DTU cover
with the mounting screws. See Figure 47. Installation of DTU Cover and Power and Media
Converter Unit PFSA185 page 65.
4. Install the Stressometer cables, see 2.7 Installation of cable set between DTU and Connec-
tion Unit DTS PFSC230.
5. Install the Air Purge supply hose from the Air Purge Filter Regulator unit to the connection
(6) at the DTU cover. For air specification see 1.8 DTU Air Purge.
6. Install the Air Purge supply hose (5) from the DTU cover to the PFSA185 connection.
7. Connect the cables from PFSC230/Stressometer Cabinet (3, 9 and 10) to the PFSA185.
Note: If the DTU is to be installed, wait to connect the connectors on the PFSA185 to get
access to mount the DTU. The optical cables shall be connected to avoid getting dirt on the
connectors.
8. To avoid thart dirt gets into the protection caps, park them to each other. The parked protec-
tion caps may then need to be fixed to the PFSA185 with straps.
9. If the length of the cables should need adjustment, see 2.7 Installation of cable set between
DTU and Connection Unit DTS PFSC230.
Tip
If it is hard to turn the bayonet lock of the optical connection the 120° to locking position - hold
the end of the anti-kink between two fingers and carefully move it in a small circular rotation, while
turning the lock.
CAUTION
Make sure the pins of the Pulse Encoder, auxiliary cable engages correctly in the PFSA185
connector, so that the connector nut can be threaded the full length.
10. Fasten the the cables to the strain relief connector bracket (2).
11. Install the upper cover as protection of the PFSA185 and connectors.
For final steps of installation of Covers, see position B-D in Figure 48. Installation of DTU
Covers page 65.
64 3BSE076743R0101 en Rev B
2 Installation
2 8
9
3
10
4
11
12
Figure 47. Installation of DTU Cover and Power and Media Converter Unit PFSA185
1. Rotation stop and bracket for vibration damper

2. Strain relief connector bracket
3. X3- Roll DC power from Cabinet
4. Power and Media Converter Unit PFSA185
5. Air purge hose to PFSA185
6. Air purge hose connection
9. X2- Auxiliary Pulse encoder signal to PFSC230
10. X7- Low voltage and status signals
11. Protection hose connection
12. Clamp for securing protection hose
A B C D
Figure 48. Installation of DTU Covers
3BSE076743R0101 en Rev B 65
2 Installation
a. Position the lower cover in a 2° down angle by a loose mounting of the screws to the bear-
ing house flange
b. Place the upper cover to the lower.
c. Raise the lower cover and tighten the screws to the bearing house flange.
d. Mount the screws that holds the upper cover to the lower. Mount the screws that holds the
upper cover to the bearing house flange.
2.6 Installation of DTU PFSA107
ELECTRICAL
minutes.
1. Make sure that the mains power has been switched off for 10 minutes and that air supply is
off.
2. If the the Power and Media Converter Unit PFSA185 is installed, disconnect the electrical
cables (8) from the PFSA185 for better access to the DTU. The optical cables to the
PFSA185 should remain in place to avoid getting dirt on the connectors. See Figure 50. DTU
installation page 68.
3. Inspect the 100-pin connector on the Stressometer roll and DTU shaft for dirt and moisture.
4. Make sure the DTU and Stressometer mounting surfaces are clean and without any burrs.
Clean carefully with a solvent, and if necessary, use an abrasive cloth to remove small burrs.
CAUTION
Avoid lifting the DTU in the Pulse Encoder cover. Be careful not to damage equipment inside the
DTU cover. Support the weight of the DTU when it is not attached to the Stressometer roll.
66 3BSE076743R0101 en Rev B
2 Installation
5. Check the position of the Stressometer roll locator pin. Position the DTU shaft to match the
Stressometer roll flange, and gently push the DTU into position.
6. Make sure that the DTU can be pushed in all the way by hand.
7. Fasten the DTU (1) by tighten the three screws in a criss-cross pattern.
8. Make sure there are no vibrations created by nearby mill machinery that will affect the com-
ing measuring.
9. Turn the Stressometer Measuring Roll and measure the static run-out in radial direction at
the end of the Pulse Encoder cover according to Figure 49. Measuring point of static run-out
page 67 . Static run-out is measured as the absolute difference between minimum and
maximum measurement for one rotation.
• If max rpm is 2000, the static run-out must be <0,1 mm.

• If max rpm is 2400, static run-out must be <0,05 mm.
If the static run-out is outside above limits, it has to be adjusted. Perform as follows:
a. Unscrew the three screws, remove the DTU and re-check that the mounting surfaces
are clean and without any burrs.
b. If certain about a fault after checking the surfaces, i.e. you have observed a stable
angle in which the DTU is offset from the central axis, carefully grind the end of the
Stressometer roll with a fine sharpening stone to correct the misalignment. In extreme
cases this can also be done on the DTU flange.
c. In extreme cases the roll end must be turned in a lathe or ground in a grinding
machine.
Contact ABB to discuss the amplitude of the static run-out and possible actions to take if
there still are uncertainties in the installation of the DTU.
Figure 49. Measuring point of static run-out
10. Install the rotation stop bracket between the DTU and the DTU Cover see Figure 26. DTU
Cover page 33.
11. Connect the signal cable from the PFSA185 connection X1 to the DTU measuring signals
connection (5). See figure below.
12. Connect the excitation cable from the DTU to the PFSA185 connection X4 (7).
13. Connect the Pulse Encoder cable to the PFSA185 connection X5 (3).
3BSE076743R0101 en Rev B 67
2 Installation
14. Connect the Air Purge hose from the DTU cover to the DTU connection (6).
Open Air Purge supply and check for leaks at the connection points.
15. Reconnect the cables (8) if disconnected in step 2.
16. Fasten the cables inside the cover to the strain relief connector bracket (2), see Figure 47.
Installation of DTU Cover and Power and Media Converter Unit PFSA185 page 65.
17. Make sure that the seal is installed between the covers.
18. Mount the DTU cover as shown in position B-D, see Figure 48. Installation of DTU Covers
page 65.
19. Switch on the Stressometer Cabinet mains power.
20. Perform PWA-check, see 3.4.3.5 Automatic Force Pulse Detection and Integration.
Note: If the DTU and DTU Cover is installed in a 90° angle - adjust the PWA according to the
position.
7
2
4 8
Figure 50. DTU installation
1. DTU PFSA107
2. X1-Measuring signal cable connection
3. X5-Pulse Encoder connection
5. Measuring signal cable connection on DTU
7. X4- DTU excitation power connection
8. PFSA185 electrical connectors
68 3BSE076743R0101 en Rev B
2 Installation
2.7 Installation of cable set between DTU and

Connection Unit DTS PFSC230
ELECTRICAL
Switch off electrical power to the Flatness System cabinet before starting any work.
Start at the Connection Unit DTS.
Connection Unit DTS PFSC230 end
1. Lay the protection hose/ cable in the final routing.

2. Remove the transport protection from the protection hose by removing the shrink sleeve and
loosen the hose clamps.
3. Identify the two clamps (4) that are closest to the cable end. Loosen these two clamps that
are only parked for transport .
4. Make sure that the end of the multi-cable grommet (6) is positioned 130 mm from the end of
the protection hose. To adjust the position of the multi-cable grommet: loosen clamp (7)
and push it down further, or pull it up with the adjusting cable (5). Fasten the clamp (7) 150
mm from the end of the protection hose. See Figure 51. Connection of cables and protective
hose page 70.
5. Loosen the clamp (7) and push one of the optical cable down approximately 100 mm, this to
make them go through the protection hose connection (3), one by one.
6. Carefully insert the cables in the PFSC230. Tighten the clamp (7).
7. Insert the protection hose over the hose connection and fasten the two clamps (4).
8. Check that the cables can be connected and that there will be no pulling force applied to the
cables when connected, check the radius of the optical cables.
9. Connect the optical connectors.
Tip
If it is hard to turn the bayonet lock of the optical connection the 120° to locking position - hold
the end of the anti-kink between two fingers and carefully move it in a small circular rotation, while
turning the lock.
10. Connect the cables to the terminal.

11. Fasten the cables to the PFSC230 with straps.
DTU Cover end
1. Lay the protection hose/ cable in the final routing.

2. Remove the transport protection from the protection hose by removing the shrink sleeve and
loosen the hose clamps.
3. Identify the two clamps (4) that are closest to the cable end. Loosen these two clamps that
are only parked for transport . See Figure 51. Connection of cables and protective hose
page 70.
4. Make sure that the end of the multi-cable grommet (6) is positioned 130 mm from the end of
the protection hose. To adjust the position of the multi-cable grommet: loosen clamp (7) and
push it down further, or pull it up with the adjusting cable (5). Fasten the clamp (7) 150 mm
from the end of the protection hose.
5. Carefully insert the cables in the DTU Cover.
3BSE076743R0101 en Rev B 69
2 Installation
6. Insert the hose over the hose connection and fasten the two clamps (4).
7. Check that the cables can be connected and that there will be no pulling force applied to the
cables when connected, check the radius of the optical cables. Do not pull on connectors.
Tighten the clamp (7) and check that the handling did not create tension on the cable at the
PFSC230 end.
8. To connect the cables to the PFSA185, see
2.5 Installation of DTU Cover and Power and Media Converter Unit PFSA185.
A
1
130 mm
150 mm
4
Figure 51. Connection of cables and protective hose
1. Cable
2. Sealing washers
3. Protection hose connector
4. Clamp (protection hose)
5. Adjusting cable (for multi-cable grommet retraction)
6. Multi-cable grommet
7. Clamp (multi-cable grommet)
8. Draw tape, fabric
70 3BSE076743R0101 en Rev B
2 Installation
2.8 Stressometer Installation Checklist

This check list should be used by the person responsible for the installation work. It is a guide to
ensure that all installation work is finished before the commissioning starts by ABB. If the installa-
tion personnel encounter any problems or have questions, contact ABB.
Fill in the following tables.
Activity Comments
Mechanical installation of roll and bearings

Measuring Roll serial number (entry position): ………………………………
………………………..
Measuring Roll serial number (delivery position): ……………………………
…………………………..
See Figure 52. Identification plate and roll identity number page 71
Roll alignment check.

An alignment record should be completed.
Bearing position fixed.

Dowel pins or other proper procedure should be used. In some cases the
roll calibration device requires that one bolt on each bearing housing is
removed; this action must not change the roll alignment.
Bearings lubricated.
The most common type of lubrication is grease or oil circulation. Informa-
tion about the type of lubrication to use is indicated on bearings and in the
ABB documentation.
Bearing grease outlet plug removed.

One plug on each bearing should be removed in order to allow over pres-
sure or excess grease to escape. At oil-circulation it is normal with two
G3/4" outlets on each side of bearing.
Labyrinth seal tolerance normally 0,4-0,9 mm. At speed ≥1700 rpm toler-
ance is 0,2-0.6 mm.
2
60
08
82
2
X
XX
56 860 200 X
-....
93 2
82 PM
53
23
QG
0
Figure 52. Identification plate and roll identity number
3BSE076743R0101 en Rev B 71
2 Installation
Activity Comments
DTU installed.
The installation is normally made by the ABB supervisor but can also be
done by a qualified customer maintenance person.
Cables and cable connectors securely fastened on DTU and PFSA185
Activity Comments
Filter regulator installed for DTU and PFSA185
Check function of alarm at air pressure drop to DTU- If system is installed.
Check mill function of air supply shut-off to DTU at fire alarm
Activity Comments
Air pressure regulator for Measuring Roll installed.
Air pressure supply line installed and pressure available.
Check function of air supply shut-off to Measuring Roll at fire alarm.
Rubber hose installed and connected to roll through an air swivel connec-
tion that is attached to the drive shaft delivered with the Measuring Roll.
Check for air leak by hand.
Activity Comments
Cables correctly installed and terminated.
Cables in cabinet terminated according to instruction.

The cable screen of cables supplied by ABB must be connected to each
bar according to instruction. This is to ensure good signal quality.
PE-cable 50 mm² connected to PE-bar in order to ensure good signal

quality.
Activity Comments
Computers with accessories installed.
Network cables installed.

Fiber optic cable requires installed patch box that is delivered by ABB.
Electrical cables connected to computers and accessories.
Electrical power available.

98-518 V AC
Activity Comments
Bearing position fixed. (Perform after rolling)

Dowel pins or other proper procedure should be used. In some cases the
roll calibration device requires that one bolt on each bearing housing is
removed; this action must not change the roll alignment.
72 3BSE076743R0101 en Rev B
2 Installation
2.9 Operation
2.9.1 Power On
1. Switch power to on with Main switch S1.
2. Wait until the Flatness computer (FC) dislays a picture.
3. Continue with Start of Excitation.
2.9.2 Start of Excitation

1. From the Flatness computer, open the BM-Tool.
2. Make sure the Actual system mode is (2) measuring.
3. From the Quick picture selection, select "View force diagram in full screen".
4. Select " Select measured force diagram >Filtered and limited rel force, (FZWDFL)>High reso-
lution. See picture below.
Figure 53. Select measured force diagram
If the force value for any measuring zone peaks above 20 N, excitation must be restarted.
5. Set system mode request selector to (1) idle. Actual system mode indicates 1.
6. Set system mode request selector to (2) excitation. Actual system mode indicates 2.
7. Re-check force values.
3BSE076743R0101 en Rev B 73
3 System Check and

Maintenance
3.1 Introduction
This part of the manual describes the system check activities for the Stressometer system.
3.1.1 Safety Instructions

It is important that the following instructions are followed when operating the system in order to
minimize the risk of personnel injury and equipment damage. Any local statutory regulations, if
stricter than the following, are to take precedence.
3.1.1.1 Personal Safety

• Use only approved hoisting equipment when lifting cabinets.

• A protective ground wire (≥ 50 mm² copper lead) must be connected before applying the
mains voltage to the cabinet.
• Work with great care when the mains voltage is applied to the system. The voltage in the
cabinet can cause injury and may be lethal.
• Only authorized service personnel are allowed access to the cabinet.
• Personnel working with service and maintenance must know how to switch off the mains
power supply to the Flatness System equipment.
• Process technicians must be present when testing and operating the process objects and all
service personnel must be informed when performing test runs.
• Never change “System mode” without knowing what happens in the system with a mode
change.
• When subsections of the process have been checked and a test run has been performed,
interlocking chains and similar must be checked by an authorized person.
DANGER
Never look directly at the end of an installed fiber optic cable or connector because a laser
source emitting invisible light may be present. Exposure can cause permanent eye damage.
74 3BSE076743R0101 en Rev B
3.1.1.2 Equipment Safety

• Electronic devices are sensitive to Electro Static Discharge (ESD) effect. A warning label is
attached to the system to draw attention to possible damage by ESD. To avoid causing
accidental damage while handling circuit boards, it is recommended to wear a wrist strap
earthed to the chassis. The wrist strap must have a built-in protective resistor. Antistatic
bags must be used to store and transport the circuit boards.
• Avoid ESD by grounding both yourself and the tools before handling circuit boards and other
parts of the equipment.
• Never press the system Reset or Abort buttons without knowing the consequences of an ini-
tialization in the system.
• Use the grounded wrist strap installed in the cabinet when handling parts of the system.
• Handle the circuit boards carefully, particularly those containing MOS-components that can
be damaged by static electricity discharges. Note the warning label on the circuit boards.
• Always store circuit boards in envelopes of conductive plastic when not installed in the Flat-
ness System cabinet.
• Use, as far as possible, the grounded wrist strap when handling boards which are not stored
in envelopes of conductive plastic. This gives optimum protection against static electricity
discharges.
• Always switch off the voltage before extracting a board that cannot be replaced under
power. Wait for the capacitors to discharge.
• Before electrical welding is performed near the Flatness System, switch off the mains supply
voltage to the system and pull out all boards at least 20 mm.
• To ensure good electrical grounding of the board fronts tighten the screws at the top and
bottom of the front plate.
Figure 54. Warning label for ESD
3.2 System Check Intervals

Table 2
System check intervals of Measuring Roll
Activity Interval Section in this manual
Inspection of Measuring Roll sur- According to customer mainte- 3.3.4.1 Inspection of Measur-
face nance routines ing Roll Surface
Inspection of Measuring Roll bear- According to system check routines 3.3.4.2 Inspection of Measur-
ings ing Roll Bearings
Inspection of Air Purge for Measur- According to customer maintenace 3.3.4.3 Inspection of Air
ing Roll routines Purge for Measuring Roll
Oil-circulation bearing lubrication According to customer mainte- 3.3.5 Bearing Lubrication

nance routines
3BSE076743R0101 en Rev B 75
System check intervals of Measuring Roll
Oil-air bearing lubrication (Contact According to customer mainte- 3.3.5 Bearing Lubrication
ABB before use) nance routines
Oil-mist bearing lubrication According to customer mainte- 3.3.5 Bearing Lubrication

nance routines
Grease bearing lubrication According to Section 3.4.2 3.3.5 Bearing Lubrication
Drive coupling check According to system check routines 3.3.6 Drive Coupling Check
Calibration verification of Measur- Regularly, approximately 12 months 3.3.7 Calibration Verification

ing Roll Check of Measuring Roll
Table 3
System check intervals of DTU
Activity Interval Section in this manual
Visual inspection of DTU installa- According to customer mainte- 3.4.1 Visual Inspection of
tion (Outside DTU Cover) nance routines DTU installation
Replace DTU Air purge filter 6 months, more frequent depend- 3.4 System Check of Digital
ant of air quality Transmission Unit
Check DTU pressure regulator 6 month, more frequent dependant 3.4.1 Visual Inspection of
automatic drainage function on air quality DTU installation
Check DTU pressure regulator out- 6 month 3.4.1 Visual Inspection of

put pressure DTU installation
Check DTU Cover input pressure 6 month 3.4.1 Visual Inspection of

DTU installation
DTU, ABB FM service 5 years recommended
3.3 System Check of Measuring Roll
3.3.1 Introduction
The Measuring Roll is already calibrated when it is delivered from ABB. The individual sensitivity
factors for each zone are stored in the system. The zone sensitivity changes over time are
extremely low, due to the long term stability of the Pressductor sensors.
If the difference from the last calibration verification exceeds ±5% contact ABB.
The verification of the system and the sensitivity factors should be done approximately once a year.
Information
Verification should be performed each time a Measuring Roll has been recoated or regrinded.
76 3BSE076743R0101 en Rev B
3.3.2 Preparations
• Protect the Measuring Roll and its mounting details when cleaning the mill.
• Degreasers may be used to wipe off the Measuring Roll when cleaning it.
CAUTION
Spraying chemicals under high pressure to the Measuring Roll may damage it.
3.3.3 Considerations during Bearing Status Check
3.3.3.1 Working Temperature

A good indication that lubrication is functioning correctly is the temperature of the bearing housing.
Normal working temperature, measured at the bearing housing outside, is 40-70°C. The tempera-
ture of the bearing is normally 10-15°C higher than the bearing housing. The maximum allowed
bearing temperature is 130°C, but the lubrication life will be severely shortened.
With EP additives in the lubricant the bearing temperature may exceed 100°C. However the sur-
face of the bearing can react with the additive, which can lead to embrittlement.
By installing temperature transducers with alarm switches in the bearing housings, safer operation
is achieved. This may allow the upper speed limit to be increased and, in special cases, even allow
the required amount of lubricant to be decreased.
3.3.3.2 Load
In order to continuously monitor the bearing condition, a shock pulse measuring transducer can be
installed in the bearing housing. The measuring principle relies on ultrasonic sound that is emitted
by a rolling body when it hits an object in the bearing race. A continuous measurement of this kind
gives a trend recording which can be utilized to determine the suitable time to replace a bearing.
Values according to the “shock pulse” method are acceptable if dBN (decibel normalized) is < 20.
However other vibrations may cause disturbance and produce wrong indications. Vibration meas-
uring is a method used most often when a fault has been found, this to predict bearing replace-
ment.
If basic characteristics such as rotational speed and geometry are known, it can be determined
whether the fault is caused by misalignment in the coupling or by a Measuring Roll bearing. With
good knowledge of the machinery units it can be determined whether the fault lies in the Stress-
ometer system or originates from equipment that is nearby, e.g. an attached drive motor.
Vibration exposure of the DTU installation shall for maximum life in service not exceed 2mm/s at
10-200 Hz.
These methods and the necessary equipment are described in full detail in instructions supplied on
request by SKF and Brüel & Kjær.
Bearing housings are normally not supplied with vibration sensors at original delivery.
3BSE076743R0101 en Rev B 77
3.3.4 Visual Inspection
3.3.4.1 Inspection of Measuring Roll Surface

Inspect the Measuring Roll regularly to check for scratches or other surface damage that may
result in marks on the rolled strip. If the Measuring Roll surface looks poor, or leave marks on the
strip, it might be necessary to regrind the Measuring Roll. See Section 4.3 Regrinding Measuring
Roll for instructions.
3.3.4.2 Inspection of Measuring Roll Bearings

• Inspect the Measuring Roll bearings in accordance with the procedures used at the rolling
mill.
• A bearing that has run for a long time must be replaced with a new bearing before it wears
to a point at which there is a risk of bearing damage.
• Vibration or acceleration measuring is recommended.
See Chapter 4.4 Bearing Replacement.
3.3.4.3 Inspection of Air Purge for Measuring Roll

Inspect the Air Purge regularly, it is recommended to replace the filter at least once per year. If the
air quality is poor, the filter must be replaced more frequently.
For more information about the Air Purge regulator and filter, see dimension drawings and assem-
bly drawings in Binder B2.
3.3.5 Bearing Lubrication

Bearing housings and cartridge bearings are pre-lubricated with grease or oil which must be main-
tained with appropriate lubricants.
3.3.5.1 Check Lubrication Method

Check the data plate on the bearing housing to determine which type of lubrication is recommen-
ded in the Stressometer system.
When changing lubrication method, replace the bearing housing data plate. Check if anti-fric-
tion coating on labyrinths is needed. Re-lubrication must be done at commissioning a new or
repaired Measuring Roll.
Information
The DTU must always be connected to air pressure- independent of lubricating method
3.3.5.2 Determine Lubrication Method

Check the maximum rotation speed of the Measuring Roll and compare this with below.
78 3BSE076743R0101 en Rev B
Table 4 Recommendations for bearing lubrication.
Spherical roller bearings Grease lubrication Oil-mist lubrication Oil- Oil-circulation lubrication
circulation lubrication only.
D = 130 mm < 1500 rpm < 2100 rpm > 2100 rpm
D = 150 mm < 1200 rpm < 1700 rpm > 1700 rpm
The following factors determine the selection of lubricating system, and therefore the lubrication
quality:
• Rotational speed.
• Environmental conditions, for example temperature, vibrations and surroundings.
• Lubrication methods.
Table 5 Lubrication methods
Lubrication Method Advantages Disadvantages
Grease – the simplest lubrication Simple lubrication equipment Relatively high and uneven friction
method for roll bearings after lubrication
No seal problems at bearings Not so good cooling
Good protection of bearings More manual work if not automa-

ted
Oil-air lubrication (Normally not

used, before use- contact ABB.)
Oil-mist lubrication Small oil leakage Oil-mist comes out in the environ-
ment around the lubricated
object
Oil consumption only 30-40 liter/ Somewhat complicated lubrica-

year for each bearing tion equipment
Small and stable rolling friction
Oil-circulation Good lubrication Risk for oil leakage
Good cooling Sometimes “large” system with a

lot of oil
Stable friction
3.3.5.3 Determine Amount of Lubricant

Check the required amount of lubricant for each bearing and for the applicable lubrication method.
Table 6 Amount of lubricant for each bearing
Lubrication method Amount of lubricant for each bearing
Grease lubrication 15-500 rpm 80 g/180 days
500-1000 rpm 60 g/90 days
3BSE076743R0101 en Rev B 79
1000-1500 rpm 40 g/30 days
Continuous grease lubrication 0.05-0.2 g/hour
Oil-circulation lubrication 0.8-1.2 dm3/min
Lubrication 80 60 40 g/lubrication shift

intervals (h)
10000
8000
6000
4000
3000
2000 Environment:
1500 “dry and clean”
Temperature bearing housing 40-50 ºC
1000 Operation time
≤ 60%
800
Environment:
600 “wet and dirty”
500 Temperature bearing housing 55-70 ºC
Operation time> 60%
400
300
200
150
100
50
100 200 400 600 800 1000 2000 n (r/min)
Figure 55. Grease lubrication interval (recommended)
If there is a risk of the grease being severely contaminated in service, re-lubricate the bearings
more often. When the bearing temperature > 70ºC, each step of +15ºC results in a need of reduc-
ing the time between the re-lubrications by 50 %.
Table 7 Recommended data for oil-mist lubrication (each bearing) (for all Measuring Rolls)
Oil-mist lubrication
Air consumption 1500 Ndm3/h
Air pressure at outlet nozzle 0.05-0.06 MPa
Oil flow 35-40×10-4 dm3/h
Pipe length between lubricator and bearing Minimum 1 m

Maximum 15 m
Pipe dimension (steel or copper) D = 6/4 mm
Inlet nozzle hole D = 1.5 mm
Outlet hole D = 6-8 mm
80 3BSE076743R0101 en Rev B
3.3.5.4 Determine Lubricant

Check the recommended lubricants to be used for the applicable lubrication methods.
Table 8 Recommended lubricants
Lubrication data Grease lubrication (1) (Grease MIL Oil-mist lubrication

EP recommended at bearing Oil-circulation lubrication
temperature ≤ 100° C.)
Standard lubricants DIN 51825 SAE 3310 Mar 80 DIN 51517-3 AGMA 2 EP-8EP
NLGI 2 ISO VG 100
Filtration standard ISO 4406 or SAE W/65 Value ISO

17/13
Particle size standard ISO 4572 Value B25 ≥ 75 (25μm

absolute separation)
(1)
Normal lithium grease is used for grease lubrication.
3.3.5.5 Pre-lubrication of Bearings

If the bearing is empty of grease: Open top half of bearing house or cartridge and fill the bearing
with grease. Rotate the Measuring Roll at low speed and lubricate with 150 g in each bearing
house. Over-greasing can force excess grease into the DTU and cause damage.
3.3.6 Drive Coupling Check

If the drive coupling is supplied by ABB, it is normally a CVD-coupling (Constant Velocity Drive).
The coupling requires a minimum of maintenance. However, to ensure long life a few checks and
proper lubrication is recommended for some types of drive couplings. For more information refer
to the maintenance instruction in Binder B2.
The CVD-coupling is pre-lubricated with grease and does not need refilling.
If a gear coupling is used refer to the supplier documentation.
3.3.7 Calibration Verification Check of Measuring Roll
3.3.7.1 Introduction
The Measuring Roll is already calibrated when it is delivered from ABB. The individual sensitivity
factors for each zone are stored in the system. The zone sensitivity changes over time are
extremely low, due to the long term stability of the Pressductor sensors.
If the difference from the last calibration verification exceeds ±5%, contact ABB.
The verification of the system and the sensitivity factors should be done approximately once a year.
3BSE076743R0101 en Rev B 81
Information
Verification should be performed each time a Measuring Roll has been recoated or regrinded.
3.3.7.2 Calibration Verification Equipment

The supplied calibration verification unit should be used. See picture below.
1. Mount the calibration verification beam.

2. Check the distances y1 and y2.
3. Compare the measured values of y1 and y2.
4. The acceptable difference between y1 and y2 is ± 0,3 mm.
3
2
1 4
y y
1 2
1. Stop ring
2. Calibration verification beam
3. Bracket
4. Tube
3.3.7.3 Preparations
DANGER
Avoid staying close to the rotating Measuring Roll during calibration verification. It is always
recommended that the rotation is stopped when the load beams need to be moved to the next
zone. Be careful when touching the Measuring Roll surface when power supply is on, as the
surface temperature can be much higher than the ambient temperature.
• The tube should be locked to the brackets or stays in the right position with the two stop
rings.
• Tube grooves should be placed in the center of the zones.
• Use composing stick on the Measuring Roll surface and distance to surface edges.
The brackets are designed to be fixed on the Measuring Roll bearing housings or on the support
for the Measuring Roll.
• Check that there is no “viper-blade”, “brass-brushes” or similar on the Measuring Roll, which
can cause measurement disturbance during the calibration verification check.
• Clean the surface of the Measuring Roll.
• Be sure that the wheel of the calibration weight does not load the Measuring Roll when the
Measuring Roll is stationary.
82 3BSE076743R0101 en Rev B
• There should be no air pressure in the Measuring Roll during the calibration phase.
• Before starting the calibration allow the Measuring Roll to rotate with slow speed (100 rpm) in
approximately 1/2 hour (depending on the start temperature of the Measuring Roll). Rotation
produces uniform temperature on the Measuring Roll surface.
• The BM-Tool for handling of Roll Calibration is described in B Roll Calibration Verification.
3.4 System Check of Digital Transmission Unit
3.4.1 Visual Inspection of DTU installation

Inspect the DTU installation from outside the DTU cover with attention to:
• DTU installation as visable - properly attached to Stressometer flange and bearing housing.
• DTU cover and the seal as visible - No damage. Check that the drain holes in the lower
cover are not obstructed.
• Electrical cables/protection hose connected to the DTU cover - no damage or sharp bends.
• DTU Air Purge Filter/regulator unit - check for leaks or damage. Replace filters every 6
months. Poor air quality may require more frequent replacement.
• Check that pressure regulator automatic drain is working.
• Condition of air hoses and couplings - check for leaks or damage.
• Connection Unit DTS PFSC230 as visable for damage on unit and connections.
3.4.2 Spare Parts

Table 9 Spare parts
Name No./unit Destination Part Number Manufacturer
First Filter 5 μm 1 Filter/regulator DTU 4338-01 Norgren
Second Filter 0.01 μm 1 Filter/regulator DTU 4344-01 Norgren
3.4.3 Pulse Encoder
3.4.3.1 Encoder Auxiliary Connection

The auxiliary Encoder signals is obtained at the Connection Unit DTS PFSC230 by a cable from the
PFSA185. The cable between the PFSC230 and the cabinet is optional.
• INCR-PC
• INCR-NC
• INCR +90-PC
• INCR +90-NC
• SYNC-PC
• SYNC-NC
• +24 VC
• 0 VC
3BSE076743R0101 en Rev B 83
3.4.3.2 Adjustment of Pulse Encoder

The Pulse Encoder is factory set and should not be adjusted.
3.4.3.3 Encoder Pulses

The Encoder on the DTU generates the pulses SYNC, INCR and INCR+90°. Turn the Measuring
Roll slowly by hand and check the function of the SYNC pulse. The Data Concentrator board indi-
cator SYNC flashes for every SYNC pulse (once per revolution).
In reversible mills with two Measuring Rolls, one Measuring Roll is connected to the left Data Con-
centrator board SYNC indicator and the other Measuring Roll is connected to the right Data Con-
centrator board SYNC indicator.
3.4.3.4 Roll Rotation Direction Indication

The Data Concentrator board detects roll rotation direction through the INCR and INCR+90° pul-
ses from the Encoder. The direction is indicated by the Data Concentrator board indicator DIR.
In reversible mills with two Measuring Rolls, one Measuring Roll is connected to the left Data Con-
centrator board DIR indicator and the other Measuring Roll are connected to the right Data Con-
centrator board DIR indicator. Check the roll rotation direction indication while turning the Measur-
ing Roll(s) slowly in both directions.
If the Encoder are correctly wired the indicators should illuminate according to:
• DIR extinguished = clockwise (ADCB) direction.

• DIR illuminated = counterclockwise (ABCD) direction.
Roll rotation direction definition is according to picture below.
C B-D A
X
A
D B
C
X
Section X-X
Figure 56. Roll rotation direction indication
3.4.3.5 Automatic Force Pulse Detection and Integration

The Force Pulse detection and integration is done automatically by the BM-part if selected. The
term ‘Force Pulse detection and integration’ means detection (always active) of the actual force
pulse position and adjustment of the Force Pulse Integration window. This window is the angle
window where the system integrates (uses) the actual force pulse to make a force sensor sample.
The activation of automatic Force Pulse Integration window adjustment (based on the detected
force pulse position) is done by activating Box 1 [IdentPulseEnable] in Force pulse handling setting
under Configuration and maintenance > Force pulse handling.
84 3BSE076743R0101 en Rev B
BM1 Graphical User Interface - Windows Internet Explorer Provided by IBM x
BM Tool GUI BMS1 2010-06-10 09:53:45
Engineer Displays Force pulse parameters

The system work with active parameters. When the system mode changes, the paramters for that mode
Force pulse handling will be read and made active. The former active parameters will be overwritten.
Configuration maintenance Active Force pulse settings and status

Roll data and design
Sensor A offset 5.903 rad Open offset -0.012 rad
Roll excitation
Tracking band 0.100 rad Close offset -0.012 rad
System mode
System status Maximal wrap angle 0.785 rad
Force pulse handling
Force pulse handling settings
Force measuring ?
Channel calibration 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Bias calibration
Roll calibration verification
Analog status Mode related Force pulse settings
Digital status
IP, Mill, Date Information
View Force measuring (mode 2) Roll calibration verification (mode 5) Simulation (mode 7)
Simulation
Signal processing
Backup
Help Force pulse position detection Applied force pulse integration
Identified sensor A offset 6.003 rad Applied A-sensor offset 6.915 rad
Identified pulse angle 0.509 rad Applied pulse angle 0.761 rad
Calculated wrap angle 0.421 rad Min. pulse angle apply limit 0.200 rad
Calculated current pulse; 0.849 rad Max. pulse angle apply limit 1.371 rad
Pulse detection status

?
Quick picture selection: 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

incr
System mode request 7 SYNC
A-sensor C-sensor
Actual system mode 7
System status Tracking Hand Tracking Band
wa
Roll speed 5.6 rps Slot Angle sa B-sensor D-sensor
Rotation (Clockwise=0) 0 A SensorOffset
OpenOffset CloseOffset
Roll identity Dummy
INT
Figure 57. Force pulse handling
Information
Box 2 [IdentPulseHold] should be deactivated to let the adjustment of the Force Pulse Integration
window to be based on the latest detected force pulse position.
To get information about the actual status of the Force Pulse detection and integration, press the
"Force measuring (mode 2) button.
Figure 58. Force measuring parameters
In Status, Box 1 [IdentPulseActive] indicates that the identified Force Pulse position is used in the
adjustment of the Force Pulse Integration window. This Box should be active when automatic
Force Pulse Width detection and adjustment is selected.
3BSE076743R0101 en Rev B 85
3.4.3.5.1 Definition
The Force Pulse detection and integration handling has the following definitions.
1
2
A C
3 9
7
4 10
B D
5
6 11
Figure 59. Force pulse detection status
1. incr
2. SYNC
3. Tracking band
4. SlotAngle
5. ASensorOffset
6. +OpenOffset
7. wa
8. INT
9. TrackingBand
10. sa
11. +CloseOffset
The total force pulse angle consist of two parts, the wrap angle (wa) and the slot angle. Note that
parameters above have separate values for every System mode are only updated after a System
mode change, i.e. check the influence of a parameter change by changing the local copy at Con-
figuration and maintenance > Force pulse handling and when satisfied store the result under the
corresponding System mode.
The following System mode are using Force pulse parameters and Force pulse handling settings:
• Force measurement (2)

• Channel calibration (3)
• Roll calibration (5)
• Simulation (7)
3.4.3.5.2 Tracking Window Definition

Necessary input for the detection is the definition of the tracking window (defined by Sensor A off-
set, Tracking band and Maximal wrap angle). The tracking window is the angle window where the
system assumes to find the force pulse of the Sensor A.
The tracking window goes from the value: Sensor A offset - Tracking band up to Sensor A offset +
SlotAngle + Maximal wrap angle + Tracking band.
86 3BSE076743R0101 en Rev B
Above parameters have separate values for every System mode and only updated after a System
mode change. For the Flatness measurement mode (2) select Configuration and maintenance >
Force Measuring.
The sensor slot in radians, SlotAngle (sa), is calculated from RollCoreDiameter and SensorSlot-
Width, which are found at Configuration and maintenance > Roll data and design.
3.4.3.5.3 Tracking Band

The Tracking band could be seen as the allowed “uncertainty” in the Sensor A offset and Maximal
wrap angle parameters. The Tracking band parameter increases the allowed search area for finding
the actual force pulse position.
3.4.3.5.4 Detection
The detection result is found as the identified Sensor A offset, Ident. Sensor A offset, and the iden-
tified pulse angle, Ident. pulse angle, see Figure 59. Force pulse detection status page 86.
The identified Sensor A offset could be limited upwards using Sensor A offset + Tracking band
(Box 5 deactivated in Status) and identified pulse angle could be limited downwards using Sensor
A offset + SlotAngle (Box 6 deactivated in Status).
The identified pulse angle is then compensated for the nature of the detection algorithm. This is
done by calculating the real current pulse angle from the identified, Calc. curr pulse angle, i.e. the
total angle when force signal information is available. Calculation of identified wrap angle, Calc.
wrap angle, is done by using the identified pulse angle, Ident. pulse angle.
3.4.3.5.5 Detection Error

Following Boxes in Status indicates that there is some faults or limitation, see: Figure 58. Force
measuring parameters page 85
• Box 7 [IdentSensorError] indicate that the identified sensor do not correspond to the selec-
ted, in normal case, the Sensor A.
• Box 5 [IdentASensorOffsetNotLimited] indicate that the identified Sensor A offset is not limi-
ted.
• Box 6 [IdentPulseAngleNotLimited] indicate that the identified pulse angle is not limited.
If Box 5 [IdentASensorOffsetNotLimited] or Box 6 [IdentPulseAngleNotLimited] is deactivated then

the problem could be that the given tracking window (defined by Sensor A offset , Tracking band
and Maximal wrap angle) is misaligned compared to the actual force pulse position.
3.4.3.5.6 Integration
The corresponding adjustment of the Force Pulse Integration window is found as the used (applied)
Sensor A offset, Sensor A offset apply, and the used (applied) pulse angle, Pulse angle apply.
There are possibilities to manually add or subtract static angle offsets to the used (applied) Sensor
A offset and the used (applied) pulse angle. Those are called Open offset and Close offset.
Above parameters have separate values for every System mode and are only updated after a Sys-
tem mode change. For the Flatness measurement mode (2) Configuration and maintenance >
Force Measuring, see Figure 57. Force pulse handling page 85.
The used (applied) Sensor A offset can be manipulated by Open offset. The used (applied) pulse
angle is manipulated by both Open offset and Close offset.
3BSE076743R0101 en Rev B 87
When the adjustment of the Force Pulse Integration window is done automatically by the BM-part
then the used (applied) Sensor A offset, Sensor A offset apply, is calculated as Ident. pulse angle +
Open offset. Similarly the used (applied) pulse angle, Pulse angle apply, is calculated as Calc. curr
pulse angle + Open offset + Close offset.
3.4.4 Maintenance using DTS Tool
3.4.4.1 Maintenance functions

Service- Maintenance
The Maintenance Menu contains five tabs:
1. Backup tab
Functions for making and restoring of backups, loading predefined configurations are grou-
ped in this menu.
2. Logging tab
This tab shows functionality from the logger that is built into the DTS Tool.
3. Values tab
Specific values that are of interest, for example earth leakage, can be shown here.
4. Firmware tab
Contains functionality for upgrading software in the DTS.
5. Control tab
Command control for DTS functions.
See Figure 60. Backup tab page 89 for positions.
88 3BSE076743R0101 en Rev B
3.4.4.1.1 Backup tab
Figure 60. Backup tab
1. Backup tab
2. Logging tab
3. Values tab
4. Firmware tab
5. Control tab
6. Backup folder- Open the backup folder button
7. Make backup- Enter name of the backup
8. Make backup button
9. Restore backup- Select backup
10. Restore backup button
11. Restore configuration- Select predefined configuration
12. Restore button
A backup could be made or restored. Making backup means to collect a set of predefined data
from the DTS and store it into a backup file on the hard disk of the FC. Restoring backup means
selecting a backup file from the hard disk and sending the content of that file down to the DTS.
By pressing the Open (6) button the folder containing backup files is opened in Windows explorer
to enable simple copying of backup files to/from memory sticks etc.
To make a backup, enter a name of the backup (7) and then press the Make button (8).
3BSE076743R0101 en Rev B 89
CAUTION
Do not Restore a backup when the mill is rolling.
To restore a backup, select the backup file that shall be restored (9) and then press the Restore
button (10).
Configurations:
The DTS Tool is delivered with a predefined set of configurations that could contains settings to
adapt the DTS to different Stressometer versions and roll types.
CAUTION
Do not restore a configuration when the mill is rolling.
To restore a configuration, select the configuration that shall be downloaded (11) and then press
the Restore button (12) in the configuration field.
90 3BSE076743R0101 en Rev B
3.4.4.1.2 Logging tab
Figure 61. Logging tab
1. Logging toggle switch

2. Autostart logging toggle switch
3. Sample count field
4. Open Log folder button
The DTS Tool contains a built in logger service that logs a predefined set of values from the DTS.
Log files are stored in a predefined folder with file names representing the time and date when the
logged was saved to file.
There is an upper limit of how big a log file could be and how much data the logfolder can contain.
If a log file needs to be saved but the log folder is filled, the oldest files in the log folder is removed
until there is room to save the new logfile. No prompting occurs before removing older files.
Enabling the Logging means that the logging service is automatically started and the Sample count
field (3) (see Figure 61. Logging tab page 91) starts to increment.
If Autostart Logging (2) is ON, the logging service will start automatically the next time the DTS Tool
is started, this is useful for example for long term logging.
The Open Log folder button (4) opens the folder contains log files in Windows explorer to enable
simple file copying to memory sticks etc.
3BSE076743R0101 en Rev B 91
3.4.4.1.3 Values tab
Figure 62. Values tab
1. Roll leakage
2. Short circuit
3. Error lower limit
4. Warning lower limit
5. Indication bar
The Values tab has an indicator of the PFSA240 leakage to ground. The indication bar changes
colour to orange when passing the Warning lower limit, and to red when passing the Error lower
limit.
For more information see 6.4.1.1 Roll DC Supply Unit PFSA240.
3.4.4.1.4 Firmware tab
92 3BSE076743R0101 en Rev B
Figure 63. Firmware tab, for downloading new software
Firmware download
1. Current firmware version

2. Select firmware for download
3. Download button
4. System status indicator
CAUTION
Do not download firmware when the mill is rolling. The DTS connection must be ok to be able to
download new firmware.
The procedure for downloading new firmware is:
1. Make sure the System status indicator (4) indicates OK.

2. Make sure the firmware file is available at disc (D:\Stressometer\DTS Tool\ApplicationData
\Firmware by clicking on the “Select firmware for download” Combo box (2) and selecting
the desired firmware. See figure below. The download takes 30-60 seconds.
3. When the download is complete the dialog below is shown.
3BSE076743R0101 en Rev B 93
Figure 64. Firmware dialog
4. Toggle power to the PFSK287 unit (by toggling the fuse marked F4 or F5 depending on
which roll the PFSK287 is connected to) in order to make the new firmware apply to the sys-
tem (firmware change is applied only after power up of the PFSK287 unit). Do not use the
Reset PFSK287 button.
5. When the PFSK287 unit has restarted and the System status indicator (4) indicates OK
again, the “Current Firmware version” (1) and the “Selected firmware for download” (2) shall
now correspond to each other as shown in the figure below.
3.4.4.1.5 Control tab

The control tab has a button for reset of the PFSK287 board in the Signal Control unit PFSA287.
Reset of the PFSK287 shall only be performed if the protective shut down of the system has been
activated.
CAUTION
Do not reset the PFSK287 when the mill is rolling.
94 3BSE076743R0101 en Rev B
Figure 65. Control tab
1. Reset PFSK287 button
3.4.4.2 Check handling directory for available storage space

Storage space snapshot directory
It is necessary to check that the snapshot folder does not occupy too much storage space.
The folder is located in the FC computer.
It is recommended to delete all content in the snapshot directory on a regular basis.
To check for storage space in snapshot directory:
1. Log in as System Engineer.

2. Select the applicable Overview menu for the DTS and push the Open Snapshot folder but-
ton.
3. Right-click and select properties of the folder.
4. Perform step 1-3 for the second DTS, if applicable.
Storage space backup folder
It is necessary to check that the backup folder does not occupy too much storage space.
The folder is located in the FC computer.
It is recommended to check and delete unnecessary content in the backup folder on a regular
basis.
To check for storage space in backup folder:
3BSE076743R0101 en Rev B 95
1. Log in as System Engineer.

2. Select the applicable Overview menu for the DTS and push the Open Snapshot folder but-
ton.
3. Right-click and select properties of the folder.
4. Perform step 1-3 for the second DTS, if applicable.
96 3BSE076743R0101 en Rev B
4.1 Introduction
ELECTRICAL
Before changing any components in the Flatness System cabinet switch off mains power.
ELECTRICAL
minutes.
4.2 Replacing Measuring Roll
4.2.1 Removal of Measuring Roll

Before replacing the Measuring Roll, remove the DTU. The definition of Measuring Roll A or B,
depends on the cabling between the Measuring Rolls and the Flatness System cabinet. The con-
nection units for Measuring Roll A and Measuring Roll B are shown in the circuit diagram.
Follow this procedure:
1. Determine the identity of the Measuring Roll to be mounted by checking the Measuring Roll.
2
60
08
82
2
X
XX
56 860 200 X
-....
93 2
82 PM
53
23
QG
0
Figure 66. Delivery identity plate and Measuring Roll identity number.
3BSE076743R0101 en Rev B 97
2. Start the BM Tool

3. Set the BM-part to Idle mode: select Configuration and maintenance > System mode and
then System mode request = 1.
This will switch off Roll excitation.
ELECTRICAL
minutes.
4. Remove the DTU. See 4.5.1 Removal of DTU PFSA107.

5. Note the position of shims at removal. Recover the shims.
6. Connect lifting eyes to the Stressometer Roll according to chapter Unpacking. Remove the
Stressometer Roll in reverse order of installation. See 2.2.4 Mechanical Installation.
4.2.2 Installation of Measuring Roll
ELECTRICAL
minutes.
1. Make sure that the mains power has been switched off for 10 minutes.
2. Mechanically mount the Measuring Roll, see 2.2.4 Mechanical Installation.
3. Switch on the mains power.
4. Locate the RollData file (RollDb.cfb) for the roll to be mounted.
Information
If the System has been updated from STU to DTU, the old RollDb.cfb and SystDb.cfb should not
be used. After update from STU to DTU, the roll data files must be updated before installation in a
DTU system. Contact ABB for updated RollDb and SystDb files.
5. Use a FTP client to send the roll-data file to the SystemFS:/ folder of the MVME 3100.
6. Restore roll data/parameters. Include roll data, by checking the appropriate check box:
Backup handling > Make and Restore back-up > Make, see chapter 5.2.4 Restoring
Backup.
7. Check that Roll Identity is correct/as expected: select Configuration and maintenance > Roll
data and design. (See Figure 66. Delivery identity plate and Measuring Roll identity number.
page 97)
8. Select cross-talk calculation. Also set cross-talk calculation in the FC-part accordingly.
9. Select Configuration and maintenance > System mode and then System mode request = 5
(Roll calibration verification).
10. Click on "Reset and restart" in "Roll Calibration verification" display.
11. Return to Idle mode: select Configuration and maintenance > System mode and then Sys-
tem mode request = 1.
12. Flash the new configuration: select Backup handling > Make and Restore back-up > Flash,
see chapter 5.2.4 Restoring Backup.
13. Set the BM system in Force measurement mode: select Configuration and maintenance >
System mode and then System mode request = 2.
98 3BSE076743R0101 en Rev B
4.2.3 Measuring Roll data update after installation

Adjust the Measuring Roll diameter data according to the Figure after installation as follows:
Select Roll data and design from the Engineer Displays menu
Configuration and maintenance | Roll data and design
A mode change is required and a Flash to make permanent.
4.3 Regrinding Measuring Roll
4.3.1 Introduction
Due to the wear to which the measuring roll is subjected in service, it is necessary after some time
to regrind the hardened steel rings that protect the force transducers. This must be done before
the diameter difference between the centre and the periphery rings reaches 0,2 mm on the Stand-
ard Measuring Roll, or 0,1 mm on the Foil Measuring Roll.
Information
When the Measuring Roll has been ground to the minimum diameter limit the rings must be
replaced. Please refer to the Technical Reference Manual for more information about the ring
replacement.
If the Measuring Roll has minor scratches or pick-ups, use this method:
• The Measuring Roll can be ground in place.

• Let the Measuring Roll rotate at slow speed (about 70 rpm) by the drive motor.
• Use abrasive paper fitted to a wooden block or a grindstone. Particle size should be 600
grain/inch2.
Move the wooden block or grindstone continuously along the whole length of the Measuring Roll,
to ensure as even grinding as possible.
The roll can be re-ground to the minimum permitted diameter.
3BSE076743R0101 en Rev B 99
Roll type Outside diameter on delivery Minimum permitted diameter

( after grinding)
Standard roll Ø 313 mm Ø 313 ± 0,5 mm Ø 307 mm
Standard roll Ø 400 mm Ø 400 ± 0,5 mm Ø 394 mm
When the measuring Roll has been ground to the lower limit, replace the rings.
4.3.2 General Method 1

Use this method:
1. Remove the DTU. See instruction in chapter 4.5.1 Removal of DTU PFSA107.
2. Remove the bearings. See instruction in chapter 4.4.1 Removing Old Bearing.
3. Set up at grinding of the Measuring Roll surface. Use bearing rings for protection of the shaft
bearing surface, see picture below.
For instance NU 2226 inner ring = 130 x 153.5 x 64 mm with distance-ring = 130.3 x 150 x
24 mm (inside NU2226). Assembly temperature is 120-130°C. At dismounting use oil injec-
tor or SKF tool 721867/bearing type.
CAUTION
Protect the shaft bearing surface to prevent damage from support wheels.
2 2
1 3
3 3
Figure 67. Measuring Roll grinding method 1.
1. Couplings
2. Inner ring from bearing as protection on shaft bearing surface
3. Support wheels
Grinding data:
• Grinding wheel: type 33A 60 or softer (friable aluminiumoxide) for both 313 mm and 400 mm
Standard tool steel Measuring Roll.
— Peripheral speed: grinding wheel max 30 m/s, Measuring Roll max 30 m/min.
— Lateral speed rate: 50% of grinding wheel width per revolution of the Measuring Roll.
• Grinding wheel AS D120-R60B56 (Cubic boron nitride) for HSS (high speed steel).
Information
No grinding of Wc/Co coated rolls, Use instruction- Polishing of Wc/Co coated rolls.
100 3BSE076743R0101 en Rev B

4.3.3 General Method 2

Use this method:
1. Remove the DTU. See instruction in chapter 4.5.1 Removal of DTU PFSA107 .
2. Remove the bearings. See instruction in chapter 4.4.1 Removing Old Bearing.
3. For regrinding, set up the Measuring Roll between two centre points as shown in Figure 68.
Measuring Roll grinding method 2 page 101 . A detachable pivot centre is supplied and
marked for the Measuring Roll. Adjust so that the run-out is < 0.01 mm at both bearing sur-
faces.
4. Ensure a generous coolant supply, at least 40 liters/min.
5. Find the maximum diameter of the rotating Measuring Roll. Start by touching this point with
the grinding disc and then grind down max 10 μm/ sweep.
6. The last five sweeps over Measuring Roll surface should be 5 μm/ sweep until the desired
surface finish has been reached.
7. After regrinding a calibration verification check of the Measuring Roll can be performed (see
chapter 3.3.7 Calibration Verification Check of Measuring Roll,) but this is normally not nee-
ded.
1 2 2
0.01
Ra 0,4
A B
5
0.01 AB
0.03
Figure 68. Measuring Roll grinding method 2
1. Fixed pivot centre

2. Bearing surfaces
3. Detachable pivot centre
4. Run-out demand before regrinding
5. Ra corresponds to international standard ISO 221
Grinding data:
• Grinding wheel: type 33A 60 or softer (friable aluminiumoxide) for both 313 mm and 400 mm
Standard tool steel Measuring Roll.
— Peripheral speed: grinding wheel max 30 m/s, Measuring Roll max 30 m/min.
— Lateral speed rate: 50% of grinding wheel width per revolution of the Measuring Roll.
• Grinding wheel AS D120-R60B56 (Cubic boron nitride) for HSS (high speed steel).
3BSE076743R0101 en Rev B 101

Information
No grinding of Wc/Co coated rolls, Use instruction- Polishing of Wc/Co coated rolls.
4.3.4 Repolishing of Wc/Co coated rolls
4.3.4.1 Introduction
The roll surface is coated with a hard layer of wear resistant tungsten carbide. The coating has a
polishing margin of 30 μm (1/10 of thickness).
The coating will during normal condition last many years without any maintenance. However, if the
surface is exposed to a sudden impact, minor scratches or marks could occur on the roll surface.
If this cause marks on the rolled strip, a polish of the roll surface can be done.
For polishing minor scratches or marks it is recommended to use super finishing equipment. The
parameters are dependent on equipment used and the required surface roughness. Contact ABB
for a recommendation.
If the coating has major damage the roll must be re-coated. Contact ABB for more information.
4.3.4.2 Procedure
To polish the Stressometer WC/Co coated roll, use the oscillating polishing belt procedure.
The belt should be applied with a speed controlled motor. The polishing belt pressure to the
roll should be controlled with an oscillating rubber contact roll.
4.4 Bearing Replacement
4.4.1 Removing Old Bearing

Following this procedure:
1. Remove the DTU (with Measuring Roll still in the mill). See instructions in chapter: 4.5.1
Removal of DTU PFSA107.
2. Lift off the Measuring Roll from the mill.
3. Support the roll on the measuring surface (ring surface). Use "felt" protected wood, rubber
blocks or similar, for the support material; dimensions L = 500, h = 200, t = 100 with support
radius of 160 mm or adequate.
4. Remove the bearing housings and labyrinths. The outer ring of the labyrinth seals are
removed by pressing the inner ring. The rings are pressed out using a short lever (see Figure
69. Removing old bearing page 103). Do not jerk or strike the components or they will be
damaged.
5. Remove bearing by connecting the oil injector to the journal and pump in oil continuously
until the bearing is floating on the oil film. After a short time oil begins to emerge between the
bearing and the journal. Then there is a thin film of oil between the bearing and the journal,
which enables the bearing to be easily pulled off the journal.
6. Pull gently, to check that the bearing is floating on the oil film.
7. Pull off the bearing in one fast go, otherwise the bearing may get stuck on the shaft, so that
a puller must be used. The oil pressure drops rapidly when the bearing has passed over the
groove in the mating surface. When using a puller apply the force on the inner ring.
102 3BSE076743R0101 en Rev B

CAUTION
Connection of an oil injector can damage the journal end, and result in unbalance of the DTU.
8. After use of injector- check the run-out with an indicator. Adjust with scraper so that the run-
out will be < 0.03. When supporting on the bearings, the internal clearance can make the
journal move.
Tip
In certain cases it may be better to remove the old bearing using a grinding machine. Cut bearing
rings instead of using a puller (less damage). Do not grind on the shaft bearing surface.
Figure 69. Removing old bearing
4.4.2 Assembling New Bearing

Brand new bearings in an unopened and undamaged packaging are normally clean and require no
further cleaning. The anti-corrosion coating on the bearings has no adverse effect on lubrication,
and does not need to be removed.
1. Inspect and clean the shaft seating and lubricate with thin machine oil.
2. Lubricate the seal rings with grease.
3. First apply on the shaft all sealing components that are to be on the inside of the bearing.
Lubricate the sealing rings with grease.
4. Heat the bearing with an induction heater. An oven or a mineral-oil bath with a temperature
of 100-110°C can also be used.
5. Slide the hot bearing onto the shaft with the marked face outwards.
6. Check that the inner ring is located hard against the shoulder. If shaft shoulder or distance
rings for bearing location have an axial run-out of > 0.02 mm, the position of the bearing can
become tilted and produce axial vibration on the Stressometer roll.
7. Install the locking washer and lock nut before the bearing cools off. When the inner ring of
the bearing cools, a clearance is formed between the ring and the shoulder of the shaft. This
clearance is intentional and necessary.
3BSE076743R0101 en Rev B 103

8. Lock the nut by bending the tab of the locking washer into the recess in the nut.
9. If the bearing is grease-lubricated, fill all spaces in the bearing with grease from both sides.
10. Fill the bottom half of bearing housing or cartridge with grease.
11. Fit the remaining seal components that must be well lubricated.
12. When the Measuring Roll is installed in the mill, mount the DTU and DTU cover. See instruc-
tion in chapter 2 Installation.
4.5 Replacing DTS equipment
4.5.1 Removal of DTU PFSA107

The PFSA107 DTU construction requires no maintenance action such as internal cleaning or
inspection. If the DTS Tool indicates a fault in the DTU, the unit must be replaced. Do not try to
open the DTU.
ELECTRICAL
minutes.
Information
Prevent dirt or fluids from entering open electrical, optic or pneumatic connections.
CAUTION
Avoid lifting the DTU in the Pulse Encoder cover. Be careful not to damage equipment inside the
DTU cover. Support the weight of the DTU when it is not attached to the Stressometer roll.
Parameters to changed after a DTU replacement or repair, except mechanical and electrical adjust-
ments are PWA-check.
1. Perform PWA-check, see 3.4.3.5 Automatic Force Pulse Detection and Integration.
2. Make sure that electrical power has been switched off for 10 minutes and that air supply is
off.
3. Remove the DTU top cover, see figure below.
a. Remove the screws that connect the upper cover to the lower.
b. Remove the screws that connect the upper cover to the bearing house flange.
Loosen the screws that hold the lower cover to the bearing house flange. Position the
cover in a 2° down angle.
c. Lift the upper cover off the lower.
104 3BSE076743R0101 en Rev B

A B C
Figure 70. Removal of DTU upper cover
4. If it is difficult to separate the upper cover from the lower, proceed as follows.
a. Insert two of the cover screws in the cover blind holes in the forward section of the
lower cover, see Figure 26. DTU Cover page 33.
b. Tighten the screws, and as the upper cover is without holes - it will be forced up.
5. Disconnect the cables from the strain relief connector bracket (2) , see Figure 47. Installation
of DTU Cover and Power and Media Converter Unit PFSA185 page 65.
6. Disconnect the Air purge hose from the DTU connection (6), see Figure 71. DTU installation
in cover page 106.
7. Disconnect the electrical cables (9) from the Power and Media Converter Unit PFSA185 to
get better access to the DTU. The optical cables (8) to the PFSA185 shall remain in place to
avoid getting dirt on the connectors.
8. Disconnect the Pulse Encoder cable at the PFSA185 connection X5 (3).
9. Disconnect the excitation cable at the PFSA185 connection X4 (7).
10. Disconnect the measuring signals cable at the DTU connection (5) and PFSA185 connection
(2).
11. Disconnect the rotation stop from the DTU vibration damper.
12. Remove the rotation stop bracket. See Figure 47. Installation of DTU Cover and Power and
Media Converter Unit PFSA185 page 65.
13. Note the position of the Stressometer roll and DTU shaft. Loosen the screws that con-
nect the DTU flange to the Stressometer Roll flange.
14. Support the weight of the DTU and remove the screws. Lift the DTU up from the cover.
15. Install protection covers at the DTU connectors.
16. If no further action is to be performed in the cover, it is recommended to install the upper
cover to avoid getting moisture and dirt inside the covers.
3BSE076743R0101 en Rev B 105

7
2
3 8
4
9
10
11
Figure 71. DTU installation in cover
1. DTU PFSA107
2. X1- Measuring signal cable connection
3. X5- Pulse Encoder connection
5. Measuring signals cable connection on DTU
7. X4- Roll excitation power connection
8. Optical connectors
9. Electrical connectors from PFSC230/Stressometer cabinet
10. Air purge hose to PFSA185
11. Air purge hose connection
4.5.2 Removal of DTU Cover and Power and Media Converter Unit
PFSA185
ELECTRICAL
minutes.
106 3BSE076743R0101 en Rev B

1. Make sure Mains power has been switched off for 10 minutes and that air supply is closed.
2. Remove the DTU, see 4.5.1 Removal of DTU PFSA107.
3. Loosen the Stressometer cables from the strain relief connector bracket (2). See Figure 47.
Installation of DTU Cover and Power and Media Converter Unit PFSA185 page 65
4. Disconnect the PFSC230/Stressometer Cabinet copper cables (9) and optical cables
(8) from the PFSA185 connections. Install the protection caps on the optical cable connec-
tors. See Figure 71. DTU installation in cover page 106.
5. Disconnect the Air Purge supply hose (10) from the PFSA185 (4).
6. Remove the bolts that holds the PFSA185 to the bracket. Lift the PFSA185 out from the
Cover.
7. Disconnect Air Purge hose at connection (11).
8. Protect the cable connections and Air Purge hose from fluid and dirt.
9. Remove the cables from the DTU cover. See 4.5.7 Removal of cables between DTU and
Connection Unit DTS.
10. Support the weight of the DTU Lower Cover and remove the bolts to the bearing house
flange.
11. Lift the Cover off the bearing house flange.
4.5.3 Installation of Roll DC Supply Unit PFSA240
ELECTRICAL
minutes.
1. Make sure that the main switch has been switched off for 10 minutes.
2. Carfully place the PFSA240 into it´s position by raising the forward side of the unit and
engage the folded plate to the Stressometer Cabinet tray.
3. Position the unit so that the hex screws can be fitted to the threaded plate in the cabinet.
Tighten the screws.
4. Connect the cable connectors and the earth cable at the front of the PFSA240.
4.5.4 Removal of Roll DC Supply Unit PFSA240
ELECTRICAL
minutes.
1. Make sure that the main switch has been switched off for 10 minutes.
2. Disconnect the three connectors and the earth cable on the front of the PFSA240.
3. Remove the four hex screws securing the unit to the cabinet.
4. Raise the forward side of the unit and lift the unit so that the folded plate disengages from
the cabinet.
5. Carefully remove the PFSA240 from the cabinet.
3BSE076743R0101 en Rev B 107

4.5.5 Installation of Signal Control Unit PFSA287
ELECTRICAL
1. Make sure that Mains power has been switched off.

2. Open the Cabinet door. Position the PFSA287 to the bracket.
3. Install the screws to the bracket.
4. Connect the electrical connectors to the unit.
5. Disconnect the connectors from the other PFSA287- if installed. This to avoid mixing of IP-
addresses.
6. Switch Mains power to on.
7. Set the IP-address of the new PFSA287 according to 1.9.2.5.3.1 IP address tab.
8. If the new PFSA287 replaces another unit, restore the backup taken from the old unit taken
before its removal- to the new unit. Otherwise load the proper predefined configuration.
9. Connect the other PFSA287- if installed.
4.5.6 Removal of Signal Control Unit PFSA287

1. Perform backup of settings with the DTS tool - 3.4.4.1 Maintenance functions.
2. Make sure that Mains power has been switched off.
3. Open the Cabinet door. Locate the PFSA287. See Figure 29. Flatness System cabinet page
36.
4. Disconnect the connectors from the unit.
5. Support the weight of the PFSA287 and remove the screws that hold it to the bracket.
6. Remove the PFSA287 from the cabinet.
4.5.7 Removal of cables between DTU and Connection Unit DTS
ELECTRICAL
minutes.
The cables between the DTU and the Connection Unit DTS PFSC230 are placed in a protective
hose. If the the cables need to be replaced, they are removed together with the protective hose.
DTU Cover end
1. Make sure that Mains power has been switched off for 10 minutes.
2. Loosen the Stressometer cables from the Power and Media Converter Unit PFSA185 and
the strain relief connectors in the Cover, see 4.5.2 Removal of DTU Cover and Power and
Media Converter Unit PFSA185.
3. Protect the cable connectors from damage or dirt.
4. Support the weight of the protective hose and loosen the two clamps (4). See Figure 51.
Connection of cables and protective hose page 70.
5. Pull the protection hose off the connection (3) and carefully remove the cables from the DTU
Cover.
108 3BSE076743R0101 en Rev B

Connection Unit DTS end
1. Loosen the staps holding the cables to the Connection Unit DTS PFSC230. See Figure 51.
Connection of cables and protective hose page 70.
2. Loosen the Stressometer cable connectors in the PFSC230.
3. Protect the cables from damages and dirt.
4. Support the weight of the protective hose and loosen the two clamps on the protection
hose.
5. Pull the hose from the hose connection and carefully remove the cables from the PFSC230.
4.6 Replacing FC and Rack Mounted Boards
Information
When switching on the mains power to the cabinet after board replacement, wait approximately
30 minutes after switching on. The boards need to reach working temperature before doing any
calibration.
4.6.1 Replacing a Flatness computer, FC

1. Make sure there is a saved backup of Flatness computer FC from commissioning or other
installation, otherwise perform backup according to 5.3.1 Backup/Restore Procedure.
2. Switch off the mains power.
3. Replace the FC and reconnect cables.
4. Switch on the mains power.
5. After the connection is established and everything is working: restore the backup with the
changes to the new FC.
Information
Changes that has been done on the HMI etc. are not accessible on the new FC.
4.6.2 Replacing Rack Mounted Boards
ELECTRICAL
3BSE076743R0101 en Rev B 109

1 2 3 4
Figure 72. Removing a board
To remove a board:
1. Unlock the screws.

2. Pull out the red lock.
3. Grab the lock and gently push the lock up or down. The turning of the handles will extract
the board from the backplane contact.
4. Gently pull the board out from the frame.
1 2 3 4
Figure 73. Inserting a board
To insert a board:
1. Insert the board.

2. Unfasten the locks and gently push the board into the backplane contact.
3. Grab the lock and gently push the lock down or up. The turning of the handles will lock the
board in the backplane contact.
4. Lock the screws.
4.6.3 Replacing a Digital Signal Processing Board PFSK 151

1. Switch the mains power off.

2. Replace the board, see chapter 4.6.2 Replacing Rack Mounted Boards.
3. Run a new Channel calibration, see Section A Channel Calibration.
4. Save configuration to flash: select Backup handling > Make and Restore back-up > Flash.
This saves the application to the MVME 3100 flash area.
110 3BSE076743R0101 en Rev B

4.6.4 Replacing a Data Concentrator Board PFSK 152


4.6.5 Replacing a Microprocessor Board (MVME 3100)


2. Check the strappings.
4. Check the boot flash version: MVME 3100 [BMS BOOT 1.0/0]
5. Set boot parameters using "c" (see chapter 4.7 Changing MVME 3100 Boot Line) according
to the delivery documentation. Type "." (dot) to empty a string.
6. Transfer the BM-part software by following the restore instructions, see chapter 5.3 Backup
and Restore of a FC or a Logger. This also restores the customer application.
7. Set the BM-part in Force measurement mode: select Configuration and maintenance > Sys-
tem mode and then System mode request = 2
Information
When changing the MVME 3100 the IP-address will be lost.
8. See the delivery documentation for the IP-address.

9. To confirm, select Configuration and maintenance > IP settings and mill designation.
4.7 Changing MVME 3100 Boot Line

To alert/set the MVME 3100 boot line, for example the IP-address, the MVME 3100 start-up must
be interrupted.
1. Start the console window in the FC computer. Open folder "Service" on the desktop and use
the predefined icons "Tera Term for BMS".
2. Check that the console cable is connected to the correct MVME3100 board, see Figure 75.
Connection of console terminal page 112.
3. In a system with two Rolls, and when only working with BMS2, check that the console termi-
nal cable are connected to the MVME card to the right. See Figure 75. Connection of con-
sole terminal page 112.
4. Press the Reset button on the MVME 3100 board. System auto-boot will now occur after
only 2 seconds. The digit below the text "Press any key to stop auto-boot ..." in the console
terminal window is the counting down-time.
5. Within 2 seconds, press the space key in the console terminal. If you do not succeed, go to
Step 1 and make a new attempt.
3BSE076743R0101 en Rev B 111

Figure 74. Console terminal screenshot
6. Now you can change e.g. the IP-address: type "c" and enter the new values. The BMS1
(and BMS2) IP-address (inet on Ethernet) should be according to the Application Descrip-
tion. The BM Tool IP-address (host inet) is also specified in the Application Description.
7. The "IP settings and mill designation" tool display can be used to check the IP-addresses.
Figure 75. Connection of console terminal
1. Connection of console terminal for BMS1

2. Connection of console terminal for BMS2
112 3BSE076743R0101 en Rev B

4.8 Adjusting Software Parameters
Information
To permanently keep modified parameter values a Save configuration (Flash) operation is
required.
Information
Modified parameters only affect the behavior of the System when the System mode changes.
4.8.1 Manually Deactivating/Activating Sensors

This section describes how to manually deactivate/activate sensors/zones/channels using the BM
Tool GUI. Select "Roll data and design" in the menu. In this view, select the zone you want to disa-
ble/enable.
4 8 12 16 20 24 28 32
Activate/Deactivate transducers in zone select zone
Requested amount
3500
3000
Figure 76. Select Zone
Figure 77. Activate/deactivate transducers
To deactivate a complete zone or channel, use the "all sensors" alternative (= 15), e.g. deactivate
sensors A through D of zone 5.
To verify that the sensors have been properly enabled/disabled: select Configuration and mainte-
nance > Roll data and design.
3BSE076743R0101 en Rev B 113

Roll zone width [mm]

52
26
0
5 10 15 17 22 27 32
Manually deactivated sensors (bit0=A-sensor on top)
5 10 15 17 22 27 32
Figure 78. Part of roll data and design display
4.9 Partly Covered Zone, Strip Stress Profile Display
4.9.1 Introduction
This section describes how the strip edges are handled in the Stressometer software.
The system measures where the strip is located in relation to the Measuring Roll. This is used to
calculate the strip covers for each zone and on which zones the strip edges are located.
The system has four strip edge indicators, two for each side, One gives the current edge position
and one displays the edge on the HMI system.
LowZone and HighZone variables in the profile hold information for display purposes. LowEdge-
Zone and HighEdgeZone variables hold the physical strip edge position.
The strip edge handling is controlled as follows:
• Parameter edgeActive: if TRUE then the partly covered edge zones is displayed on the HMI.
• Parameter minIndicationLimit: defines the minimum cover zone to be displayed on the HMI,
and is used to calculate the LowZone and HighZone values.
• Parameter minCoveredLimit; defines the minimum cover width for calculation purposes, and
is used to calculate the LowEdgeZone and HighEdgeZone values.
• Parameter minEdgeDeadband defines the dead band that is used to define the beginning of
the zone.
a1 = minCoveredLimit (default 13 mm)
b = stripEdgeDeadband (default 2 mm)
y = minIndicationLimit (default 13 mm)
x = strip covered zone width
z = zone number
xw = Zone width
114 3BSE076743R0101 en Rev B

Table 10 Definition of edge handling
Definition value for edgeActive for EdgeZone for con- Zone for HMI Cover width at
zone z HMI trol zone z
x < a1 N/A z±1 z±1 0
x > a1 + b N/A z z±1 x

x<y
x>y TRUE z z x
x < xw
x>y FALSE z z±1 x

x < xw
Follow this procedure to set the parameters (see the Engineer display):
1. Select Measurement settings > Strip edges > Edge cover handling.
4.9.2 Minimum Coverage for Stress Calculation

Parmeter minCoveredLimit defines the smallest coverage in mm that is required for considering the
zone as partly covered. If the FEMS part of the system considers the zone as partly covered, the
edge zone compensated value of the zone will be sent to the control part of the system. This will
then be presented on an Engineer display. Default minCoveredLimit is 13 mm.
The zone is considered partly covered if the strip covers a part of the Measuring Roll which is larger
than minCoveredLimit + stripEdgeDeadband. The zone is not covered if the strip covers less than
minCoveredLimit.
4.9.3 Edge Zone Indication Limit

Parameter minIndicationLimit decides whether the value of the zone shall be presented on the
Operator display when the "Edge ind." button is pressed. If "Edge ind." is not pressed only fully
covered zones will be presented on the Operator display. Default minIndicationLimit is 13 mm.
When the Edge position is calculated into the hysteresis set in the HMI consideration will be taken.
A new edge position will not be calculated if the new edge position has moved less than the set-
tings of the hysteresis in the HMI.
4.10 Edge Zone Compensation

The influence of the edge zone in the flatness calculation can be modified through the edge zone
compensation function in the FS-part.
The distributed force of the edge zone is calculated as follows:
Soft edge compensation

Fd = (w(x) - Force [edge zone])/(cover width [edge zone]) + ((1 - w(x)) Force [edge zone -/+ 1])/
(cover width [edge zone -/+ 1]) where x = covered part of the edge zone (mm) and w(x) = weight as
a function of the strip cover degree.
3BSE076743R0101 en Rev B 115

The weight w(x) is a function of the strip cover degree (in mm) and described in four points. The
actual weight is interpreted between the given function points, limited to 0..1. The function is con-
stant or growing with increasing x values. The function is configurable through HMI.
The function is configurable via HMI.

Example of numbers: 0,0; 0,0; 0,0; 20,1.0; gives the function w(x )
1.0
0
10 20 mm
Pair of numbers: 0,0.5; 0,0.5; 10,0.5; 20,1.0; gives the function w(x )
1.0
0
Pair of numbers: 0,0; 5,0; 10,0.75; 20,1.0; gives the function w(x ) 10 20 mm
1.0
0
5 10 20 mm
Figure 79. Examples of functions for pairs of numbers
Follow this procedure to set the parameters (see the Engineer display):
1. Select Measurement settings > Strip edges > Edge cover weight handling.
Edge cover weight handling

Edge cover Edge weight
0.0 mm 1.0
0.0 mm 1.0
0.0 mm 1.0
0.0 mm 1.0
Figure 80. Edge cover weight handling settings
Information
Partly covered zone compensation is activated when the cover edge is > 0. It will not affect the
measurement before the edge cover is higher than the minimum coverage limit. See section
Minimum Coverage for Stress Calculation.
116 3BSE076743R0101 en Rev B

5.1 Introduction
The following parts can be backed up or restored in the Stressometer system:
• The BM-part
• The FC-computer
• The logger system, if used
5.2 Backup/Restore of the BM-part
5.2.1 Folder Structure

It is necessary to have a backup of the software of the BM system. Figure 81. Example of BM Tool
folders for file administration page 117 shows an example of a folder structure.
D:
Stressometer
Bms
Backup
100678 CM2
Applic
2012-10-26
SystDb.cfb
System
Roll
8208734
2012-10-26
RollDb.cfb
Software
(C:)
Figure 81. Example of BM Tool folders for file administration
The logical name of the drives can vary depending on the computer settings, e.g. if a restore is
done from the BMS- FC computer.
SystDb.cfb is the file name for "system logical back-up". RollDb.cfb is the file name for "roll logical
back-up".
3BSE076743R0101 en Rev B 117

Examples:
• Backup of the BM system software, for example D:\Stressometer\Bms\Backup\100678

CM2\System (100678 CM2 = order number, mill designation).
• Backup area for the BMS application (the SystDb.cfb file), for example D:\Stressometer\Bms
\Backup\100678 CM2\Applic\2012-10-26, containing system logical backup (100678 CM2
= order number, mill designation, 2012-10-26 = date)
• Backup of the Measuring Roll(s) (the RollDb.cfb file), for example D:\Stressometer\Bms
\Backup\Roll\8208734\2012-10-26, containing Measuring Roll logical dump (8208734 =
Roll identity)
5.2.2 Saving Configuration to Flash

The system configuration is kept in the primary volatile memory while you are working with the sys-
tem. This configuration will be lost if you switch off the power to the cabinet, it must be saved if you
wish to keep it for later use. This section describes how this is done.
1. Use the BM-Tool to change to Idle mode: select Configuration and maintenance > System
mode and then System mode request = 1.
2. Select Backup handling > Make and Restore back-up, see Figure 82. Make and Restore
Back-up page 119.
Information
Before you start to Flash, never press the Restart(RST) or Abort(ABT) buttons on the MVME 3100
board or switch off the power, because all settings entered after last Flash will be lost.
3. To save the system in the Flash memory, click on "Flash" under "Save configuration to flash"
(see Figure 82. Make and Restore Back-up page 119). Flash active is indicated by Status bit
DumpBinDbActive, Box 6 and LED I5 is lit red. Flash is successfully completed when Status
bit DumpBinDbOk, Box 7 and LED I5 lits green for 0.5 seconds.
Information
Restore is automatically handled by the BM-part at init or start-up of the system. It means that
the contents of the Flash memory are transferred into the primary memory.
118 3BSE076743R0101 en Rev B

Figure 82. Make and Restore Back-up
5.2.3 Making Backup

1. Use the BM Tool to change to Idle mode: select Configuration and maintenance > System
2. Select Backup handling > Make and Restore backup see Figure 82. Make and Restore
Back-up page 119.
3. To select file RollDb.cfb, put a mark in the check box for "Include roll data" see Figure 82.
Make and Restore Back-up page 119.
4. To select file SystDb.cfb, Put a mark in the check box for "Include system data" see Figure
82. Make and Restore Back-up page 119.
Information
Do not press the Reset/Abort buttons on the MVME 3100 board during the Restore operation.
Do not switch off the power during the Make operation.
3BSE076743R0101 en Rev B 119

5. To backup the primary memory contents into the selected files, click on "Make" under
"Make/Restore back-up". Backup Make active is indicated by Status bit DumpActive, Box 1
and LED I5 on PFSK 152 is lit red. Backup is successfully completed when Status bits FileO-
kay, RecOkay, MembOkay, gtRecOkay, Box 3, 6, 7, 8 and LED I5 on PFSK 152 lits green for
0.5 seconds.
6. Close the BM Tool and Internet Explorer.
7. Double click on the icon "FTP BMS1(2)" to backup the files RollDB and SysDB.
8. When the direction dialog box appears, select "g".
9. When transferring the files with FTP, the program will create a new folder with the date
(YYYY-MM-DD).
At location D:\Stressometer\bms\backup\BMS1\YYYY-MM-DD in the FC computer.
The transferred files will be placed in that folder.
10. Click on "Refresh". When the file is visible in "Local System", the file is copied.
11. Start BM Tool.
12. Change to Force measurement mode: select Configuration and maintenance > System
120 3BSE076743R0101 en Rev B

5.2.4 Restoring Backup

1. Use the BM Tool to change to Idle mode: select Configuration and maintenance > System
2. Close the BM Tool and the Internet Explorer.
3. When restoring, place your desired files (RollDb.cfb and/or SystDb.cfb) in the Delivery ver-
sion-folder.
At location D:\Stressometer\bms\backup\BMS1\DeliveryVersion in the FC computer.
4. Double click on the icon "FTP BMS1(2)" to restore the files RollDB and SysDB.
5. When the direction dialogue box appears, select "p".

6. The restore is finished.
7. Start the BM Tool.
8. Select Backup handling > Make and Restore backup see Figure 82. Make and Restore
Back-up page 119.
9. To select file RollDb.cfb, tick the check box for "Include roll data" see Figure 82. Make and
Restore Back-up page 119.
10. To select file SystDb.cfb, tick the check box for "Include system data" see Figure 82. Make
and Restore Back-up page 119
Information
Do not press the Reset/Abort buttons on the MVME 3100 board during the Restore operation.
Do not switch off the power during the Restore operation.
11. To transfer the selected files into the primary memory, click on "Restore" under "Make/
Restore backup". Backup Restore active is indicated by Status bit PopDbRun, Box 1 and
LED I5 on PFSK 152, is lit red. Restore is successfully completed when Status bits FileOkay,
RecOkay, MembOkay, gtRecOkay, Box 3, 6, 7, 8 and LED I5 on PFSK 152 lights green for
0.5 seconds.
12. To save the configuration to Flash: click on "Flash" under "Save configuration to flash" see
Figure 82. Make and Restore Back-up page 119. Wait until saving is complete.
13. Restart the BM Tool to verify the new roll identity.
14. Run a new Channel calibration, see A Channel Calibration.
15. Change to Force measurement mode: select Configuration and maintenance > System
3BSE076743R0101 en Rev B 121

5.3 Backup and Restore of a FC or a Logger
5.3.1 Backup/Restore Procedure

Information
This is applicable when restoring to an identical computer.
1. Ensure the USB-memory stick is connected.
USB
USB
2. Restart your station/computer.

3. When the following text appears on screen, select "Start Ghost..."
122 3BSE076743R0101 en Rev B

4. When the following picture appears on the screen, select the operation you want to perform
and press Enter
Stressometer Ghost on USB backup and restore utility

Revision: - Date : 2010 - 04 - 27
Copyright ( e ) ABB AB 2010
1. Restore a backup of computer disk from USB.

2. Make a backup of computer disk on USB.
3. Quit
Make your choise (1/ 2/ 3) :
5. The selected action will take approximately 10-15 minutes to perform. When the action is
complete, restart the computer using the power button.
As a complement of making the ghost, also copy the Stressometer folder (including all sub-
folders) in the FC and FL (Flatness Logger) computers.
The copied folder should be stored in a safe place, like a server.
The ghost type of backup cannot be used if a (spare) computer of a different type or version
will be used in the future.
3BSE076743R0101 en Rev B 123

6 Fault Tracing
6 Fault Tracing
Information
To perform fault tracing, the system network communication must be up and running.
Fault tracing is based on two different scenarios:
6.1 Fault Tracing During Rolling
6.2 Fault Tracing Without Rolling
Follow the pertinent flow chart to locate and solve the problems. Figures referred in the decision
trees are found in the chapter Fault Tracing displays.
124 3BSE076743R0101 en Rev B

6 Fault Tracing
6.1 Fault Tracing During Rolling
No measurement values on operator

display
Open Engineer display, Flatness System part

(See Figure: Engineer display)
Force measurement shows measurement values ?

(See Figure: Engineer display, pos 2)
Yes No
Check LEDs on the cabinet VME-rack

See chapter: BM part
Are some LEDs red ?
No Yes
Check LEDs on the PFSA240. Yes
See chapter: DTS Tool
Are some lights red ?
No
See chapter BM part
Click Rolling status Check System Alarm list if yellow

(See Figure: Engineer display, pos 4) (See Figure: Engineer display, Pos 10)
Ensure that all boxes are marked Select Alarm list, Click Acknowledge, so
(See Figure: Rolling Status) that only active alarms are shown
(See Figure: Alarm list, pos 1 or 2)
If boxes are not marked, carry out the
procedures to correct the problem Carry out the procedures to
correct the problem
3BSE076743R0101 en Rev B 125

6 Fault Tracing
6.2 Fault Tracing Without Rolling
Check the LEDs in the Cabinet ( See figure: LED

indication for successfully completed MVME3100
application startup)
Are all LEDs green ?
Yes No
See chapter: BM Tool
Open Engineers display
Check system alarm list, if yellow

(See figure: Engineer display, pos 10)
Click acknowledge so that only active alarms

are shown
Carry out the procedure to correct the problem
126 3BSE076743R0101 en Rev B

6 Fault Tracing
6.3 Fault Tracing Displays
6.3.1 Engineer Display
1
2
4
5
6
7
9 10
Figure 83. Engineer display.
1. Rolling direction
2. Force zone
3. Distributed force
4. Rolling status
5. Flatness, compensated and uncompensated
6. Unit Profile
7. Language
8. Measuring request
9. Process alarm
3BSE076743R0101 en Rev B 127

6 Fault Tracing
10. System alarm
Figure 84. System alarm list
1. Acknowledge page text button (actual page)

2. Acknowledge list text button (complete list)
3. Alarm number
4. Status identification number
0= Accumulated alarm
1= active alarm
*1 = active alarm (After clicking Acknowledge)
5. Fault description
6.3.2 Rolling Status

All checkboxes must be set to deliver flatness value.
128 3BSE076743R0101 en Rev B

6 Fault Tracing
Figure 85. Rolling status
1. The mill is rolling in the right direction

2. Actual values from strip width, thickness and tension are ok.
3. Ticked box, all communication links are working and all FSA-objects are in running state.
6.4 BM-part
The electronic equipment in the ABB cabinet sometimes display one or several red LEDs, it
may occur on the Roll DC Supply Unit located high up in the cabinet or on the cards in the VME-
rack located below the roll excitation. See Figure 86. LED indication for successfully completed
MVME3100 application startup. page 129 and Table 11. page 130.
MVME 3100 PFSK152 PFSK151
RUN 24V-OK 3,3V-OK DSP-RUN 3,3V-OK Green

SYS DSP-RUN SYNC 5V-OK Green/Red
BFL DIR I1 Yellow
I2 I3
I4 I5
I6 I7
Figure 86. LED indication for successfully completed MVME3100 application startup.
3BSE076743R0101 en Rev B 129

6 Fault Tracing
If a red LED is active, do as follows:
1. Open the BM Tool.

2. Select display ”System status”. This display will tell what object is alarming. Box 32 (see Fig-
ure 87. BM Tool- System Status page 130 ) should be true on all objects. However, box 32
on one or several objects will be false if the hardware shows red LED.
Figure 87. BM Tool- System Status
Status Indications on the The Roll DC Supply unit PFSA240.
Table 11 LEDs on the PFSA 240
Power Green indicates that mains is connected.

POWER
DC OUTPUT DC Output Green indicates that PFSA240 generates power to PFSA185
WARNING warning Yellow indicates that leakage to earth is detected or SYNC signal is missing.
ALARM
Alarm Red indicates that a faulty condition has caused the PFSA240 to switch off. Faulty
conditions can be low mains voltage or that the PFSA240 is broken.
130 3BSE076743R0101 en Rev B

6 Fault Tracing
6.4.1 Common Problem Areas
6.4.1.1 Roll DC Supply Unit PFSA240

The most common reason for Roll Excitation fault is wrong resistance or earth fault in the circuit
due to damage cables or other parts. In some cases the Roll DC Supply Unit is malfunctioning.
If the roll excitation shuts down it indicates something being wrong with the power circuit running
from the Roll DC Supply Unit via cables and the DTU to the Stressometer roll.
To restart the Roll DC Supply Unit:
1. Set BM-system in Idle mode (mode 1).

2. Check DTS tool Event list for fault.
3. Perform repair of fault.
4. Reset PFSK287, see DTS Tool.
5. Go back to force mode (mode 2)
Select display ”I/O status” and check if digital inputs are inverted correctly. Several input signals
should be inverted, see “Digital input – control” and compare with a backup screen dump showing
OK status.
Information
It is possible to acknowledge one or several alarm signals. However, if the alarm keeps coming
back despite preventive efforts, contact ABB for more information.
6.5 Operator Station
6.5.1 Message "No network connection!"

When selecting a new display and the message "No network connection!" is shown on the screen,
the reason is that the Socket communication with FC is not working.
ERROR!
No network connection!
Ok
Warning: Applet Window
Figure 88. Display with No network connection
1. If there are HTML displays but no dynamic data, then check whether the HMI Server For
FSA application is started and is running on FC.
2. Check the cables and the LAN switch LEDs.
3. Excecute a ping command to test the link between FC and operator station, IP: 10.71.3.1.
6.6 Fault Tracing the DTS

Open the DTS Tool and go to the System Overview menu.
3BSE076743R0101 en Rev B 131

6 Fault Tracing
In the menu there shall be a yellow (warning) or red (alarm/error) indication that indicates where the
fault is located.
In the example below the System Status indicator indicates Error. The menu indicates protective
shut-down and many alarms/errors and warnings.
Figure 89. Example of faults indicated in System Overview menu
If it was a transient fault that has “disappeared” there will be no indication in this menu, instead an
indication in the Event list will show information about the transient fault.
In the Overview menu there is an indication that shows:
DTS State - Indication can be Measuring or Protective shutdown. Measuring means that the sys-
tem is in normal operational mode. Protective shutdown means that an alarm has forced the sys-
tem to switch off excitation power. See 3.4.4.1.5 Control tab.
Excitation - Indication can be On or Off. This is an indication of Roll excitation.
Figure 90. DTS State and Excitation indication
132 3BSE076743R0101 en Rev B

6 Fault Tracing
6.6.1 Event List

For the System Engineer there is an event list as shown in the figure below.
Figure 91. Event list menu
1. Reset event server

2. Show events
Information
Look at Error severity events at time of protective shut down. If a protective shut down has
occurred and and the system has been reset and restarted:
• Ignore warnings and informative text that have occurred after start up.
• The Event list is cleared at start of PFSA287.
Events occur when alarms/warnings becomes active or inactive. These events are shown as
entries in the Event list. It is possible to sort events in different ways by clicking on the header field,
for example the Time header which causes events to be sorted according to time stamp (click
again and the sorting changes order).
3BSE076743R0101 en Rev B 133

6 Fault Tracing
Event list
Attribute Description
NR A number representing the order on which the events have occurred.
Severity Could be Error,Warning or Informative.
ID Unique ID for the alarm that caused the event. Should be used when referring to the
alarm. See Table 12. page 134.
Source Name of the DTS the event comes from. See 1.9.2.5.3 Settings for a description on
how to set a user-friendly name for the DTS.
Title A descriptive title for the event.
Message Could be one of the following: - Hi Limit Active

- Hi Limit Inactive
- Lo Limit Active
- Lo Limit Inactive
- Inaktive
+ Inaktive
+ Active
Time Time A timestamp is telling when the event has occurred.
Pressing the Reset event server button (1) (see Figure 91. Event list menu page 133) deletes all
entries in the event list located in the PFSK287 unit. This operation cannot be undone.
It is also possible to select from which DTS events shall be shown by clicking the “Show Events”
checkbox (2).
Table 12 Event list alarm description
Alarm
Alarm description
ID.
6 Internal Power Supply
13 PFSA107 Temperature 1
14 PFSA107 Temperature 2M
15 PFSA107 Temperature 2S
17 PFSA287 Temperature
18 Roll Leakage
29 Excitation Voltage
30 Excitation Current
31 Data
32 PulseT
33 Clock
134 3BSE076743R0101 en Rev B

6 Fault Tracing
Alarm
Alarm description
ID.
41 Mains Voltage
57 Supply leakage PFSA240
58 PulseE
66 24VDC
68 PFSA 240 Status Warning
69 PFSA185 Status Warning
72 PFSA 240 Status Error
73 PFSA185 Status Error
6.6.2 Ethernet Failure

Table 13 Alarm description and suggested action - Ethernet failure
ID This fault is not represented in the event list and has no ID.
Details The communication supervision in the DTS Tool has detected that there is no
contact between the DTS Tool and the PFSA287 unit
Consequence Impossible to diagnose the DTS.
Cause Connection to DTS not enabled, see the Connection setting described
in 1.9.2.5.3 Settings.
No network cable between the DTS Tool and the PFSA287.
PFSA287 has been powered off.
IP Address mismatch between DTS Tool pc and the PFSA287 unit
Suggested Action Put the connection to ON in the DTS Tool, see the Connection setting descri-
bed in Chapter 1.9.2.5.3 Settings.
Check network cable.
Power on the PFSA287.
Check that the IP Address setting described in 1.9.2.5.3 Settings matches the
address in the PFSA287 and that there are only one network node with that
address on the network.
3BSE076743R0101 en Rev B 135

6 Fault Tracing
6.6.3 System Snapshot

The purpose with the snapshot function is to automatically gather information that shall be used
when communicating with support personnel from ABB/Västerås.
To take a snapshot, log in as System Engineer, open the System Overview Menu and press the
Status Snapshot button (1) shown in the figure below.
Figure 92. Snapshot buttons
1. Status Snapshot
2. Open Snapshot Folders
By pressing the Open snapshot folder button (2) the folder containing snapshots opens in windows
explorer.
The location where snapshot files are stored is decided by the DTSTool.AppSettings.DTU1Snap-
shotFolderName parameter in the ApplicationSettings.xml file.
Figure 93. Structure in the snapshot folder
Figure 93. Structure in the snapshot folder page 136 shows that every time the snapshot button is
pressed a new subfolder is created with it´s name containing current date and time. That subfolder
then contains the snapshot files as shown in Figure 94. Files located in a snapshot folder page
137.
136 3BSE076743R0101 en Rev B

6 Fault Tracing
Figure 94. Files located in a snapshot folder
When corresponding with ABB Support line (or similar) and a snapshot is requested, the files (1 or
more depending on the situation) can be sent to ABB in order to be able to give as good support
as possible. Making a zip of a snapshot results in a file with an approximate size of 400kB (includ-
ing all 4 files) which makes it suitable to attach in a mail.
3BSE076743R0101 en Rev B 137

Appendix A Channel Calibration
A Channel Calibration
Information
The system should be powered (with closed cabinet door) for at least 30 minutes before starting
Channel Calibration. It is important that Channel Calibration is performed first, then the Bias
Calibration (if applicable), and finally the Roll Calibration verification.
1. Start the BM Tool.

2. Set the BM system to Channel calibration mode
Configuration and maintenance > System mode > System mode request = 3.
3. Select the Channel calibration display
Configuration maintenance > Channel calibration.
4. Click the Start channel calibration button (the button becomes ‘yellow’ and Box 1 in Status
will be activated).
5. Channel calibration is ready when the start button change colour from yellow to gray, and
Box 1 in Status is deactivated. The calibration progress is indicated by the progress bar.
6. If Box 2, 5 and 32 are activated, the Channel calibration was successful.
If Box 2 or 5 are not activated, the calibration process failed.
Box 4, 6 and 7 together with the showed array (measured and filtered channel sensitivity)
can give a hint about which type of error that has occurred, and which channels that failed.
7. To save the new configuration
Back-up > Make and restore back-up > Flash. The Flash progress is indicated by the pro-
gress bar.
Information
A new Channel Calibration is required after:
• Restore of the Application SystDb or Rolldb.

• Replacement (new) or interchange of Signal Processing board (PFSK 151).
• Use of signal processing Cross connection table.
• Cold Start-up after software upgrade.
138 3BSE076743R0101 en Rev B

Appendix A Channel Calibration
Figure 95. Channel calibration.
3BSE076743R0101 en Rev B 139

Appendix B Roll Calibration Verification
B Roll Calibration Verification
B.1 Procedure
1. Start the BM tool, if not already started.
2. Set the BM system to Roll Calibration verification.
Configuration and maintenance> System mode, System mode request=5
3. Select the Roll calibration verification display Configuration and maintenance>Roll calibration
verification.
Figure 96. Roll calibration verificaton
Roll calibration mode is active by the Status bit RoCalibrAct (Box 1)
Information
If cross-talk is used, the Force compensation settings bit ForceLimEnable (Box 27) must be off.
See also Appendix "Roll Calibration force diagram".
4. If it is a new verification, click the Reset and restart button, before the Req.verification button
is activated.
140 3BSE076743R0101 en Rev B

5. Click on the Req.verification button(the button-text becomes "bold" to activate the Roll verifi-
cation. Verification active is indicated by Status bit VerifyActive, (Box 2)
6. Load a zone at a time using the calibration device, see 3.3.7.2 Calibration Verification Equip-
ment.
7. Check the force signal by using an oscilloscope. Make sure that the force pulses are in the
center of the integrating window. Use the View function to set the ZoneBigForce bit (Box 7).
8. Click on the Acknowledge button when the zone reach the final value and are stable. The
StatusAckowCond bit (Box 14) must be set to Acknowledge.
Figure 97. Roll calibration verification acknowledge
Successful zone Acknowledge is indicated by Status bit AcknowActive, (Box15). LED I5 is lit
green for 1 second.
9. If box 14 is not set, click the question mark at the right of the box-field "Roll calibration sta-
tus".
Boxes 1-13 will give the reason, if needed click "Calibration parameters" button to adjust the
parameters.
10. Move the calibration weight to the next zone and repeat step 6-9, until all zones are done.
11. The result (SSCF) is OK when a straight line +/- tolerance is achieved.
If Roll Calibration control bit OrgZscfComp (Box 6) is set, the display indicates SSCF com-
pensated with stored (roll-data)SSCF.
If Roll Calibration control bit OrgZscfComp (Box 6) is not set, the Roll calibration force dia-
gram indicates measured raw SSCF.
12. Click the Req. Verification button to turn it Off (the text button becomes plane). Verification
Off, is indicated by Status bit VerifyActive (Box 2) becomes extinguished.
3BSE076743R0101 en Rev B 141

13. Do Not save.

The normal procedure is to do a verification only. This means that the Roll calibration data is
not permanently saved.
If the decision is to keep the new parameter values, click on the Save button.
The Status bit SaveCond(Box17) must be set, else the SSCF can not be saved.
Figure 98. Roll calibratiom verification save
Successful Save is indicated by Status bit SaveCompl(Box18)

LED I5 green for 2 seconds.
If Save fails, LED I5 lit red for 2 seconds.
14. To Flash the new configuration, select Back-up handling> Make and Restore back up>
Flash, see chapter "5.2.2 Saving Configuration to Flash".
This is to check/compare the latest verified SSCF with the used/permanent SSCF.
15. To back-up the new configuration, select back-up handling > Make and Restore back up>
Make, see chapter "5.2.3 Making Backup".
The system backup will include even the unsaved roll calibration values, if you want to import
them into EXCEL etc. for examination.
This is to check /compare the latest verified SSCF with the used/permanent SSCF.
Information
If you want to restart the Roll calibration verification from the beginning, go back to step 2, and
click Reset and restart button.
Note that all acknowledged zones done so far, are cleared (cancelled).
142 3BSE076743R0101 en Rev B

B.2 Roll Calibration Force Diagram

In the Figure below the ‘green’ bars indicates the measured SSCF values. The ‘yellow’ bar indi-
cates the SSCF and cross-talk force.
Figure 99. Roll Calibration Force
According to the above Figure we have:

Fr(z) = Mv(z)/S(z) + Mv(z-1)/S(z-1) +Mv(z+1)/S(z+1)
where:
Fr(z) = radial calibration force
Mv(z) = measured SSCF value for loaded zone in focus (z)
S(z) = sensitivity of sensors for zone (z)
(z-1) = zone index on the left side of the zone in focus
(z+1) = zone index on the right side of the zone in focus
The ‘yellow’ bar in the diagram indicates the cross-talk and the normalization part when
the Roll calibration control bit OrgZscfComp (Box 6) is active.
3BSE076743R0101 en Rev B 143

Alphabetical index
Alphabetical index
acceleration boost ........................................................... 49 filter regulator unit ............................................................ 17
air purge .......................................................................... 78 flash memory ................................................................. 118
air purge .......................................................................... 17 flatness computer fc ...................................................... 109
architecture configuration ................................................ 11 flatness control system (fcs) ............................................. 11
architecture description language(adl). ............................. 12 flatness error measurement system (fems) ....................... 10
backup .......................................................................... 117 flatness measurement system (fms) ................................. 10
base measurement system (bm-part) ................................ 9 flatness server architecture (fsa). ...................................... 11
bearing housing ......................................................... 13, 77 flatness-part ...................................................................... 9
bearing housings ........................................................... 102 force distribution measurement system (fdms) ................. 10
bm tool .......................................................................... 113 force pulse ...................................................................... 86
bm-part ............................................................................. 9 friction losses .................................................................. 49
BMS .............................................................................. 112 fsa-objects ................................................................ 11, 12
board ............................................................................ 110 grease ............................................................................. 81
bonding ........................................................................... 40 grinding ......................................................................... 100
cabinet ...................................................................... 54, 55 grounding .................................................................. 40, 62
cable duct ....................................................................... 55 hold down force .............................................................. 48
cable sheath .................................................................... 58 humidity .......................................................................... 51
cables ....................................................................... 55, 58 i/o-cables ........................................................................ 57
calibration verification unit ................................................ 82 interference ............................................................... 39, 56
channel calibration mode ............................................... 138 ip address for a pfsa287 .................................................. 30
check list ......................................................................... 71 labyrinth seals .................................................................. 43
commissioning ................................................................ 71 logging ............................................................................ 91
communication link .......................................................... 57 lubricated bolts ................................................................ 48
compounding effect ........................................................ 48 lubrication .................................................................. 52, 78
cooling system ................................................................ 17 mandrel ........................................................................... 46
corrosion protection ........................................................ 41 measuring roll .................................................................. 97
cross-talk ...................................................................... 143 measuring width .............................................................. 45
delivery check ........................................................... 41, 53 measuring zone ............................................................... 13
detection ......................................................................... 87 measuring zones ............................................................. 15
documents ...................................................................... 41 mechanical stop .............................................................. 48
drain holes ....................................................................... 83 MVME 3100 .................................................................. 110
DTS ................................................................................. 19 mvme 3100 boot line ..................................................... 111
dts tool password ............................................................ 25 oem-architectures ........................................................... 11
dtu cover ......................................................................... 33 oil .................................................................................... 52
earth fault ...................................................................... 131 onnetion unit dts pfsc230 ............................................... 32
edge position ................................................................ 114 particle size ..................................................................... 51
edge zone compensation .............................................. 115 polish ............................................................................ 102
electrical bonding ............................................................ 40 power and media converter unit pfsa185 ........................ 34
electro static discharge (esd) ........................................... 39 pressductor principle ....................................................... 13
EMC ................................................................................ 55 product levels .................................................................. 10
encoder signals ............................................................... 83 protective shut-down ..................................................... 132
erminal .......................................................................... 112 pulse encoder ................................................................. 16
event list ........................................................................ 133 reset event server button ............................................... 134
FC ................................................................................. 109 reset of the pfsk287 ....................................................... 94
fiber optic cable ............................................................... 57 restore backup .............................................................. 121
filter ................................................................................. 78 roll ................................................................................... 47
144 3BSE076743R0101 en Rev B

Alphabetical index
roll calibration verification ............................................... 140

roll excitation fault .......................................................... 131
roll dc supply unit pfsa 240 ........................................... 31
rotary transformer ............................................................ 15
save .............................................................................. 118
scratches ................................................................ 48, 102
shim plate ........................................................................ 45
snapshot folder ............................................................. 136
snapshot function .......................................................... 136
software ........................................................................ 114
software architecture configurations ................................ 11
speed control .................................................................. 49
standard measuring roll ................................................... 12
start menu ....................................................................... 22
stator housing ................................................................. 15
storage space ................................................................. 95
storage space in backup folder ....................................... 95
store ................................................................................ 41
surface finish ................................................................. 101
system overview menu .................................................... 26
system status indicator .................................................... 22
temperature ............................................................... 42, 77
tracking ........................................................................... 86
unpacking ....................................................................... 41
usb-memory stick .......................................................... 122
wc/co coated roll ........................................................... 102
vertical alignment ............................................................. 45
windings .......................................................................... 13
wrap angle ...................................................................... 42
zone sensitivity changes .................................................. 81
3BSE076743R0101 en Rev B 145

—
ABB AB
Industrial Automation
Measurement & Analytics
Force Measurement
SE-721 59 Västerås Sweden
Tel: +46 21 32 50 00
Internet: www.abb.com/stressometer
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Stressometer Flatness System With Standard Roll: User Manual

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Stressometer Flatness System

© Copyright 2014- 2018 ABB. All rights reserved.

3 System Check and Maintenance

B Roll Calibration Verification

1.2 Cyber Security Disclaimer

1.3 Disposal and Recycling

1.3.1 Environmental Policy

1.3.2 Recycling Electrical and Electronic Equipment, WEEE

1.3.3 Recycling the Transport Material

1.3.4 Disposal of the Product

1.3.4.1 Dismantling and Recycling of the Product

1.4 Flatness System Overview

Figure 1. Example of a Flatness System

1. Roll Drive system (optional)

1.5 Flatness Functionality

Measuring Roll BM-part Flatness Client Computer

Figure 2. The two main parts of the Flatness System

1.5.1 System Product Levels

Force Measurement Measurement Flatness Flatness Error Flatness Control

Target Models Actuator Models

Figure 3. Flatness Systems

• The FDMS performs the following operations:

• The FMS performs the following operations:

• The FEMS performs the following operations:

1.5.2 Flatness Server Architecture (FSA)

1.5.3 Software Description

1.6 Measuring Roll

1.6.1 Mechanical Design

Figure 4. Transducer arrangement in Standard Measuring Roll

1.6.1.1 Design and Electrical Operation of Transducers

1.6.1.2 Bearings and Seals

1. Bearing house for direct mounting on the Measuring Roll support.

Figure 5. Bearings with seals.

1.6.1.3 Air Purge

Figure 6. Air Purge in Standard Measuring Roll

1. Air filter regulator

1.7 Digital Transmission Unit - DTU

There are two types of DTU.

• PFSA107-Z42 1-42 measuring zones, blue washer at the 100-pin connector.

A label plate is positioned on the DTU, it states:

DTU Technical Data

Degree of protection (DTU cover) IP65

Number of measurement signals transmitted Up to 64

Operation temperature (ambient) +5 to + 70 deg C.

Storage temperature -25 to + 70 deg C.

Operation speed Up to 2400 rpm

Bump test 60068-2 10g

Vibration tolerance (recommended) < 2 mm/s at 10 to 200 Hz

Type of bearing Sealed hybrid deep groove

1.7.1 Digital Transmission Unit

Figure 7. Digital Transmission Unit

1.7.2 Pulse Encoder

• A total of 3 signals and one excitation on 1024 pulse channels.

• A balanced RS422 signal

Figure 8. Pulse Encoder

1.8 DTU Air Purge

Figure 9. Air flow inside the DTU Cover

Pressurized air for cooling and purge

Particle size: ≤0.1 μm (acc. to ISO8573-1 class

Oil contents: ≤0.01 ppm/weight air (acc. to

Max consumption: 5 Ndm³/s (≈300 l/min)

Air Supply temperature +5 - +35 deg C.