Preliminary: Model 2080-03 and 2080-13 Scanners Installation and Maintenance Manual

Model 2080-03 and 2080-13 Scanners
Installation and Maintenance Manual
Preliminary
July 2000 Part No. 46019100

Model 2080-03 and 2080-13 Scanners
Installation and Maintenance Manual
Preliminary
July 2000
P/N 46019100 i
Model 2080-03 and 2080-13 Scanners Installation and Maintenance
Confidentiality Statement
This manual is a product of Honeywell International Inc. in Cupertino, California. It is intended for use only by
Honeywell International Inc. and customer personnel in connection with Honeywell International Inc. products. It is
strictly prohibited to copy this manual or any part thereof or to transfer this manual or any part thereof to any non-
Honeywell International Inc. person or entity, except customer personnel for use in connection with Honeywell
International Inc. products. Persons employed by a third-party service company shall not have access to this manual.
Notice
All information and specifications contained in this manual have been carefully researched and prepared according to the
best efforts of Honeywell International Inc., and are believed to be true and correct as of the time of this printing.
However, due to continued efforts in product improvement, we reserve the right to make changes at any time without
notice.
To order additional or revised copies of this publication, contact Honeywell International Inc.,
One Results Way, Cupertino, CA 95014-5991, U.S.A. Telephone (408) 255-1500.
Trademarks
All trademarks and registered trademarks are the properties of their respective holders.
Copyright
© 2000 by Honeywell International Inc., One Results Way, Cupertino, CA 95014-5991, U.S.A.
All rights reserved. No part of this publication may be reproduced or translated, stored in a database or retrieval system,
or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the
prior written permission of Honeywell International Inc.
Printed in the United States of America.
ii P/N 46019100
Model 2080-03 and 2080-13 Scanners Installation and Maintenance Contents
Contents
1. Introduction................................................................................................................................ 1-1
1.1. Purpose and Scope............................................................................................................. 1-1
1.2. Intended Audience ............................................................................................................. 1-1
1.3. Related Reading................................................................................................................. 1-2
1.4. About This Manual............................................................................................................ 1-2
1.5. Conventions ....................................................................................................................... 1-3
2. Understanding the Scanners ..................................................................................................... 2-1
2.1. Scanner Features................................................................................................................ 2-1
2.2. Installation Overview......................................................................................................... 2-4
2.2.1. Scanner Installation Checklist .................................................................................. 2-5
3. Preparing the Site ...................................................................................................................... 3-1
3.1. Electrical Ground Requirements........................................................................................ 3-2
3.2. Power Requirements.......................................................................................................... 3-3
3.3. Cable Requirements........................................................................................................... 3-3
3.3.1. Cable Specifications ................................................................................................. 3-3
3.3.2. Pre-Assembled Cables .............................................................................................. 3-4
3.3.3. Conduit Size.............................................................................................................. 3-4
3.3.4. Conduit Installation.................................................................................................. 3-5
3.3.5. Cable Tray................................................................................................................ 3-6
3.4. Environmental and Plumbing Requirements ..................................................................... 3-8
4. Unpacking the Scanners ............................................................................................................ 4-1
4.1. Inspecting the Shipment .................................................................................................... 4-1
4.2. Unpacking the Hardware ................................................................................................... 4-3
4.2.1. Scanners.................................................................................................................... 4-3
4.2.2. Sensors and Accessories ........................................................................................... 4-4
4.2.3. Basis Weight Sensor Storage .................................................................................... 4-5
5. Installing the Scanners ............................................................................................................... 5-1
5.1. Using the Scanner Installation Checklist........................................................................... 5-1
5.2. Installing the Scanner ........................................................................................................ 5-1
5.2.1. Radiation Safety........................................................................................................ 5-2
5.2.2. Scanner Installation Procedures................................................................................ 5-2
5.3. Installing and Aligning the Heads/Sensors........................................................................ 5-8
5.3.1. Head Alignment ........................................................................................................ 5-8
5.3.1.1. Head Installation and Alignment Procedure ................................................ 5-11
5.3.1.2. Radiation Safety........................................................................................... 5-11
5.3.1.3. Radiation Interlock System.......................................................................... 5-12
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Contents Model 2080-03 and 2080-13 Scanners Installation and Maintenance
5.3.1.4. Section 1 – Mounting the Heads .................................................................. 5-13

5.3.1.5. Scanner Height and Pass Angle Check ........................................................ 5-20
5.3.1.6. Section 2 – Aligning the Heads.................................................................... 5-23
5.4. Air and Water Connections ............................................................................................. 5-27
5.5. Electrical Connections ..................................................................................................... 5-30
5.5.1. Electrical Connections to the Heads ....................................................................... 5-30
5.5.2. Cable Installation – Host Computer System to Scanner......................................... 5-30
5.5.3. Grounding............................................................................................................... 5-35
5.5.4. Ground Safety Test ................................................................................................. 5-35
6. Maintaining the Scanners and Sensors .................................................................................... 6-1
6.1. Preventive Maintenance..................................................................................................... 6-1
6.1.1. Daily.......................................................................................................................... 6-2
6.1.2. Monthly..................................................................................................................... 6-2
6.1.3. Every 3 Months......................................................................................................... 6-3
6.1.4. Every 6 Months......................................................................................................... 6-3
6.2. Monthly Inspection and Cleaning Procedure .................................................................... 6-3
6.2.1. Maintaining the Motor.............................................................................................. 6-5
6.3. Replacing Mechanical Assemblies .................................................................................... 6-6
6.3.1. Replacing Head Carrier Wheels ............................................................................... 6-7
6.3.1.1. Upper Head Assembly.................................................................................... 6-7
6.3.1.2. Lower Head Assembly................................................................................. 6-10
6.3.2. Replacing Belts....................................................................................................... 6-10
6.3.2.1. Upper Belt Replacement Procedure ............................................................. 6-11
6.3.2.2. Lower Belt Replacement Procedure............................................................. 6-13
6.3.3. Replacing the Power Track..................................................................................... 6-14
6.4. Troubleshooting the Scanners.......................................................................................... 6-18
6.4.1. Mechanical Troubleshooting .................................................................................. 6-18
6.4.1.1. Adjusting Belt Tension................................................................................. 6-18
6.4.2. Scanner Electronics Troubleshooting..................................................................... 6-18
6.4.2.1. Scanner Switches.......................................................................................... 6-19
6.4.2.2. Scanner Termination Board ......................................................................... 6-21
6.4.3. Scanner Schematics ................................................................................................ 6-22
6.4.4. Circuit Board Replacement Guidelines .................................................................. 6-22
6.5. Maintaining the Sensors .................................................................................................. 6-27
6.5.1. Radiation Safety...................................................................................................... 6-27
6.5.1.1. Radiation Warning Lamps ........................................................................... 6-28
6.5.2. General Maintenance and Troubleshooting Notes ................................................. 6-28
6.5.2.1. Removing Head Cover(s) and/or Separating Sensor Heads......................... 6-28
6.5.2.2. Cleaning Windows ....................................................................................... 6-30
6.5.2.3. Replacing Windows ..................................................................................... 6-31
iv P/N 46019100
Model 2080-03 and 2080-13 Scanners Installation and Maintenance Contents
Appendices
A. Scanner Installation Checklist..................................................................................................A-1

B. Radiation Licensing Requirements ..........................................................................................B-1
B.1. Nuclear Sensor Shipment to a U.S. End-User Site............................................................B-1
B.2. Nuclear Sensor Shipment to a U.S. OEM Site ..................................................................B-4
B.3. Radioactive Materials Regulations ....................................................................................B-5
B.3.1. Regulatory Authority................................................................................................B-5
B.3.2. Licensing...................................................................................................................B-5
B.3.2.1. Specific License Requirements ......................................................................B-6
B.3.2.2. General License Requirements.......................................................................B-6
Glossary..........................................................................................................................................GL-1
Table of Figures
Figure 2-1. Model 2080-03 Scanner with Major Features................................................................2-2
Figure 2-2. Model 2080-13 Scanner .................................................................................................2-3
Figure 3-1. Scanner Air and Water Plumbing...................................................................................3-8
Figure 5-1. Scanner Installation (Sheet 1 of 4) .................................................................................5-3

Figure 5-2. Scanner Reference Illustration.......................................................................................5-9
Figure 5-3. Side View of Sheet Centered in Air Gap......................................................................5-10
Figure 5-4. Lower Head Platform...................................................................................................5-13
Figure 5-5. Bulkhead Board Cover Removal..................................................................................5-14
Figure 5-6. Checking Head Height .................................................................................................5-15
Figure 5-7. Placing the Lower Head ...............................................................................................5-17
Figure 5-8. Scanner End View of Pass Angle .................................................................................5-19
Figure 5-9. Improvised Alignment Fixtures....................................................................................5-21
Figure 5-10. Fine and Dynamic Head Adjustment .........................................................................5-22
Figure 5-11. Lower Head X-Direction Adjustment ........................................................................5-24
Figure 5-12. X Alignment ...............................................................................................................5-25
Figure 5-13. Scanner Water Plumbing............................................................................................5-28
Figure 5-14. Water and Air Connections to the Upper Head..........................................................5-29
Figure 5-15. Scanner-to-Host Computer System Termination Wiring Diagram I..........................5-31
Figure 5-16. Scanner-to-Host Computer System Termination Wiring Diagram II ........................5-32
Figure 5-17. Scanner-to-Host Computer System Termination Wiring Diagram III.......................5-33
Figure 5-18. Motor End Distribution Board Schematic ..................................................................5-34
P/N 46019100 v
Contents Model 2080-03 and 2080-13 Scanners Installation and Maintenance
Figure 6-1. Control Switch on the Scanner Termination Board .......................................................6-4

Figure 6-2. Mounting Hardware for Mechanical Assemblies...........................................................6-6
Figure 6-3. 2080-03 and 2080-13 Scanner Upper Head Carrier.......................................................6-8
Figure 6-4. Belt Installation at the Carriage ....................................................................................6-12
Figure 6-5. Lower Head Carrier and Belt .......................................................................................6-13
Figure 6-6. Upper Power Track Carrier Bracket.............................................................................6-15
Figure 6-7. Lower Power Track Carrier Support Bracket...............................................................6-15
Figure 6-8. Upper Power Track Support Bracket ...........................................................................6-16
Figure 6-9. Lower Power Track Support Bracket...........................................................................6-17
Figure 6-10. Scanner Installation Connection for Basis Weight and IR Sensors (Sheet 1 of 2) ....6-23
Figure 6-10. Scanner Installation Connection for Basis Weight and IR Sensors (Sheet 2 of 2) ....6-24
Figure 6-11. Upper Grateful Head to Power Track Wiring ............................................................6-25
Figure 6-12. Lower Grateful Head to Power Track Wiring............................................................6-26
Figure 6-13. Window Frame Replacement, and Static and Fine Head Alignment .........................6-33
Table of Tables
Table 3-1. Cable and Conduit Information.......................................................................................3-4
Table 3-2. Belden Tray Cable Equivalents .......................................................................................3-7
Table 3-3. Minimum Separation of Cables .......................................................................................3-7
Table 3-4. Typical Sensor Air and Water Requirements..................................................................3-9
Table 5-1. Pass Angle Requirements ..............................................................................................5-20
Table 6-1. Manual Switches............................................................................................................6-19

Table 6-2. System Switches ............................................................................................................6-20
Table 6-3. LEDs on the Scanner Termination Board......................................................................6-21
vi P/N 46019100
Model 2080-03 and 2080-13 Scanners Installation and Maintenance Introduction
1. Introduction
1.1. Purpose and Scope

The purpose of this manual is to provide the information necessary to install,
start up, and maintain the Honeywell-Measurex 2080-03 and 2080-13 Scanners.
The chapters are presented in the sequential order necessary to install the
scanners. Although the Model 2080-03 and 2080-13 Scanners are typically
installed by Honeywell-Measurex personnel, the scanners can also be installed by
the supplier of the extrusion line or by the end user.
Tasks such as sensor calibration, control tuning, and operator training are not
included in this manual. For information on those areas, refer to the
documentation that shipped with the sensor and the computer control equipment.
1.2. Intended Audience

It is assumed that the people responsible for installing the scanners are
experienced in the installation, interconnection, and startup of typical industrial,
electrical, and electronic systems, and that they will only require technical details
specific to the Honeywell-Measurex system.
If you are planning to install the Model 2080-03 and 2080-13 Scanners for the
first time, it is recommended that you contact Honeywell-Measurex regarding the
availability of training in your area. To avoid violating regulatory restrictions on
the installation and testing of Honeywell-Measurex sensors containing radioactive
sources, you should carefully review and comply with the requirements
summarized in Appendix B, “Radiation Licensing Requirements.”
P/N 46019100 1-1

Introduction Model 2080-03 and 2080-13 Scanners Installation and Maintenance
1.3. Related Reading

The following documents contain related reading material:
P/N Document Title

44070004 Radiation Safety Training Manual
(for Honeywell-Measurex employees)
44071500 Radiation Safety Manual for
Honeywell-Measurex Customers
46014801 Source 15 Basis Weight Sensor
User Manual
MN462400 IR Manual: Grateful Head
Transmission IR Sensor
User Manual
Note:
In addition to the documents listed above, refer
to the Production Release and Bill Of Materials
for your system.
1.4. About This Manual

There are 6 chapters in this manual, and they are presented in the order necessary
to install the scanners. There are also 2 appendices and a glossary.
Chapter 1, Introduction, provides the purpose and scope of the manual, the
intended audience, related reading material, and a list of conventions used
throughout the document.
Chapter 2, Understanding the Scanners, provides a brief overview of the

hardware components of the scanners and how they fit into the overall extrusion
line installation.
Chapter 3, Preparing the Site, details the grounding and power specifications,
the environmental and utility requirements, and the cable and conduit
specifications required to install the scanners.
Chapter 4, Unpacking the Scanners, provides instructions for unpacking and

inspecting the scanners at the site.
1-2 P/N 46019100

Model 2080-03 and 2080-13 Scanners Installation and Maintenance Introduction
Chapter 5, Installing the Scanners, describes how to install the scanner

components.
Chapter 6, Maintaining the Scanners and Sensors, presents maintenance

information for the Model 2080-03 and 2080-13 Scanners.
Appendix A, Scanner Installation Checklist, is used to verify the installation

of the scanners. The checklist can be copied and used with each installation.
Appendix B, Radiation Licensing Requirements, provides information from

the Honeywell-Measurex Radiation Safety Office to the OEM, Honeywell-
Measurex, and end user regarding regulatory requirements that apply to the
installation and testing of Honeywell-Measurex sensors containing radioactive
sources.
1.5. Conventions
The following conventions are used in this manual:
Courier New 10 pt User commands and typed entries are shown in this
or 11 pt Bold special type.
Courier New 10 pt System responses are shown in this special type.

or 11 pt Regular
Italics In a command line or error message, words and

numbers shown in italics represent filenames,
words, or numbers that can vary; for example,
filename represents any filename.
In text, manual titles are shown in italics.
Times New Roman In text, boldface is used for key terms, button
12 pt Bold names, menu and screen selections, and emphasis.
P/N 46019100 1-3

Introduction Model 2080-03 and 2080-13 Scanners Installation and Maintenance
UPPERCASE In a command line, words in uppercase letters are

filenames or words that must be entered exactly as
they appear in the command line.
lowercase In an error message, words in lowercase letters are

filenames or words that can vary.
In a command line, words in lowercase letters

indicate variable input.
Key-1 In text, names of keys are written with initial caps;

for example, Tab.
[Key-1] In command lines, names of keys are enclosed with

square brackets and written with initial caps; for
example, [Tab].
[Key-1]-[Key-2] Keys pressed simultaneously are shown separated

by a hyphen; for example, [Ctrl]-[C].
[Key-1], [Key-2], [Key-3] Keys pressed in sequence are shown separated by

commas; for example, [Alt], [F], [A].
[] In command lines, square brackets signify that the

content is optional.
<> Angle brackets enclose commands and parameters

used to construct diagnostic command lines.
\ or / A slash or backslash precedes a directory

specifier; for example, /DATA or \DATA.
1-4 P/N 46019100

Model 2080-03 and 2080-13 Scanners Installation and Maintenance Understanding the Scanners
2. Understanding the Scanners
The Model 2080-03 and 2080-13 Scanners (09208003 and 09208013) are
compact, precision scanners that support Honeywell-Measurex online thickness
sensors in a variety of industrial applications, such as flat die extrusion and vinyl
calender.
The scanners can support a number of different quality parameter sensors. A

host computer controls the scanners and sensors. The sensors scan back and forth
across the moving web, sending information about product quality parameters and
sensor position to the host computer. One or more operator consoles display this
information as a profile.
The following sections provide an overview of the Model 2080-03 and 2080-13
Scanners, related system components, and the installation procedure:
• Scanner Features
• Installation Overview
2.1. Scanner Features

The Model 2080-03 and 2080-13 Scanners consist of a frame and drive motor
with belts and pulleys that move a sensor across a sheet to measure the product.
A digital encoder generates pulses used to track the position of the sensor heads.
For information about the sensors, refer to the sensor documentation supplied
with your system.
Honeywell-Measurex configures the scanners to meet each customer’s unique

requirements. Refer to Figure 2-1 for an illustration of a typical configuration
for the Model 2080-03 Scanner. Figure 2-2 shows the Plow, the Tray, and the
Extrusions that mark the difference between the 2080-03 and the 2080-13
Scanners.
P/N 46019100 2-1

Understanding the Scanners Model 2080-03 and 2080-13 Scanners Installation and Maintenance
Figure 2-1. Model 2080-03 Scanner with Major Features
2-2 P/N 46019100

Figure 2-2. Model 2080-13 Scanner
P/N 46019100 2-3

2.2. Installation Overview

Installation of the Model 2080-03 and 2080-13 Scanners is performed by
Honeywell-Measurex service personnel, the end user, or the extrusion line
supplier (also referred to as the Original Equipment Manufacturer (OEM)).
This manual assumes that the installer is experienced at performing the

installation, interconnection, and startup of typical industrial electrical and
electronics systems, and only requires technical details specific to the Honeywell-
Measurex system. If you are planning to install a system for the first time, you
should contact Honeywell-Measurex and register for installation training in your
area.
Model 2080-03 and 2080-13 Scanners are configured by Honeywell-Measurex

at the factory to meet the special needs of each customer. The details of your
hardware installation probably will vary from the basic system described in this
manual. These details are described in the Production Release document that
shipped with the scanners. Review the Production Release thoroughly before
starting the installation. This document is part of the scanner system and must be
kept on file at the installation site.
There are regulatory restrictions on installation and testing of Honeywell-

Measurex sensors containing radiation sources (X-ray or radioactive). When a
nuclear Basis Weight Sensor is mounted on a Model 2080-03 or 2080-13 Scanner,
it will contain a radioactive source (as indicated by the labels on the sensor head).
Therefore, you must read and comply with all of the safety and regulatory
restrictions in the Radiation Safety Training Manual for Honeywell-Measurex
employees (P/N 44070004) or the Radiation Safety Manual for Honeywell-
Measurex Customers (P/N 44071500), and the requirements summarized in
Appendix B, “Radiation Licensing Requirements.” For further information,
contact the Honeywell-Measurex Radiation Safety Office.
The scanner installation procedure includes:
• Unpacking and inspecting the equipment
• Placing and installing equipment
• Providing system utilities (air, water) as needed
• Installing and terminating interconnecting cables between system

components
2-4 P/N 46019100

• Verifying that the scanner is functioning correctly by completing the

Scanner Installation Checklist
• Ensuring that the applicable portions of a sensor installation and/or the

required installation radiation safety tests are conducted by persons
specifically licensed for these operations (refer to Appendix B,
“Radiation Licensing Requirements”)
This procedure does not include calibrating the sensor(s), control tuning, or
installing other system components, such as the host computer (or its software).
Refer to the manuals provided with your system for information about these
components and procedures.
2.2.1. Scanner Installation Checklist

Appendix A, “Scanner Installation Checklist,” contains an installation checklist
for the Model 2080-03 and 2080-13 Scanners. You should make a copy of this
checklist to use for each scanner installation. Use it as a guide when preparing the
site (Chapter 3), unpacking the scanner (Chapter 4), installing the scanner
(Chapter 5), and verifying the installation.
P/N 46019100 2-5

2-6 P/N 46019100

Model 2080-03 and 2080-13 Scanners Installation and Maintenance Preparing the Site
3. Preparing the Site
Before installing Model 2080-03 and 2080-13 Scanners, you must determine
where the hardware components will be placed and then prepare the site. The
site preparation includes:
• Determining the precise hardware location, including space for

access to all openings
• Constructing and installing mounting pads
• Mounting bolts
• Determining electrical grounding requirements
• Preparing power outlets
• Determining cable lengths
• Assembling and routing cables
• Cutting the floor for bottom cable entry
• Purchasing and installing conduit and cable trays
• Preparing water and air plumbing
• Drilling or punching entry holes in hardware cabinets
P/N 46019100 3-1

Preparing the Site Model 2080-03 and 2080-13 Scanners Installation and Maintenance
Use the installation diagrams in Chapter 5, “Installing the Scanners,” to help you
determine the physical dimensions and requirements for your scanner installation.
In addition, the following sections of this chapter define the scanner installation
specifications:
• Electrical Ground Requirements
• Power Requirements
• Cable Requirements
• Environmental and Plumbing Requirements
Use the Scanner Installation Checklist to guide you through the site preparation.
3.1. Electrical Ground Requirements

All Honeywell-Measurex equipment must be properly grounded to prevent
electrical shock. Proper grounding also ensures reliable and accurate signal
transmission between hardware components. Never apply power to any
Honeywell-Measurex unit until after properly terminating the equipment
ground.
All grounding must comply with the U.S. National Electrical Code (NEC) and
local electrical codes.
To properly ground the scanner:
• The enclosure around the scanner must have a low impedance path to
the third wire (green) safety ground.
• The distance from the scanner to a proper ground cannot exceed 100 feet
(30.5m).
3-2 P/N 46019100

3.2. Power Requirements

The Model 2080-03 and 2080-13 Scanners use 24 VDC from a power supply
located in the MSS enclosure. No other power is required for the scanner, itself.
3.3. Cable Requirements

Typically, 3 cables are required between the scanner and the MSS enclosure.
A fourth cable is needed whenever 2 sensors are installed on the scanner, or
where cable lengths exceed 250 feet (76.2m). For details, refer to the installation
drawings in Chapter 5, “Installing the Scanners,” and your Production Release
document.
Each cable length must not exceed 300 feet (91.4m).
3.3.1. Cable Specifications

The following list describes general specifications for cable installation:
• Place cables in a metal conduit or in a cable tray.
• When cable trays are used, use only cables that have been approved
for this use.
• Fill conduit no more than 40% full (current NEC spec.).
• Run all AC power cables in a conduit or cable tray that is separate

from any conduit or cable trays used for signal cables.
• If it is more convenient, you may use the same conduit or cable tray
for both signal cables and DC power cables.
• Run all cables without splices.
• Extend all cables beyond the conduit or cable tray ends a minimum of
12 feet (3.7m) for terminations.
• Identify and label each cable end.
Recommended conduit-type cables are listed in Table 3-1. The cable numbers
correspond to the numbers on the installation drawings in Chapter 5, “Installing
the Scanners.”
P/N 46019100 3-3

Table 3-1. Cable and Conduit Information
Cross-
P/N Cable Vendor Sectional
(Qty) No. Information Description Area Max. Length
60000328 1 Belden 8718 DC motor power 0.13 in 2 300 ft (91.5m)

(1) 2C, 12 AWG, shielded (82 mm2 )
60000139 2 Belden 8620 DC power 0.11 in 2 300 ft (91.5m)
(1) 4C, 16 AWG, 600V, PVC (71 mm2 )
60000194 3 and 4 Belden 8775 Signals and Control 0.17 in 2 300 ft (91.5m)
(2) 11 pair, 22 AWG, shielded pair, twisted (109 mm2 )
60000466 5 Belden 9912- Ground 300 ft (91.5m)
(1) 1X100-189 1C, 12 AWG
60000261 6 ITT A1072-04 Ground 0.07 in 2 100 ft (30.5m)
(1)* 1C, 6 AWG, Green, PVC (not supplied) (45 mm2 )
* Ground cables shall have a continuous outer finish that is either green or green with one or more yellow stripes
(per NEC Spec. 310-10b).
3.3.2. Pre-Assembled Cables

At the time of this printing, pre-assembled cables are offered in lengths of 20,
100, and 250 feet.
3.3.3. Conduit Size

To calculate the correct size of conduit for your installation, use the following
procedure:
1. Determine the quantity of each cable type in a run.
2. Calculate the sum of the individual cross-sectional areas of all the cables
in the run.
3. Determine the conduit size. For example, for a system configured to use
cables numbered 1, 2, 3, 4, and 6, the sum of cable cross-sectional areas
is 0.65 in2 (4.2 cm2). Therefore, a conduit with a diameter of at least
1.5 inches must be used to meet the “40% full” requirement of the NEC
specification.
3-4 P/N 46019100

3.3.4. Conduit Installation

The conduit system provides a protective passageway for the system cables. This
section specifies conduit requirements that meet or exceed the NEC specification.
Table 3-1 lists the cables approved for use in conduits (not for cable trays). You
can use this information to obtain the cable locally, if necessary, and to assist in
calculating the size of the conduit needed for the cable runs.
When installing the conduit system:
• Use rigid metal conduit on all signal runs. Where races are exposed to the
weather, at wet locations, or where the conduit is embedded in concrete,
use galvanized steel conduit. The steel conduit forms an electromagnetic
shield around the signal cables. Using conduit made of an alternative
material degrades the shielding effect.
• Ensure that any bends in rigid conduit do not damage the conduit wall or
reduce the internal diameter. A run of conduit from outlet to outlet, from
fitting to fitting, or between outlet and fitting should have less than the
equivalent of 4 one-quarter bends (360° total), including those bends
located immediately at the outlet or fitting.
• Use insulated bushings at the conduit exits to protect wires from abrasion.
• Use pull boxes or oversized elbows below stations and at major junctions
to ease cable pulling and to minimize the risk of cable damage.
• Use NEC-specified pull boxes that provide enough free space for all
conductors in the box.
P/N 46019100 3-5

3.3.5. Cable Tray

A cable tray provides a protective passageway for the system cables. You can use
a cable tray in place of rigid metal only where it is permitted and only when you
adhere to the requirements listed in this section. The following tray requirements
meet or exceed the NEC specification:
• Use one of the following types of tray systems (in decreasing order of
preference):
− Fully enclosed ducting with a tight-fitting cover
− Open ducting
− Ventilated trough
− Solid tray
− Ventilated tray or open ladder
• Use materials and installation procedures that meet NEC Article 318
specifications (or the local equivalent in foreign countries).
• Do not use nonmetallic cable trays or ducting.
• Ground the cable tray system throughout its entire length.
• Do not expose the cable tray system to harsh environmental conditions,

including hazardous chemicals, high temperatures, steam, water, or direct
sunlight.
• Protect the cable tray system from mechanical damage and abrasion.
• Cables must be suitable for cable tray systems, and they must meet the
requirements of NEC Article 725 for Class 2 and Class 3 circuits. Refer
to Table 3-2 for the Belden-equivalent cable for use in cable trays.
3-6 P/N 46019100

Table 3-2. Belden Tray Cable Equivalents
Vendor P/N Description Cable O.D. Insulation and Jacket Thickness
Belden 9333 11 pair, 22 AWG, individual, PVC 0.551" (1.40 cm) 0.016" (0.406 mm) insulation
0.053" (1.35 mm) jacket
Belden 9328 1C, 6 AWG, Green, PVC (ground) 0.316" (8.026 cm) 0.070" (1.778 mm)
• Do not run Honeywell-Measurex cables in the same cable tray system as

Class 1 power, lighting, and control cables.
• Route trays carrying Honeywell-Measurex cables as far away as possible

from the following types of cabling:
− Class 1 power, lighting, and control cables
− Cables carrying frequently switched fluctuating heavy currents,

such as motor, generator, discharge lighting, or inductive heating
When it is necessary to run Honeywell-Measurex cables parallel to such

wiring, maintain the minimum separation as shown in Table 3-3.
Table 3-3. Minimum Separation of Cables
Power Wiring Minimum Separation
120V 10 amp. 24 inches

5 kV 800 amp. 120 inches
• If trays carrying Honeywell-Measurex cables must cross over power

cabling, make the crossover directly across (perpendicular to) the power
cabling with as much space as possible between the cable tray and the
power cabling.
• If the existing wiring at your site does not produce radiated electrical
interference, either continuously or of a pulsed nature (such as master time
clock system wiring), you can run Honeywell-Measurex cables in the same
tray system as existing wiring.
• If a run is not horizontal, secure the cables to the cable tray.
P/N 46019100 3-7

3.4. Environmental and Plumbing Requirements

The environmental and plumbing requirements for the system are determined
principally by the sensors/heads. Refer to the sensor manuals and the Production
Release document for the specific requirements of your 2080 scanner system.
This section describes some of the requirements, using a typical 2080 system as
an example.
The scanner requires plumbing for potable water and instrument air that is dirt-
and oil-free. Figure 3-1 shows the environmental and plumbing requirements for
a typical scanner installation. Additional specifications (for example, added
airflow) may be described in the Production Release for each particular scanner.
Note:
Some sensors require a water source that is temperature-
stabilized to ±1.5°F (±0.8°C). The use of an external
water chiller for the factory water supply is recommended.
Cooling water should be of potable quality for cleanliness
and pH. See the specific sensor manual for exact
temperature specifications.
Figure 3-1. Scanner Air and Water Plumbing
3-8 P/N 46019100

Typical environmental requirements for the Model 2080-03 and 2080-13

Scanners and sensors are listed below and in Table 3-4. See the specific sensor
manual for exact temperature specifications.
• Humidity Range: relative humidity, noncondensing 10% to 75%
• Maximum Moisture Content: 0.02 lb./lb. (0.009 kg/kg)
• Maximum External Temperature
• Ambient Temperature = 113°F (45°C)
• Sheet Temperature = 212°F (100°C)
Table 3-4. Typical Sensor Air and Water Requirements
Requirement Specification
Water Cooling Sensors on the scanner are often water-cooled. Cooling water should not exceed
72°F ±1.5°F, max.; 0.5 GPM/sensor; potable.
Air Basis Weight Sensors on the scanner are driven by static air pressure and use
continuously flowing air for the air curtain. Plumbing for instrument air (clean, dry,
oil-free) should be 60 psi for the sensor at the head, and 4 to 6 CFM at 30 to 50 psi
for the air curtain at the head.
P/N 46019100 3-9

3-10 P/N 46019100

Model 2080-03 and 2080-13 Scanners Installation and Maintenance Unpacking the Scanners
4. Unpacking the Scanners
This chapter describes the procedures you must perform when a Model 2080-03
or 2080-13 Scanner arrives on-site. The procedures include:
• Inspecting the shipment
• Unpacking the hardware
• Identifying scanner and sensor accessories
4.1. Inspecting the Shipment

Carefully inspect the shipment when it arrives on-site:
1. Verify that you received everything on the manifest. If there are

shortages, contact the Honeywell-Measurex factory of origin (Regional
Delivery Center); for example Cupertino, California, or Waterford,
Ireland.
2. Inspect the shipment for damage before unpacking the hardware. If the
shipment shows evidence of damage, follow this procedure:
a. Leave the damaged material in the original shipping container.

DO NOT remove it.
b. If a damaged shipping container holds a radioactive source

(shipping containers that hold radioactive sources are clearly
labeled as to their contents), contact the Honeywell-Measurex
Radiation Safety Office. (Honeywell-Measurex Cupertino security
personnel can reach the Radiation Safety Office staff after normal
working hours.)
P/N 46019100 4-1

Unpacking the Scanners Model 2080-03 and 2080-13 Scanners Installation and Maintenance
WARNING:
Do not move or handle a damaged shipping
container or sensor head that contains a
radioactive source until you have discussed
the situation with the Honeywell-Measurex
Radiation Safety staff.
c. Tell the driver to record the nature and the extent of the damage on
both the carrier's copy and the delivery copy of the freight bill.
d. Immediately contact the carrier for an inspection of the shipment.

Obtain a copy of the inspection report to support your claim.
e. File the claim as quickly as possible. Consult Honeywell-

Measurex Parts Order Service before estimating the cost of repair.
Repair costs should include material, labor, and shipping plus
special handling, if applicable.
If you have any questions concerning a claim, contact the

Honeywell-Measurex Traffic Manager at:
Honeywell-Measurex Corporation
One Results Way
Cupertino, California 95014-5991
Phone: (408) 255-1500
or
Industrial Estate
Waterford, Ireland
Phone: Waterford 72151
f. If a scanner is damaged and must be completely replaced, call the

Configuration Group Manager as soon as possible to get the new
unit into the operations plan.
3. After inspecting the shipment and reporting any damage, move the
hardware into the installation area and unpack it.
4-2 P/N 46019100

4.2. Unpacking the Hardware

Electronic equipment is fragile and must be moved and unpacked carefully. Use
special care when unpacking large, heavy pieces of equipment, such as the
scanner and sensor. Only experienced personnel using the proper tools should
handle the equipment.
4.2.1. Scanners
WARNING:
Scanners are heavy. To avoid
personal injury, use caution
when moving scanners, and
when unbolting and removing
the dollies.
The following steps must be performed by experienced personnel:
1. Calculate and take into account the weight of the Model 2080 Scanner.
The weight of a scanner is approximately 5 pounds per inch of beam
length (between the end supports) plus 250 pounds (0.89 kg per cm plus
113 kg).
2. Move the scanner to the installation site before removing the packing
material.
Scanners are shipped on universal dollies that are the property

of Honeywell-Measurex.
SHIP THE DOLLIES TO:
One Results Way
Cupertino, California 95014-5991
U.S.A.
3. If lifting eyebolts are installed in the upper beam, use chains and a
spreader bar to connect to the lifting crane.
P/N 46019100 4-3

4. If placing a forklift under the beams, first place two 2 x 6 wood backups
under the beam to avoid damaging the aluminum tracks.
Caution:
If the scanner is equipped with a “dirty
environment” kit, the carriage on the lower
beam can be crushed when the scanner is set
on the floor. Make sure that the scanner is
set on a pedestal or pads.
5. Ensure that the equipment is supported when the dollies are removed.
Caution:
Use care when unbolting and removing the
dollies. Scanner beams are aligned at the
factory. A drop of only a few inches onto a
hard surface could affect the alignment.
6. Do not remove any packing material until each piece of equipment is

mounted. If the scanner is moved with the heads mounted, ensure that the
heads are supported during the move.
7. Save the packing material, if possible, and reuse it if the equipment is ever
moved.
4.2.2. Sensors and Accessories

Model 2080-03 and 2080-13 Scanners are shipped with accessory kits. (For
example, many sensors ship with paddles for measuring product samples.)
Ensure that you have received all of the required installation kits for the
installation of the corresponding equipment. Refer to the Production Release for
the list of purchased accessories.
Sensor/head installation and alignment is discussed in Chapter 5, “Installing the

Scanners.” However, sensor-specific tasks such as sensor calibration are not
covered. Refer to the documentation that came with your sensor(s) and host
computer equipment for sensor-specific information.
4-4 P/N 46019100

4.2.3. Basis Weight Sensor Storage

Sensor heads are sometimes shipped separately from the scanner, and must be
mounted on the scanner on-site. Nuclear Basis Weight Sensors contain
radioactive sources, and require special handling. This section describes how to
store a nuclear Basis Weight Sensor until it is mounted onto the scanner.
You must be licensed in order to perform many operations on a sensor

containing a radioactive source, such as mounting Basis Weight Sensor heads
on a scanner. Appendix B, “Radiation Licensing Requirements,” contains
information on licensing and regulatory requirements that apply to OEMs and
end users. For additional information on radioactive sources and safety, refer
to the Radiation Safety Training Manual for Honeywell-Measurex employees
(P/N 44070004) or the Radiation Safety Manual for Honeywell-Measurex
Customers (P/N 44071500).
WARNING:
The Basis Weight Sensor contains a radioactive source
(KR-85, SR-90, AM-241, or PM-147). OEMs or end users
who plan to conduct Basis Weight Sensor installation,
required safety tests, repairs, etc., are required to obtain a
Radioactive Materials License that explicitly authorizes
the operations to be conducted and names the individuals
who may do so. If an explicit Radioactive Materials
License cannot be obtained, operations of the type listed
above must be performed by authorized Honeywell-
Measurex employees or other appropriately licensed
individuals.
If you must store a Basis Weight Sensor head before it is mounted on a scanner,
you must place it in an access-restricted area controlled by licensed personnel,
such as a locked room or cabinet. If you must store a Basis Weight Sensor for a
period of weeks or months, you can usually arrange for Honeywell-Measurex to
store it for you. For more information, contact the Honeywell-Measurex
Radiation Safety Office.
WARNING:
During storage, a shipping shield must
always be bolted to each sensor head
containing a radioactive source.
P/N 46019100 4-5

4-6 P/N 46019100

Model 2080-03 and 2080-13 Scanners Installation and Maintenance Installing the Scanners
5. Installing the Scanners
This chapter contains installation information for the 2080-03 and 2080-13
Scanners. The instructions are presented in the order of the tasks to be performed.
The locations and names of signals that exit the scanner for the MSS enclosure
and the host computer system are discussed and described. However, specific
setup and connection instructions for the MSS enclosure and the host computer
system and sensors are not discussed. For details on those subjects, refer to the
documentation that came with your host computer system and/or sensor(s).
5.1. Using the Scanner Installation Checklist

During the installation process, use the checklist provided in Appendix A,
“Scanner Installation Checklist.” A copy of the checklist should be used for each
scanner installation.
Before starting the hardware installation, verify that the site has been properly
prepared for the scanner. Refer to Part I of the Scanner Installation Checklist to
verify that everything has been completed and signed off. Use Part II to complete
the installation of the hardware.
5.2. Installing the Scanner

The following sections cover the procedures for installing the scanner, and
provide instructions for adjustments that may be required. For sensor-specific
information, refer to the Production Release documents that came with your
sensors.
P/N 46019100 5-1

Installing the Scanners Model 2080-03 and 2080-13 Scanners Installation and Maintenance
5.2.1. Radiation Safety

If the sensor heads contain a radioactive source (indicated by labels on the head),
various radiation safety precautions and regulatory restrictions must be followed.
Information on licensing and regulatory requirements that apply to OEMs and end
users is contained in Appendix B, “Radiation Licensing Requirements.” Further
information on radioactive sources and safety is available in the Radiation Safety
Training Manual for Honeywell-Measurex employees (P/N 44070004) or the
Radiation Safety Manual for Honeywell-Measurex Customers (P/N 44071500).
WARNING:
The Basis Weight Sensor contains a radioactive
source (KR-85, SR-90, AM-241, or PM-147). OEMs
or end users who plan to conduct Basis Weight Sensor
installation, required safety tests, repairs, etc., are
required to obtain a Radioactive Materials License
that explicitly authorizes the operations to be
conducted and names the individuals who may do so.
If an explicit Radioactive Materials License cannot be
obtained, operations of the type listed above must be
performed by authorized Honeywell-Measurex
employees or other appropriately licensed individuals.
5.2.2. Scanner Installation Procedures
Install the scanners using installation drawings 092080-03 and 2080-13xx I

(Figure 5-1), and Part II of the Scanner Installation Checklist (see Appendix A).
Details relating to the installation and alignment of the heads/sensors pass angle
adjustments and electrical connections are described in greater detail later in this
chapter.
Installation placement details are shown in Figure 5-1 (Sheets 1 thru 4) for
reference purposes only. Always use the latest revision of the installation
drawing (P/N 092080xxI) to keep track of any changes to the Model 2080-03 or
2080-13 Scanner that may have been made since this manual was published.
5-2 P/N 46019100

Figure 5-1. Scanner Installation (Sheet 1 of 4)
(Note the optional radiation light box 7.25 inches (184.2 mm) above the scanner.)
P/N 46019100 5-3

5-4 P/N 46019100

P/N 46019100 5-5

5-6 P/N 46019100

Notes for Figure 5-1:
P/N 46019100 5-7

5.3. Installing and Aligning the Heads/Sensors

The Model 2080-03 and 2080-13 Scanners support a variety of sensors to measure
sheet properties. Examine the Production Release for your system. It defines the
type and orientation of the sensor(s) for the system, the input and output slots, the
facilities requirements, and the required accessory kits.
Scanners are often shipped with the heads already mounted and aligned by the
Honeywell-Measurex factory. Head alignment should be verified during scanner
installation. The procedure is detailed later in this chapter. Read the following
information before proceeding to align the heads or to verify their alignment. The
accuracy of measurement of the sensors depends on many variables. The
following simple precautions will help guarantee satisfactory performance.
The windows on the sensors must be kept as clean as possible. The cover on the
electronics end of the scanner must be kept in place, except when it is necessary
to access switches, wiring, or components. The heads are sealed to protect the
sensors and printed circuit boards. Head carrier tracks and wheels should be free
of dirt and debris. Compressed air is used with some sensors for cooling and/or to
keep dust and other contaminants from degrading sensor performance. Such air
must be dry and oil-free. Water-cooled sensors require water with low mineral
content and a neutral pH factor to avoid corrosion of metal parts. Water leaks can
seriously damage sensors.
5.3.1. Head Alignment

Figure 5-2 shows an overhead view of a typical Model 2080-03 Scanner, shown
with the scanner heads at a 0° pass angle for the sheet. Sensor (cross-sheet)
motion is the x-axis. Sheet Motion ("machine direction") is the y-axis. The
spacing (air gap) between the upper and lower heads is the z-axis. The types and
location of the radiation display lamps and the location of the Emergency Stop
Button and other switches may be configured differently for each installation. An
example of a typical configuration is shown in Figure 5-2. Refer to your
Production Release document for details on your specific system.
For accurate scanning, the opposing heads must retain their alignment over the
full range of scan in both the forward and reverse directions. Special timing belts
are used to ensure that the cross-sheet alignment of the heads remains constant.
Beam alignment and track alignment are not required, and there are no jacking
screws for field alignment.
Heads must be aligned in the x-, y-, and z-axes. Adjusting the head alignment
along one axis may impact the alignment of the heads along one or both of the
other two axes. For this reason, it is recommended that when aligning the heads
you verify and/or adjust the air gap (z-axis) first.
5-8 P/N 46019100

Figure 5-2. Scanner Reference Illustration
Air gap adjustments are relative to the plane of sheet motion. The upper head
must be parallel to the sheet and to the lower head. One-half of the specified
spacing should be between the sheet and the upper head, and the other half below
the sheet as shown in Figure 5-3.
For an accurate check of the air gap, it may be necessary to improvise

an alignment fixture using string or paper to simulate the path of the sheet
(see Section 5.3.1.5, “Scanner Height and Pass Angle Check”).
P/N 46019100 5-9

Figure 5-3. Side View of Sheet Centered in Air Gap
The head gap is calibrated for each system and must remain that calibrated size.
Each system is supplied with spacer (gap) bars the size of the correct head gap.
The Calibration Data Package has the correct gap size and related specifications
for the sensor in your particular system. Do not change the gap width on the
scanner from its originally calibrated size (as stated on the Honeywell-Measurex
Production Release form and Calibration packet) as this will cause the Calibration
Data Package to be inaccurate.
WARNING:
If the air gap of a sensor containing a radioactive
or X-ray source is changed from its original size
(for example, from a 0.4-inch gap to a 0.5-inch
gap), regulations require that a radiation survey
be performed and documented before the sensor
is put into use. This survey must be performed
by an individual who is specifically licensed to
perform this operation.
5-10 P/N 46019100

5.3.1.1. Head Installation and Alignment Procedure

The procedure described here is for a Basis Weight Sensor/head that uses a
radioactive source. A head using a radioactive source is used as an example
here so that a discussion of radiation interlock switches can be included. Non-
radioactive heads, however, are aligned using the same method.
The procedure is in 2 sections:
• Section 1 – Mounting the Heads assumes that the head is not mounted, and
that a complete Head Installation and Alignment is necessary.
• Section 2 – Aligning the Heads assumes that the heads have been mounted
and aligned on the scanner by Honeywell-Measurex before shipping.
Both sections require that head alignment be verified repeatedly. This is

accomplished using the 3 Alignment Pins supplied for this purpose. The
Alignment Pins are placed in the holes provided for them through the sheet
guide part of the heads for coarse and dynamic adjustment, and through the
plastic housing of the sensor, with the head cover removed, for fine and static
adjustment (only while the heads are stationary). The pins should drop freely
into the alignment holes. Further instructions on head alignment will be provided
as appropriate in the following sections.
5.3.1.2. Radiation Safety

If the sensor heads contain a radiation source, X-ray or radioactive (indicated by
labels on the head), various radiation safety precautions and regulatory restrictions
must be followed. Information on licensing and regulatory requirements that apply
to OEMs and end users is contained in Appendix B, “Radiation Licensing Require-
ments.” Further information on radioactive sources and safety is available in the
Radiation Safety Training Manual for Honeywell-Measurex employees
(P/N 44070004) or the Radiation Safety Manual for Honeywell-Measurex
Customers (P/N 44071500).
P/N 46019100 5-11

WARNING #1:
The Basis Weight Sensor contains a radioactive
source (KR-85, SR-90, AM-241, or PM-147). OEMs
or end users who plan to conduct Basis Weight Sensor
installation, required safety tests, repairs, etc., are
required to obtain a Radioactive Materials License
that explicitly authorizes the operations to be
conducted and names the individuals who may do so.
If an explicit Radioactive Materials License cannot be
obtained, operations of the type listed above must be
performed by authorized Honeywell-Measurex
employees or other appropriately licensed individuals.
WARNING #2:
If the air gap of a sensor containing a radioactive
or X-ray source is changed from its original size
(for example, from a 0.4-inch gap to a 0.5-inch gap),
regulations require that a radiation survey be per-
formed and documented before the sensor is put into
use. This survey must be performed by an individual
who is specifically licensed to perform this operation.
5.3.1.3. Radiation Interlock System

The source head has magnetic switches while the receiver head has a magnet.
These are mounted with both facing toward the gap. When the heads move apart,
the switches open. These switches drive a relay. When the switches are closed, the
relay is closed, permitting the computer to drive the shutter. When the switches are
open, the relay is open. This not only breaks the line from the computer, but it pulls
the line going to the shutter high, preventing the shutter from opening. A yellow
LED provides the status of the switch. The LED is lit when the heads are split
(switch open). Silk-screened on the backplane is “HEADS SPLIT.” (The use of
magnetic head interlock switches replaced external head in-place switches.)
The Radiation Safety Lamps are part of the radiation interlock system; if a lamp
burns out, it must be replaced before the head shutter can be opened again. The
red lamp is illuminated when the shutter is commanded open, and the green lamp
is illuminated while the shutter is closed. The red and green lamps operate
independently. If the red lamp is on, always assume that the head shutter is open
and that radiation is being emitted from the source head.
5-12 P/N 46019100

5.3.1.4. Section 1 – Mounting the Heads

The procedure for mounting the heads is as follows:
1. Push the Head Carriers to the offsheet end of the scanner. (All
adjustments and installations are carried out in the offsheet position.)
2. Loosen the pass angle clamps from the Head Adjustment Plate
(see Figure 5-4).
3. With the head arcs attached to the head assembly, rotate the head
assembly onto the Head Adjustment Plate.
4. Align the Bulkhead Board in the head to the side of the scanner through
which the Power Track cables and hoses feed (see Figure 5-4).
Figure 5-4. Lower Head Platform
P/N 46019100 5-13

5. Remove the head cover.
6. Remove the Cable Cover from the head.
7. Connect the cables to the Bulkhead Board

(see Figure 5-5).
8. Install the Cable Cover.
9. Install the head cover.
10. Tighten the Pass Angle Clamps.
11. Attach the hoses.
12. Adjust the Pass Angle.
Caution:
When handling the sensor head containing the
radioactive source with the source window exposed
(no cover plate), keep the source window directed
away from yourself and others.
Figure 5-5. Bulkhead Board Cover Removal
5-14 P/N 46019100

13. Verify that the head is at the correct height. Place a Gap Bar on top of
the Window Frame as shown in Figure 5-6. The middle of the Gap Bar
should be aligned (in the Z direction) with the Specified Product Path
Height as specified on the Scanner Installation drawing (see Figure 5-1).
Figure 5-6. Checking Head Height
P/N 46019100 5-15

If a small adjustment is required to bring the head to the correct height or to move
the lower head in the Y direction, perform the following steps. This assumes that
the Model 2080 Scanner is vertical or very nearly vertical, and that it has been
shimmed correctly (refer to Figure 5-1).
1. Loosen the four 3/8-24 retaining nuts on the Head Adjustment Plate.
2. Adjust the height of the head with the four 3/8-24 leveling nuts that
contact the Head Adjustment Plate.
3. If the pass angle of the heads is set to 0° and the path of the sheet through
the machine will be truly horizontal, it is useful at this point to level the
top surface of the head using the same nuts. Use a 2-foot or longer level
and check both the X and Y directions.
4. Tighten the four 3/8-24 retaining nuts. It is probable that this adjustment
will require additional minor modification to align the lower head to the
upper head.
5. For the nuclear Basis Weight Sensor, remove the Shipping (Radiation)
Shield from the head containing the source (normally the Upper Head).
6. Loosen the pass angle clamps from the Carriage Mounting Plate.
Caution:
After removing the Shipping Shield, be very careful
not to damage the sensor window. The window is
covered with a thin, electrically conductive coating.
7. Place the Upper Head on top of the Lower Head. The head separation
switch in the Upper Head should be aligned with the head separation
switch in the Lower Head, and both bulkhead boards in the heads should
be on the same side of the scanner (see Figure 5-7). If the specified air
gap is to be large, it may be best to place the Gap Bars on the Lower Head
first and then place the Upper Head directly on the Gap Bars.
5-16 P/N 46019100

Figure 5-7. Placing the Lower Head
P/N 46019100 5-17

8. Loosen the Pass Angle Clamps from the Carriage Mounting Plate.
9. Separate the heads using the head “quick release.”
10. Slide the lower head onto the Carriage Mounting Plate.
11. Remove the Head Cover.
12. Remove the Cable Cover from the head.
13. Connect the cables to the Bulkhead Board

(refer back to Figure 5-5).
14. Install the Cable Cover.
15. Install the Head Cover.
16. Tighten the Pass Angle Clamps.
17. Attach the hoses.
18. Adjust the Pass Angle (see Figure 5-8).
5-18 P/N 46019100

Figure 5-8. Scanner End View of Pass Angle
P/N 46019100 5-19

5.3.1.5. Scanner Height and Pass Angle Check

The pass angle is the angle at which the product passes through the scanner.
Many scanners have a 0° pass angle, but up to 60° of tilt is possible. Table 5-1
lists the Honeywell-Measurex part numbers of the arcs for the various ranges of
pass angles.
When your scanner was ordered, the head platforms were mounted using the
proper arc for the pass angle specified.
Table 5-1. Pass Angle

Requirements
Pass Angle P/N
0° – 10° STANDARD
10° – 15° 07701500
07707300
15° – 60° 07701500
07707300
07705600
The pass angle is indicated on the Production Release form. To set the pass
angle, refer to Figure 5-9 and perform the following steps:
1. Move the heads to the offsheet end of the scanner. All adjustments are
carried out in the offsheet position.
2. Improvise an alignment fixture using string or paper to match the pass

angle of the sheet (see Figure 5-9). The string should be entirely in the
plane of the sheet, passing through the air gap between the heads.
3. Adjust the scanner’s height so that the sheet passes through the center of
the air gap between the heads.
5-20 P/N 46019100

Figure 5-9. Improvised Alignment Fixtures
4. Place a 4-foot (or longer) level against the end supports of the scanner
frame, and use the mount bolts and/or shims to adjust the scanner until the
end supports are vertical.
− If the pass angle is correct, the heads should be parallel to the sheet
path, and the string should be equidistant from both the upper and
lower sensor heads.
− If the pass angle is incorrect, loosen the pass angle clamps on the
upper and lower heads and rotate the heads into position.
5. If the pass angle is 0 degrees, place the small end of the alignment pin in
the small hole in the arcs, and rotate the head until the pin slides into the
hole in the pass angle clamp (see Figure 5-10).
6. Tighten the pass angle clamps.
P/N 46019100 5-21

Figure 5-10. Fine and Dynamic Head Adjustment
5-22 P/N 46019100

5.3.1.6. Section 2 – Aligning the Heads

To align the heads, perform the following steps:
1. Place the 2 Gap Bars between the Upper and Lower Heads as shown in
Figure 5-10. Make certain that optional hardware (for example, the sheet
guide extenders) is not interfering with the free movement of the gap bars.
(Note that gap alignment is done on the stainless window frames, not the
aluminum sheet metal cover.)
2. Check that the Upper Head is parallel to the Lower Head by carefully
sliding the Gap Bars between the 2 heads at the window frames and
checking for a loose or tight fit at different spots. Ideally, the bars will
just touch the window frames at all locations without binding. It is
acceptable for the periphery of the air gap to be slightly out of parallel;
however, a precise fit of the bars in the area of the sensor and receiver
window frames (in both the X and Y directions) is very important.
3. Adjust the air gap and/or Y alignment as necessary. With the Gap Bars
still in place between the heads, loosen the 3/8-24 retaining nuts and adjust
the 3/8-24 leveling nuts on the Head Adjustment Plate. Repeat the
procedure described in step 4 of Section 1 – Mounting the Heads.
4. For the fine and static adjustment of the heads, insert the 3 Alignment Pins
into the holes in the Plastic Housing of the sensor with the Head Cover
removed.
5. For the coarse and dynamic adjustment of the heads, insert the
3 Alignment Pins into the holes in the sheet guides as indicated in
Figure 5-10. When the heads are properly aligned to one another, the
pins will drop freely into the holes as the heads scan back and forth
along the scanner frame.
6. For coarse adjustment of the heads in the X direction, move the Lower
Head on the scanner as follows (refer to Figures 5-11 and 5-12):
a. Remove the Alignment Pins.
b. Remove the cover from the Motor Drive end of the scanner.
c. Use a 7/16-inch wrench to loosen the 2 clamping bolts securing the

flange to the bottom gear on the drive shaft.
P/N 46019100 5-23

Figure 5-11. Lower Head X-Direction Adjustment
d. Remove one of the loosened bolts and insert it into the threaded
hole between the clamping bolts. The flange is pressure-fitted to
the gear. Tightening the bolt you have just inserted will break the
flange free. Once the gear moves freely, replace the clamping bolt
to its original position.
e. Move the Lower Head until it is aligned with the Upper Head
and the Alignment Pins drop freely into place. If the pins do not
drop freely because of a Y offset, partially tighten the bolts on
the flange enough to hold the X alignment before making further
Y adjustments.
f. Continue to iterate between adjusting the air gap, the X direction,

and the Y direction as needed until the Alignment Pins drop freely.
Small, incremental changes are recommended.
5-24 P/N 46019100

Figure 5-12. X Alignment
P/N 46019100 5-25

g. Once the heads are aligned with each other, fully tighten the
clamping bolts holding the flange to the drive gear. Alternately
tighten the mounting hardware on the upper and lower heads,
continuing to check that the Alignment Pins move freely.
h. Replace the Motor Drive end cover.
7. For fine adjustment of the heads in the X direction, move the lower head
on the scanner as follows (refer to Figure 5-12):
a. Use a 7/16 wrench to loosen the four 1/4-inch bolts that hold the
Quick Disconnect Clamp to the Carriage Mounting Plate. The
upper head is now free to move within the slots in the Quick
Disconnect Clamp.
b. Move the head until the pins drop freely, then tighten the four
1/4-inch bolts.
Caution:
Be sure to remove the Alignment Pins
before moving the Heads. Failure to do so
can cause excessive strain on materials, and
permanently damage the heads and carriers.
8. Remove the Alignment Pins and push the heads to the other end of the
scanner, then replace the Alignment Pins and verify that the pins still drop
into place. If there is a misalignment in the X direction, perform the
following steps (refer to Figure 5-12):
a. Locate the belt tensioning bolt for the Upper Head inside the
Upper U-beam.
Caution:
A locking nut holds each belt tensioning
bolt. The belt will unwind around the
tensioning bolt if the bolt is not held while
the locking nut is loosened. Maintain at
least one full wrap of the belt around the
tensioning bolt.
5-26 P/N 46019100

b. Use an open-end 7/16-torque wrench to hold the tensioning bolt,

and then loosen the 15/16-inch locking nut.
c. Turn the torque wrench, set to 80 in-lb., until it clicks.
d. Tighten the lock nut without moving the tensioning bolt.
Repeat this procedure with the belt for the Lower Head. If the heads still
do not stay aligned in the X direction from one end of the scanner to the
other, adjust the tensioning slightly so that the Lower Head can be moved
into alignment with the Upper Head (that is, so the Alignment Pins drop
freely into the alignment holes). Fully tighten the locking nut.
9. Run the Heads from one end of the scanner to the other several times.
Recheck the alignment using the Alignment Pins, and repeat the steps
listed above until correct.
5.4. Air and Water Connections

Air hoses are colored red and terminate with straight male (air curtain) and
straight female (shutter) quick-disconnect fittings at the head.
Water hoses are colored green and terminate with right angle quick-disconnect
fittings at the head. It is necessary to trace the water in/water out hoses from the
heads back to the scanner service bay. A simple way to perform this trace is to
blow pressurized air through the water hoses. Label the hoses temporarily.
Install air and water hoses into the appropriate ports. Make certain that the spring
clips on the fittings are properly seated.
Figure 5-13 shows the water plumbing for the scanner, and Figure 5-14 shows the
water in/water out ports and air connections for one model of scanner heads.
Refer to the installation document for details on your system. All possible head
plumbing connections are shown in Figure 5-14. Different sensors have different
connections. For example, the dedicated shutter air line is used on the Basis
Weight source, but not on the receiver or the IR sensor head.
P/N 46019100 5-27

Figure 5-13. Scanner Water Plumbing
5-28 P/N 46019100

Figure 5-14. Water and Air Connections to the Upper Head
P/N 46019100 5-29

5.5. Electrical Connections
5.5.1. Electrical Connections to the Heads
Caution:
Keep all wiring and cables within
the footprint of the 2080-03 or
2080-13 Scanner, and avoid having
them rub on the scanner frame.
As with all references to the sensors/heads in this manual, the following

procedures are for general information purposes only. Refer to the sensor
manual and your Production Release document for specific details.
1. Separate the heads. (See Figure 5-12.)
2. Remove the head covers. (See Figure 5-6.)
3. Remove the Bulkhead Board Cover on the upper and lower heads.
(See Figure 5-5.)
4. Connect the wires to the bulkhead board.
5. Install the wire covers and head covers, then realign the heads.
5.5.2. Cable Installation – Host Computer System to Scanner

Refer to your Production Release document and the set of schematics that was
shipped with the scanner for information specific to your system. The following
information refers to a typical 2080-03 or 2080-13 Scanner configuration.
Figures 5-15, 5-16, and 5-17 show the cable termination details between the
MSS enclosure and the Scanner Termination Board as well as the part numbers
and color codes for the recommended cables.
The motor power termination is made at the scanner end and directly to the power
supply terminal block in the MSS enclosure. (See Figure 5-18.)
5-30 P/N 46019100

Figure 5-15. Scanner-to-Host Computer System Termination Wiring Diagram I
P/N 46019100 5-31

Figure 5-16. Scanner-to-Host Computer System Termination Wiring Diagram II
Note:
Analog inputs #6, #7, and #8 are optional.
5-32 P/N 46019100

Figure 5-17. Scanner-to-Host Computer System Termination Wiring Diagram III
P/N 46019100 5-33

Figure 5-18. Motor End Distribution Board Schematic
5-34 P/N 46019100

5.5.3. Grounding
Proper grounding of a scanner is important both for safety and for reliable
operation. Scanners must be installed in compliance with Honeywell-Measurex
grounding specifications (refer to Chapter 3, “Preparing the Site”) and any
applicable local electrical codes. A good scanner installation includes the
following:
• The enclosure around the scanner must have a low impedance path to the
green wire safety ground.
• The distance from the scanner to a proper ground cannot exceed 100 feet.
• The scanner must be referenced to ground.
5.5.4. Ground Safety Test

Before connecting power to the system, check for proper grounding by
performing the following steps:
1. Disconnect the scanner frame ground.
2. Measure the resistance between the end of the frame ground wire you just
disconnected (not the frame) and the process machine (the plant).
Resistance must be less than 1 ohm.
3. Reconnect the scanner frame ground.
4. Disconnect the enclosure ground at the MSS.
5. Measure the resistance between the MSS enclosure and the process
machine (the plant). Resistance must be less than 5 ohms.
6. Reconnect the enclosure ground at the MSS cabinet.
7. Measure the resistance between the scanner frame ground and the ground
of the host computer cabinet. Resistance must be less than 5 ohms.
P/N 46019100 5-35

5-36 P/N 46019100

Model 2080-03 and 2080-13 Scanners Installation and Maintenance Maintaining the Scanners and Sensors
6. Maintaining the Scanners and Sensors
This chapter presents maintenance information for the 2080-03 and 2080-13
Scanners and for some of the sensors they use. Refer to your sensor manuals
for detailed information on maintaining the sensors.
Note:
Read the information on switches
and their functions in Section 6.4.2.1,
“Scanner Switches,” before using the
switches to control the scanners.
6.1. Preventive Maintenance
WARNING:
Only personnel with radioactivity
detection badges should clean or
maintain the scanner. Minimize time
spent near the sensors. Be sure the
radiation shutter is closed when the
windows are being cleaned. Post a
notice at the host computer console to
guard against accidental startup.
P/N 46019100 6-1

Maintaining the Scanners and Sensors Model 2080-03 and 2080-13 Scanners Installation and Maintenance
6.1.1. Daily
The following preventive maintenance items for the system must be performed
daily:
• Inspect and clean the heads.
• Inspect all water and air hoses and fittings, and repair any potential
problems.
• Check the log of standardizations for error trends.
• Check the head platform temperatures. These are shown on the MSS Card
IO Point monitor display from the MSS setup diagnostics. (Be sure to
select analog in, DAQ, and MSS number that corresponds to the scanner
and sensor in question.) This will read the raw analog voltages by channel.
To convert to °C, multiply by 10 (for example, 2.0V means 20°C). The
proper temperature for some types of heads is 100°F to 106°F (37.7°C to
41.1°C). Refer to the specific sensor manual for more information.
6.1.2. Monthly
The following preventive maintenance items must be performed monthly:
• Check the scanner power supply voltage output. Replace the power supply
if necessary.
• Check the air and water filters and flowmeters. Replace as necessary.
• Inspect and clean the scanner using the procedure described in Section 6.2,
“Monthly Inspection and Cleaning Procedure.”
• Check the head alignment. The upper and lower heads must maintain
coarse alignment over the full range of scan in both the forward and reverse
directions. Check the alignment using the Alignment Pins and Gap Bars.
Refer to the detailed procedures in Section 5.3, “Installing and Aligning the
Heads/Sensors.”
6-2 P/N 46019100

6.1.3. Every 3 Months

The following preventive maintenance items must be performed every 3 months:
• Check the Emergency Stop Switch for function and possible loose
connections.
• Check the Drive Motor Controller connections. See Section 6.4,

“Troubleshooting the Scanners,” for adjustments that may be required
for the Drive Motor Controller.
6.1.4. Every 6 Months

The following preventive maintenance items must be performed every 6 months:
• Lubricate all bearings for the drive shaft and belt pulleys with standard mill
grease. Use care to prevent damage to seals.
6.2. Monthly Inspection and Cleaning Procedure
Note:
The cavities will require more frequent
cleaning in some mill environments.
To inspect and clean the scanner, perform the following steps:
1. Set the Scan/Off Sheet switch to Off Sheet. The heads will move to the
offsheet position.
2. Remove the cover of the scanner at the cable end.
3. Switch the scan control toggle switch from COMPUTER to MANUAL.

(The scan control switch is located on the Scanner Termination Board as
shown in Figure 6-1.)
4. Inspect the cavities in the upper and lower U-beams for foreign material.
If the cavity is dirty or contaminated with scrap, blow the foreign material
out with compressed air and clean as needed.
P/N 46019100 6-3

Figure 6-1. Control Switch on the Scanner Termination Board
6-4 P/N 46019100

5. Inspect the scanner carriage assembly for signs of wear on the head
carrier's wheels. Push the carriage to one side of the track and check that
the gap between the wheels and the other side of the track is between
.002" and .010". Wheel replacement is described in Section 6.3,
“Replacing Mechanical Assemblies.”
6. Inspect the drive belt for excessive wear, especially along the edges. If a
belt is excessively worn, it should be replaced. For replacing a drive belt,
refer to the applicable procedure in Section 6.3, “Replacing Mechanical
Assemblies.”
7. Test the idler pulleys at the cable end of the scanner for wobble (a sign
of wear). When idler pulleys are new, they have little, if any, perceptible
wobble. As they wear, wobble increases. As long as the air profile does
not change, the pulleys are probably not causing undue drag. When the
wobble exceeds 1/8 inch (or if the air profile changes erratically), the
pulleys should be inspected and replaced if necessary.
8. Inspect the Power Track for wear and for loose or broken links. Repair
and adjust cable dressing as needed. For replacing the Power Track, refer
to the applicable procedure in Section 6.3, “Replacing Mechanical
Assemblies.”
9. Clean the external surfaces of the scanner.
6.2.1. Maintaining the Motor

For more information on the motor and the Copley Motor Controller board, refer
to the manuals about them that were supplied with the 2080-03 or 2080-13
Scanner. Also see Section 6.4, “Troubleshooting the Scanners,” in this manual.
Caution:
The motor does not need to be oiled. If the
red plug on the side of the motor housing is
opened, oil will pour out.
P/N 46019100 6-5

6.3. Replacing Mechanical Assemblies

Figure 6-2 shows the positions of the mounting hardware for the mechanical
assemblies discussed in the subsections that follow.
Figure 6-2. Mounting Hardware for Mechanical Assemblies
6-6 P/N 46019100

6.3.1. Replacing Head Carrier Wheels

Inspect the wheels on the head carrier assemblies monthly for wear. If they are
excessively worn, they may require replacing. To replace head carrier wheels,
perform the following steps.
Note:
It is a good practice to replace all
of the wheels at the same time.
offsheet position.
3. Switch the scan control toggle switch from COMPUTER to MANUAL.

The scan control switch is located on the Scanner Termination Board as
shown in Figure 6-1.
4. Engage the Emergency Stop Button.
6.3.1.1. Upper Head Assembly

To assemble the upper head:
1. Provide external support for the weight of the Upper Head. The Gap Bars
used together with shims may be of use.
2. Loosen the two 7/16-inch bolts on the same side of the Upper Head
Carrier (that is, the two 7/16-inch bolts that attach to the same Suspension
Bar, as shown in Figure 6-3). The Suspension Bar should now be
disconnected from the Upper Head Carrier.
3. Slide the Suspension Bar out from above the Upper Head Carrier and
remove it from the U-beam track.
P/N 46019100 6-7

Figure 6-3. 2080-03 and 2080-13 Scanner Upper Head Carrier
(Note the location of bolts that require a wrench with 7/16-inch across flats.)
6-8 P/N 46019100

4. Remove the 1/2-inch bolt that holds each wheel to the Suspension Bar,
and replace each wheel. Make certain that the washer goes back between
the Suspension Bar and each wheel.
Caution:
Failure to properly replace the washer(s)
may cause the head assembly to seize during
scanning.
5. Replace the Suspension Bar in the U-beam above the Upper Head Carrier
and secure it with the 7/16-inch bolts. Do not fully tighten the bolts at this
time.
6. Repeat steps 1 – 5 above for the wheels on the other Suspension Bar on
the Upper Head Carrier.
7. With the weight of the Upper Head still externally supported, push the
Suspension Bars apart until they are snug up against each track. Tighten
the 7/16-inch bolts that hold the Upper Head Carrier to the Suspension
Bars. The head assembly should be free to slide in the track but have
minimal play in the sheet motion direction.
8. The head alignment should be checked and adjusted immediately after

wheel replacement, as described in Section 5.3.1.6, “Section 2 – Aligning
the Heads.”
9. If no further work needs to be performed, set the scan control toggle on

the Scanner Termination Board from MANUAL back to COMPUTER.
10. Replace the cable-end cover.
11. Set the Scan/Off Sheet switch back to Scan.
12. Disengage the Emergency Stop Button.
P/N 46019100 6-9

6.3.1.2. Lower Head Assembly

To assemble the lower head:
1. Remove the cable shield from around the Lower Head Assembly and
reposition the hoses and cables for easier access to the bolts under the
Lower Head Carrier.
2. Repeat steps 1 – 12 in Section 6.3.1.1, “Upper Head Assembly,” taking

into account the important difference that the Suspension Bars now ride
under, not over, the track in the lower U-beam.
3. Provide external support for the weight of the Lower Head Assembly,
then loosen the 7/16-inch bolts that fasten the Lower Head Carrier to the
Suspension Bars.
4. Replace the cable shield and return the hoses and cables to their original
position, taking care that they will not drag on the U-beam during the
scan.
6.3.2. Replacing Belts

Belts should be inspected monthly for wear. If the belts are excessively worn,
they will need to be replaced.
To replace the belts, perform the following steps:
offsheet position.
3. Switch the scan control toggle switch (located on the Scanner Termination
Board) from COMPUTER to MANUAL.
4. Engage the Emergency Stop Button.
6-10 P/N 46019100

6.3.2.1. Upper Belt Replacement Procedure

Refer back to Figure 5-12 while performing the following steps:
1. Remove the locking nut from below the tensioning bolt. The belt will
loosen on the bolts.
2. One end of the belt is held in the slot on the tensioning bolt with
setscrews. Loosen them and take the belt off the tensioning bolt.
3. Use the Latch for Quick Head Separation to separate the Belt Buckle from
the carriage (refer to Figure 5-12.) The other end of the belt is held in the
Belt Buckle with setscrews. Loosen them and remove the belt from the
Belt Buckle.
4. Remove the belt from the scanner. The belt must be pulled out of the
U-beam, and must be removed from the pulleys on the cable end and
the motor end of the scanner.
5. Using the old belt to determine the length of the new belt, cut the new belt
to the same length as the old belt.
6. Slide the upper and lower head carriers all the way to the cable end of the
scanner.
7. Thread the new belt into the U-beam, replacing it through the cable end
and motor end of the scanner, so that the 2 ends of the belt can be
connected to the Belt Buckle.
8. Tighten one end of the belt to the Belt Buckle using the setscrews, and
tighten the other end of the belt to the tensioning bolt using the setscrews.
Be sure to maintain at least one full wrap of the belt around the tensioning
bolt, then replace the tensioning bolt in the Upper Head Carrier.
Note:
The belt must be attached as shown in Figure 6-4
or the head will not track properly, and the head
“quick disconnect” will not work.
9. Torque the scanner belt tensioning bolt to 80 in-lb.
10. Tighten the lock nut for the Belt Tensioning Bolt on the Upper Head
Carrier.
11. Readjust the head alignment as needed. For the head alignment
procedure, see Section 5.3.1.6, “Section 2 – Aligning the Heads.”
P/N 46019100 6-11

Figure 6-4. Belt Installation at the Carriage
6-12 P/N 46019100

6.3.2.2. Lower Belt Replacement Procedure

Refer to Figure 6-5 and perform the following steps:
1. Check to make sure that the Scan/Off Sheet switch is still set to Off Sheet,
and that the scan control toggle switch is still set to MANUAL (refer to
Section 6.3.2, “Replacing Belts.”)
2. Use a 7/16-inch wrench to remove the 4 bolts that hold the Non Quick
Disconnect Belt Buckle to the Carriage Mounting Plate.
Figure 6-5. Lower Head Carrier and Belt
P/N 46019100 6-13

Repeat the steps listed in Section 6.3.2.1, “Upper Belt Replacement Procedure,”
keeping in mind that all references to the Upper Head Carrier will now indicate
the Lower Head Carrier. Be sure to follow the prescribed head alignment
procedure.
6.3.3. Replacing the Power Track
Note:
Replacing the Power Track requires major
disassembly of the 2080-03 and 2080-13 Scanners.
This procedure should be performed only by an
experienced Honeywell-Measurex technician. This
section provides an outline of the procedure for
informational purposes only.
To replace the 2080-03 and 2080-13 Power Track, perform the following steps.
With the exceptions noted below, the procedure is essentially the same for the
Upper and the Lower Power Tracks.
1. Place the heads in the offsheet position.
2. Turn off air, water, and power to the scanner.
3. Danger-tag the scanner's power supply breaker in the off position.
4. Disconnect the water and air hoses from the scanner head.
5. Separate the heads and remove the Bulkhead Board Cover.
6. Disconnect the wires from the Bulkhead Board at the head.

(See Figures 5-4 and 5-5.)
7. Put the Bulkhead Board Cover and the Head Cover back on.
8. Remove the 7/16-inch bolts that secure the Power Track Bracket to the
Carriage Mounting Plate. For the upper head and lower head assemblies,
refer to Figures 6-6 and 6-7, respectively. The Power Track should now
be disconnected from the head.
9. If the Upper Power Track is being replaced, disconnect the Power Track
from the Motor End Distribution Board. Also disconnect the Power Track
from the Scanner Termination Board.
6-14 P/N 46019100

Figure 6-6. Upper Power Track Carrier Bracket
Figure 6-7. Lower Power Track Carrier Support Bracket
P/N 46019100 6-15

10. Remove the two 7/16-inch bolts that hold the Power Track Support
Bracket to the cable end of the scanner (see Figures 6-8 and 6-9).
11. Clip the tie wraps that hold the water and air hoses to the Power Track and
to the Support Bracket. If the 24 VDC line and optional cables have been
bundled with the Power Track, cut these tie wraps also. Move these lines
aside.
12. Carefully pull the Power Track out from the U-beam through the hole in
the cable end of the scanner. It may be simpler at this point to cut the
water and air hoses. Use caution to avoid spilling water on the equipment.
13. Insert the new Power Track into the hole and slide the end up to the head.
Make sure that the end that is inserted into the hole is the end that
connects to the head, not to the termination board.
Figure 6-8. Upper Power Track Support Bracket
6-16 P/N 46019100

14. For the Upper Power Track, connect the electrical lines to the Motor End
Distribution Board.
15. Connect the new Power Track hoses and cables to the Carrier Bracket with
tie wraps.
16. Place the bracket at the end of the linkage on the Power Track.
17. Connect the Carrier Bracket to the Carriage Mounting Plate using the
three 7/16-inch bolts.
18. Connect the air, water, and electronics to the head (see Figure 5-14).
19. Connect the Power Track to the Scanner Termination Board.
20. Check that there is sufficient clearance for the cables and hoses on the
Power Track.
Figure 6-9. Lower Power Track Support Bracket
P/N 46019100 6-17

6.4. Troubleshooting the Scanners
6.4.1. Mechanical Troubleshooting
6.4.1.1. Adjusting Belt Tension

No major belt adjustments should be necessary. Minor adjustments can be made
by using the belt tensioners inside the U-beams. Adjust the belt tensioning bolts
so that the torque is 80 in-lb. To prevent the belt from unwinding, secure each
tensioning bolt while loosening the jam nut. Maintain at least one full wrap of the
belt around the tensioning bolt.
Be sure to adjust each side equally. If adjustment is not performed equally on

both sides, the X-axis alignment will be altered (one of the heads will lead the
other during scanning). Check the X-axis alignment at both ends of the scanner
after any servicing. Align the heads as needed according to the procedure detailed
in Chapter 5, “Installing the Scanners.”
6.4.2. Scanner Electronics Troubleshooting

Only personnel with a thorough working knowledge of scanner operation beyond
the intent and scope of this manual should attempt system-level troubleshooting.
Refer to your system and operating manuals for further information.
6-18 P/N 46019100

6.4.2.1. Scanner Switches

Table 6-1 lists the manual switches and describes their functions.
Table 6-1. Manual Switches
Switch Function
Emergency Stop Button This switch stops head motion by interrupting the 24 VDC supply to the motor
controller. To release, turn the button clockwise as indicated by the arrows, and
it will pop back out.
The Emergency Stop Button will clear some faults caused by accidental system
interrupts (for example, when the scan head is physically jammed). Clear the
cause of the fault, set the Scan/Off Sheet switch to Off Sheet, depress the
Emergency Stop Button, wait 20 seconds, and release the button. The heads
should move to the Off Sheet position and be ready to resume scanning.
Scan/Off Sheet Switch Setting the switch to the Off Sheet position closes the shutters and stops
scanning. The heads will move to the offsheet position, and head motion will
cease.
Setting the switch to the Scan position permits the operator to initiate scanning.
The shutters will open, the software will check that the heads are measuring
within certain calibration limits (the “flag to air ratio”), and scanning will
resume. If the ratio is out of limits, the system will check the total of attempts,
and declare a fault if the out-of-limits condition remains.
The Scan/Off Sheet Switch also functions to manually control forward and
reverse motion of the scanner heads. See the description of the
Computer/Manual Toggle Switch below.
Reference/Sample Switch The Reference Switch operates only when the heads are offsheet or in single-
point scan. When set, it allows compensating factors used in measurements to be
updated. If no sensor is specified before the switch is set, software defaults to the
4203 Basis Weight Sensor.
The Sample Switch operates only when the heads are offsheet or in single-point
scan. When set, it initiates a measurement of a sample.
When either Reference or Sample is selected, a lamp comes on in the switch and
remains on until the selected operation is completed.
Computer/Manual Toggle This switch is located on the Scanner Termination Board (see Figure 6-1).
Switch It allows the operator to change control of the head motion from computer
control to manual control. The Scan/Off Sheet Switch should be set to the
Off Sheet position before the Computer/Manual Switch setting is changed.
Caution:
Changing this switch setting without first
moving the heads to the offsheet position
will cause a system fault.
When this switch is set to Manual, the function of the Scan/Off Sheet Switch
changes so that it will now control forward and reverse motion of the heads.
P/N 46019100 6-19

Table 6-2 lists the system switches and describes their functions. The status of
the system switches is indicated by LEDs on the Scanner Termination Board.
Table 6-2. System Switches
Switch Function
Head Limit Switches These are magnetically operated by the sensor heads. If the software fails to
recognize an edge-of-sheet signal and remove the ON command, the heads
continue to move until a limit switch is reached. If either limit switch closes,
software reverses the motor and scanning resumes in the opposite direction.
Preset Switch This switch is magnetically operated by the upper head and is located in the
center of the scanner.
Limit Switches These switches are magnetically operated by the sensor heads. They are used by
the software to determine absolute head position.
6-20 P/N 46019100

6.4.2.2. Scanner Termination Board

Replacement of fuses is the only type of repair possible for the Scanner
Termination Board. Any other type of failure requires replacement of the board.
Table 6-3 describes the function of the LEDs on the Scanner Termination Board.
Table 6-3. LEDs on the Scanner Termination Board
LED Source Indicates (When ON)
TACH PHASE B scanner Not used

TACH PHASE A scanner Not used
MOTOR ON computer Motor is on
FAULT scanner Motor controller fault (cycle power to clear)
DIR computer Computer directs scanner forward motion
BRAKE computer Not used
SHTR N/A All rad lamps OK and shutter has power
RED LAMP STATUS DS8 Primary red lamp – motor end OK
DS9 Primary red lamp – cable end OK
DS10 Secondary red lamp – motor end OK
DS11 Secondary red lamp – cable end OK
+24V ELEC 24V electrical power is present
+24V SOL 24V solenoid power is present
+24V MOTOR 24V motor power is present
MOTOR END LIMIT scanner Heads at motor end limit switch
CABLE END LIMIT scanner Heads at cable end limit switch
PRESET scanner Heads at preset switch
POWER TRACK UPPER RED Not used
HEALTH
UPPER GREEN Not used
LOWER RED Not used
LOWER GREEN Not used
P/N 46019100 6-21

6.4.3. Scanner Schematics

The schematics for the 2080-03 and 2080-13 Scanners depend upon the type
of sensors being used. Figure 6-10 shows the installation schematics for the
Source 15 Basis Weight Sensor. Refer to the Production Release document
for information specific to your system. The upper and lower power track wiring
schematics in Figures 6-11 and 6-12 can be used for tracing electrical paths
through the scanner.
6.4.4. Circuit Board Replacement Guidelines

When replacing circuit boards, observe the following guidelines:
• Follow standard ESD precautions.
• Exchange only one board at a time.
• Always turn the power off before inserting or removing a board.
• If a replacement board does not correct a problem, reinstall the original

board before proceeding.
• Set the jumpers and/or switches of new boards exactly as they are
positioned on the replaced board.
• Tag the defective board, noting the suspected trouble.
• Handle boards by the edges or with clean gloves.
6-22 P/N 46019100

Figure 6-10. Scanner Installation Connection for Basis Weight and IR Sensors
(Sheet 1 of 2)
P/N 46019100 6-23

Figure 6-10. Scanner Installation Connection for Basis Weight and IR Sensors
(Sheet 2 of 2)
6-24 P/N 46019100

Figure 6-11. Upper Grateful Head to Power Track Wiring
P/N 46019100 6-25

Figure 6-12. Lower Grateful Head to Power Track Wiring
6-26 P/N 46019100

6.5. Maintaining the Sensors

This section provides general information to help maintain the sensors. For
specific sensor information, refer to the documentation that came with your
sensors.
The 2080-03 and 2080-13 Scanners support the following primary sensors
at this time:
• Source 15 Basis Weight (nuclear) Sensor
• IR Sensor
The 2080-03 and 2080-13 Scanners support the following secondary sensor
at this time:
• Z-Axis Sensor
6.5.1. Radiation Safety

If the sensor heads contain a radioactive source (as indicated by labels on the
head), various radiation safety precautions and regulatory restrictions must be
followed. For example, radiation safety regulations require that the mounting
of the sensor heads on the scanner be performed only by a person specifically
licensed to perform that operation. Information on licensing and regulatory
requirements that apply to OEMs and end users is contained in Appendix B,
“Radiation Licensing Requirements.” Additional information on radioactive
sources and safety is available in the Radiation Safety Training Manual for
Honeywell-Measurex employees (P/N 44070004).
WARNING:
If the air gap of a sensor containing a
radioactive or X-ray source is changed from its
original size (for example, from a 0.4-inch gap
to a 0.5-inch gap), regulations require that a
radiation survey be performed and documented
before the sensor is put into use. This survey
must be performed by an individual who is
specifically licensed to perform this operation.
For more information, contact the Honeywell-
Measurex Radiation Safety Department.
P/N 46019100 6-27

6.5.1.1. Radiation Warning Lamps

Red and green radiation warning lamps that indicate open and closed sensor
shutter positions are mounted at one end of the 2080-03 and 2080-13 Scanners. A
lit green lamp indicates that the corresponding sensor shutter is closed. A lit red
lamp indicates that the corresponding sensor shutter is open. If it happens that red
and green lights are lit at the same time, assume that the shutter is open. If
neither radiation warning lamp is lighted, treat the sensor as though the
shutter is open. If both X-ray and Basis Weight sensors are installed in the
sensor head, the green light is only lit if both the X-ray and Basis Weight sensor
shutters are closed.
6.5.2. General Maintenance and Troubleshooting Notes
• Avoid removing the head cover until it is determined that the sensor is not
working properly.
• Inspect the log of standardizations that are run daily for error trends. This
can help you catch potential problems and repair them during scheduled
downtime.
6.5.2.1. Removing Head Cover(s) and/or Separating

Sensor Heads
If either head cover must be removed and/or the heads separated, follow the
procedures below.
• If your employer has assigned you radiation badge(s), wear the badge(s).
Do not proceed if required badge(s) are unavailable.
• If the sensor head contains X-ray source(s) only, turn off power to X-ray
tube(s) and remove the key. Do not return the key or reapply power until
sensor heads are returned to their normal configuration.
6-28 P/N 46019100

• Confirm that all source shutters are completely closed.
WARNING:
Regardless of the method used to close
shutter(s), take time to verify that the shutter(s)
are actually fully closed by following the 2 steps
listed below. This is very important due to the
high radiation levels that exist when the shutter
is open and the possibility of serious injury,
particularly to the skin, within a period of
seconds or minutes.
• If possible, request background counts and verify that they are within the
normal range for shutter closed. (Honeywell-Measurex employees should
refer to the section on “Troubleshooting High [Low] Shutter Closed [Air]
Counts” in the Radiation Safety Training Manual for Honeywell-Measurex
employees (P/N 44070004).
WARNING:
If the “shutter closed” counts
are unusual, do not proceed.
• Observe warning lights if the system is powered up; only green lamps
should be lighted. Do not proceed if the green lamps are not lighted!
WARNING:
If both green and red lamps
are lighted, do not proceed!
• Unless head power is required for the planned operations, turn off the head
power and tag the console so that no one will restore power until you are
through.
• Carefully separate heads (keep hands and all body parts away from the
source windows) and remove the head cover from the source sensor head.
• Unless access to one of the sensor windows is required, realign upper and
lower heads opposite to one another and/or attach the cover plate over the
radioactive source window.
P/N 46019100 6-29

• Note that the dose rate through the closed shutter will exceed the natural
background rate, although it will be just a small fraction of the shutter open
rate. This is normal and unavoidable, and is not a sign of shutter
malfunction or shutter design failure.
6.5.2.2. Cleaning Windows

Keep the windows on Basis Weight and X-ray sensors clean. These instructions
apply when it is necessary to clean portions of the source or detector sensor heads,
which are in the measurement gap when the heads are in their normal
configuration:
• If possible, leave the sensor heads in their normal configuration.
• If the heads must be separated for effective cleaning, follow the

instructions in Section 6.5.2.1, “Removing Head Cover(s) and/or
Separating Sensor Heads.” Once heads are separated, clean the windows
using a long-handled tool (for example, a modified flyswatter) with an
attached cleaning pad (cotton or other lint-free cloth) dipped in methanol or
isopropyl alcohol. Inspect the windows carefully and replace them if there
is damage.
• If proceeding with heads in their normal operating position, opposite one

another, command the source shutter(s) to close.
• Observe the warning lights and confirm that all red SHUTTER OPEN
warning lights are off and that all green SHUTTER CLOSED lamps are
lighted. Do not proceed if the green lamps are not lighted!
WARNING:
If both green and red lamps are
lighted, do not proceed!
• Use a long-handled tool (for example, a modified flyswatter) with an

attached cleaning pad (cotton or other lint-free cloth) dipped in methanol or
isopropyl alcohol to clean the head surfaces inside the measurement gap.
6-30 P/N 46019100

6.5.2.3. Replacing Windows
• It is important to replace the Kapton windows on the source and detector

heads promptly if they are damaged. The windows protect the basis weight
assembly and ion chamber from accumulating debris. Debris can cause
problems, including a drop in detected signal, an erratic signal, or
interference with smooth shutter operation.
• If the sensor head contains X-ray source(s) only, turn off power to X-ray
tube(s) and remove the key. Do not return the key or reapply power until
sensor heads are returned to their normal configuration.
• Confirm that all source shutters are completely closed.
WARNING:
Regardless of the method used to close shutter(s),
take time to verify that the shutter(s) are actually
fully closed by following the 2 steps listed below.
This is very important due to the high radiation
levels that exist when the shutter is open and the
possibility of serious injury, particularly to the skin,
within a period of seconds or minutes.
1) If possible, request background counts and verify that they

are within the normal range for “shutter closed.” (Honeywell-
Measurex employees should refer to the section on “Troubleshooting
High [Low] Shutter Closed [Air] Counts” in the Radiation Safety
Training Manual for Honeywell-Measurex employees (P/N
44070004).
WARNING:
If the “shutter closed” counts
are unusual, do not proceed.
P/N 46019100 6-31

2) Observe warning lights if the system is powered up; only green lamps
should be lighted. Do not proceed if the green lamps are not
lighted!
WARNING:
If both green and red lamps
are lighted, do not proceed!
• Turn off the head power and tag the console so that no one will restore
power until you are through.
• Carefully separate heads (keep hands and all body parts away from the
source windows).
• If the window to be replaced is on the source sensor head, keep hands out
of the area directly above or below the Kapton window during the entire
replacement process.
• If the window to be replaced is on the detector head, attach the shipping

shield to the source sensor head before replacing the window on the
detector head.
• Replace the windows as shown in Figure 6-13.
• Inspect the replaced windows carefully to ensure that they are not
damaged.
Note:
The Basis Weight and X-ray windows are coated
with a conductive coating that faces the air gap, not
the inside of the sensor head. Use an ohmmeter to
find the conducting surface when replacing the
windows. Be careful not to scratch or pierce the
aluminized coating; use the flat side of the test
probes, not the tips.
6-32 P/N 46019100

Figure 6-13. Window Frame Replacement, and

Static and Fine Head Alignment
P/N 46019100 6-33

6-34 P/N 46019100

Model 2080-03 and 2080-13 Scanners Installation and Maintenance Scanner Installation Checklist
A. Scanner Installation Checklist
This appendix contains the Installation Checklist for the Model 2080-03 and 2080-13 Scanners.
A copy of this checklist should be used when installing the scanners.
P/N 46019100 A-1

Scanner Installation Checklist Model 2080-03 and 2080-13 Scanners Installation and Maintenance
Installation Checklist for Model 2080-03 and Model 2080-13 Scanners

Customer Name:
System Number:
Ship Date:
Start Date:
I. Verify That Site Preparation is Complete (Chapters 3 and 4) Initials

1. Inspected system for defects or damage.
2. Inventoried all parts, including installation kits, spares, and documentation.
3. Followed unpacking instructions.
4. Assembled and terminated cables.
• Labeled cables properly per installation documentation.
• Used heat shrink.
• Used lugs where applicable.
• Provided service loops for future re-terminations of cables.
• Ensured that cables are dressed neatly and are serviceable.
5. Routed cables, conduits, and plumbing correctly.
6. Mounted all cabinets securely.
7. Sealed all conduits.
8. Distributed ground and power properly.
9. Adjusted all DC voltages per specification.
10. Followed instructions for system loads and noted deviations.
II. Verify 2080-03 Scanner Installation (after installation of Computer Control Cabinet) Initials
• Connected water plumbing and air plumbing (if installed).
• Connected cables from MSS Cabinet Termination Panel to Scanner Termination Panel.
• Connected power cable from scanner motor to scanner P/S in MSS Cabinet.
• Checked that wheels on head carriage are loaded properly.
• Followed Radiation Safety procedures for Basis Weight Sensor.
• Mounted scanner securely on rubber pads.
• Shimmed for proper web alignment.
• Checked head angle.
• Checked head gap according to Production Release.
• Checked belts for proper tension.
• Checked head alignment across entire scanner.
• Checked that power track is operating properly with correct internal clearance.
• Grounded scanner to machine frame.
• Re-tightened all termination points on scanner.
• Secured loose hoses and cables on sensors (if required).
• Checked that installation cables and hoses do not rub on pulleys.
A-2 P/N 46019100

Model 2080-03 and 2080-13 Scanners Installation and Maintenance Radiation Licensing Requirements
B. Radiation Licensing Requirements
This appendix contains information on the U.S. radiation licensing requirements

that apply to the Original Equipment Manufacturer (OEM), to Honeywell-
Measurex, and to end users of Honeywell-Measurex nuclear sensors. References
in brackets ([ ]) indicate the applicable sections of Title 10 of the Code of Federal
Regulations (CFR). In approximately half of the United States of America, the
Nuclear Regulatory Commission (NRC) has authorized state authorities to assume
responsibility for radioactive materials control. State regulations are generally
equivalent to those of the NRC, so individual state regulations are not cited in this
appendix.
There are 2 possibilities for U.S. shipment of nuclear sensors when OEMs are
involved: Honeywell-Measurex may ship the sensor to either the end-user site or
an OEM site. From a regulatory standpoint, shipping to an end-user site involves
the least difficulty for Honeywell-Measurex, the OEM, and the end user.
Regulatory considerations for both options are described below.
B.1. Nuclear Sensor Shipment to a U.S. End-User Site

In cases where Honeywell-Measurex ships a nuclear sensor to a U.S. end-user site
with OEM involvement in the equipment assembly, installation, or testing, there
are several critical regulatory and licensing issues:
Issue #1:
The end user, not Honeywell-Measurex, must have a license for the
possession and eventual use of the sensor. This is a requirement
regardless of device ownership or whether system acceptance tests have
been completed [10 CFR 30.3].
P/N 46019100 B-1

Radiation Licensing Requirements Model 2080-03 and 2080-13 Scanners Installation and Maintenance
Note:
Honeywell-Measurex has a Specific License that permits trained
and badged employees to conduct service (installation, certain
radiation safety tests, and maintenance) on Honeywell-Measurex
sensors at General Licensee sites. However, there are only a few
special cases where a Honeywell-Measurex license can cover
possession and use of a nuclear sensor outside of the Cupertino
facilities. For example, Honeywell-Measurex is permitted to
apply for a limited type of temporary off-site license for industry
trade shows.
Issue #2:
The end-user license can be one of two types: the automatically granted
General License or a Specific License [10 CFR 30.31]. A large majority
of Honeywell-Measurex customers in the U.S. have a General License.
(Refer to Section B.3, “Radioactive Materials Regulations,” for a further
explanation of these license types.)
Issue #3:
Both Honeywell-Measurex and the end user are required to report
specified details of the sensor transfer to various authorities [10 CFR
31.5(c)(8), 32.52]. This means that before the sensor ships from
Honeywell-Measurex, the Honeywell-Measurex Radiation Safety Office
must be given the end user’s name and the address where the sensor will
be located.
Issue #4:
All Generally Licensed end users are required to have certain radiation
safety checks performed upon receipt of a sensor and periodically
thereafter. These tests must be performed by a person who holds an
appropriate Specific License [10 CFR 31.5(c)(3)].
Issue #5:
All Generally Licensed end users are required to have "installation,
servicing, removal from installation, involving the radioactive materials,
its shielding or containment" performed by a person who holds a Specific
License for these operations [10 CFR 31.5(c)(3)].
Note:
The Honeywell-Measurex Radiation Safety Office
has encountered a variety of interpretations of the
wording above. Local regulatory authorities should
be contacted in situations that are unclear.
B-2 P/N 46019100

Issue #6:
The requirements in Issues #4 and #5 also apply to Specifically Licensed
end users. However, some Specifically Licensed end users may be
licensed to perform some or all of these operations themselves.
Issue #7:
If an OEM, rather than Honeywell-Measurex personnel, will be
performing radiation checks as described in Issue #4, the OEM must have
a Specific License that explicitly authorizes the operations that are to be
performed [10 CFR 30.34(c). 31.5(c)(3)].
Issue #8:
If the OEM, rather than Honeywell-Measurex personnel, will be involved
in system installation, the OEM should either have a Specific License for
the intended operations, or should comply with the applicable regulation
[10 CFR 30.34(c), 31.5(c)(3)]. If the OEM performs work that requires a
Specific License but does not have one, both the OEM and the end user of
the nuclear sensor will be in violation of regulatory requirements.
P/N 46019100 B-3

B.2. Nuclear Sensor Shipment to a U.S. OEM Site

The shipment of a nuclear sensor to an OEM site followed by shipment from the
OEM site to the end user presents certain difficulties. To protect its license and
authorization to distribute nuclear sensors, Honeywell-Measurex avoids shipping
to an OEM site unless it is clear that the OEM is in compliance with regulatory
and license requirements, as follows:
• If the OEM will ship Honeywell-Measurex nuclear sensors to Generally

Licensed end users, the OEM must have a Specific License that permits
such transfer [10 CFR 30.3, 31.5(b), 32.1(a)(2), 32.51].
• Before being permitted to ship a nuclear sensor to a Specifically Licensed

OEM, Honeywell-Measurex is required to confirm that the OEM is
appropriately licensed. This confirmation must be a license copy or other
written document and must be kept on file at Honeywell-Measurex. In
emergency situations, oral certification is permitted, but it must be
followed by written confirmation within 10 days [10 CFR 30.41(c - d),
30.51(a)(2)].
• The OEM is authorized to perform only those operations involving the

nuclear sensor that are explicitly authorized by their Specific License
[10 CFR 30.34(c)]. For example, if an OEM intends to perform radiation
safety tests, installation, service, and so forth, as outlined in Issues #4
and #5 of the previous section, the OEM's license must be written to
authorize this.
B-4 P/N 46019100

B.3. Radioactive Materials Regulations

A firm that possesses or acquires a Honeywell-Measurex process control system
containing a radioactive source is subject to the regulations of either the NRC or
the state in which the firm is located. The following sections provide an overview
of these regulations and your responsibilities with regard to them.
B.3.1. Regulatory Authority

In the U.S., the NRC is the agency responsible for regulating radioactive materials
use. However, in approximately half of the states, the NRC has granted
permission to a state agency to assume the regulation of radioactive materials.
These states are often referred to as Agreement States. Regardless of whether a
firm is in an NRC-regulated or Agreement State, the requirements that apply
differ very little.
B.3.2. Licensing
There are 2 types of radioactive materials licenses that Honeywell-Measurex
customers may hold:
• General License
The majority of Honeywell-Measurex customers have what is called a

General License. This type of license is automatically granted to anyone
acquiring a Honeywell-Measurex sensor. General Licenses do not require
a firm to file an application or to obtain any licensing documents.
However, as the holder of a General License, a firm is responsible for
satisfying a number of requirements, which are outlined below.
• Specific License
Some customers elect to obtain a Specific License or to amend a Specific

License already in effect to include a Honeywell-Measurex sensor. This
type of license is granted after approval of a license application. Applicants
must be able to demonstrate a level of radiation safety and technical
expertise appropriate for the planned use of radioactive materials.
P/N 46019100 B-5

B.3.2.1. Specific License Requirements

In order to determine the legal requirements for the possession and use of
Honeywell-Measurex sensor(s), Specifically Licensed customers must review the
terms of their licenses. Additional requirements are contained in NRC or state
regulations.
B.3.2.2. General License Requirements

Generally Licensed customers should consult the NRC or state regulations for a
complete listing of requirements. In general, these requirements include:
Item #1:
Maintaining the warning labels on the sensor head and complying with the
instructions provided on the labels.
Item #2:
Having the radioactive source(s) tested for leakage (Kr-85 sources do not
require leak testing) and the on-off mechanism (shutter) and warning
lights tested at 6-month intervals.
Note:
This testing must be conducted by a person
who holds a Specific License to perform
such tests on Honeywell-Measurex
equipment.
Item #3:
Not permitting anyone who does not hold a Specific License to perform
installation, servicing, or removal if it involves the radioactive source, its
shielding, or containment.
Item #4:
Maintaining records (which include the dates and names of the persons
performing such work) of testing, servicing, and installation involving the
radioactive source.
Item #5:
Suspending operation of the sensor immediately in the event of detection
of removable radioactive material (leakage) or failure or damage that
affects the shutter, warning lamps, and shielding until the sensor is
repaired or replaced by a person holding a Specific License.
B-6 P/N 46019100

Item #6:
Furnishing a complete description of the occurrence to the regulating
agency following damage or failure (as described in Item #5).
Item #7:
Not abandoning, disposing of, or transferring the sensor except to
someone authorized by a Specific License to receive the sensor.
Item #8:
Maintaining records of all receipts, transfers, or disposals of radioactive
material.
Item #9:
Notifying the regulatory authority of receipt or transfer of a sensor
containing radioactive material.
Item #10:
Notifying the regulatory authority of radiation incidents, theft, or loss of
radioactive material.
For firms that have contracted with Honeywell-Measurex for continuing service,
Honeywell-Measurex will provide support in radiation safety. Review the service
contract for details.
The discussion of the regulations presented above is not a legal opinion and is
intended as a general guide only. To determine the actual requirements that
apply, Honeywell-Measurex recommends consulting the applicable licenses and
the NRC or state regulations.
P/N 46019100 B-7

B-8 P/N 46019100

Model 2080-03 and 2080-13 Scanners Installation and Maintenance Glossary
Glossary
This glossary contains brief definitions of terms used throughout the manual.
ADC
Analog-to-Digital Converter. A device or circuit that changes analog voltages to digital values
for a digital computer (see also DAC).
air counts
The output of the basis weight sensor with nothing but air between the source and receiver
assemblies, read by the computer as the number of cycles counted in a specific period of time.
alarm
Audible or visual signal that indicates an abnormal or out-of-limits condition in the plant or
control system.
alphanumeric
Numerals, letters, and some special characters.
ambient pressure
External air pressure.
ambient temperature
External air temperature.
analog
The representation of numerical quantities by means of physical variables, such as voltage,
rotation, or resistance (see digital).
Analog-to-Digital Converter
A device or circuit that changes analog voltages to digital values for a digital computer.
ASCII
American Standard Code for Information Interchange. Uses 7- or 8-bit binary numbers to
represent letters, numerals, and special characters.
P/N 46019100 GL-1

Glossary Model 2080-03 and 2080-13 Scanners Installation and Maintenance
audit trail
The group of commands that handle the storage of memory changes and associated comments
on a floppy disk.
audit trail file

A record of changes made to software since installation. This file is kept on floppy or hard
disks. A command file or macro that contains Control Builder commands.
background counts
The output of the basis weight sensor with the source shutter closed, as read by the computer.
It represents electronic noise, stray radiation, and amplifier offset. It is subtracted from all
other measurements to provide a true zero reference.
backplane
A PCB with connector blocks and wiring units constituting most of the computer system's
interconnections. For example, the CPU PCB and peripheral PCBs are plugged into the
backplane to make up that particular system.
backup
Provision of alternate means of operation in case of failure of the primary means.
basis weight
The mass per unit area; that is, grams/square meter.
baud
A variable unit of data transmission speed, sometimes equal to one bit per second.
Bill Of Materials
The list of parts in an assembly.
BOM
Bill Of Materials. The list of parts in an assembly.
bus
A circuit or group of circuits that provides a path for data flow between 2 or more devices,
such as CPU, memory, and peripherals.
BW
Basis Weight. Mass per unit area. A common engineering unit is grams per square meter
(GSM).
GL-2 P/N 46019100

cable
A wire or bundle of wires (ribbon or round) used to carry electrical signals.
calibrate
To adjust the output of a device, to bring it to a desired value, within a specified tolerance, for
a particular value of the input. To ascertain the error in the output by checking it against a
standard.
caliper
The thickness of a sheet; usually expressed in mils.
CD
Cross Direction. The direction across the width of the machine at a right angle to the machine
direction.
Central Processing Unit

The part of the computer that executes instructions, performs arithmetic operations, and
contains registers.
CFR
Code of Federal Regulations.
command
The part of an instruction that specifies the action to be performed.
compatible
Indicates software/hardware that can be used on more than one computer system with little
adjustment.
Computer Control Cabinet

The system enclosure containing the computer, process interface hardware, and the disk drive.
CPU
Central Processing Unit. The part of the computer that executes instructions, performs
arithmetic operations, and contains registers.
Cross Direction
The direction across the width of the machine at a right angle to the machine direction.
cursor
A symbol placed on a CRT to identify a position.
P/N 46019100 GL-3

DAC
Digital-to-Analog Converter. A device that changes digital quantities into analog values
(see also ADC).
Danger Tag
The placement of a tag or label on a piece of equipment to WARN others not to touch or
operate it.
DAQ
Data AcQuisition.
DDC
Direct Digital Control. A digital control function based on a 3-step control procedure
(input/decision/output). In Honeywell-Measurex terminology, a DDC loop refers to a primary
control loop that has its own measurement and output.
diebolt
The bolts in the die assembly that can be adjusted to obtain an even flow of material through
an extrusion process. Also referred to as diebolt control, Auto Diebolt Interface, and
AutoProfile control software.
digital
The representation of data by discrete signal levels to indicate binary 1's and 0's. Numbers
representing all quantities in a problem or calculation.
Digital-to-Analog Converter
A device that changes digital quantities into analog values.
Direct Digital Control

A digital control function based on a 3-step control procedure (input/decision/output). In
Honeywell-Measurex terminology, a DDC loop refers to a primary control loop that has its
own measurement and output.
disk (diskette)
A circular magnetic device on which data is stored. It is accessed while it is continuously
rotating at high speed.
disk drive
A peripheral device that stores data on, and retrieves data from, a disk.
DTC
DeskTop Console.
GL-4 P/N 46019100

EIA
Electronic Industries Association.
electrical end
The end of the scanner where all terminations are made and electronic components are located.
Eurotherm (EM-1)
Eurotherm (a product of Eurotherm Corporation) provides multiple temperature sensors and
controls in zones along the length of the extruder and die. Each zone can be controlled at a
different temperature.
EUS
Environmental User Station.
execute
To perform, run, or carry out an instruction or program.
F/A
Flag-to-Air ratio. Ratio of flag counts to air counts, corrected for background counts. The
output of the detector with the flag inserted divided by the output measuring air.
fiber optics
Thin transparent fiber(s) of glass that use light pulses to carry information.
flag
A plastic or metal sample mounted on the basis weight sensor source. It is inserted into
the radiation beam during the Standardize operation to determine the amount of dirt buildup.
It provides a midrange sample check. In programming, a field used to store information
regarding status.
flag counts
The output of the Basis Weight Sensor with the flag inserted into the radiation beam, as read
by the computer.
Flag-to-Air ratio
Ratio of flag counts to air counts, corrected for background counts. The output of the detector
with the flag inserted divided by the output measuring air.
floppy disk
A thin, circular, flexible disk carrying a magnetic medium on which digital data is stored.
P/N 46019100 GL-5

floppy drive
See disk drive.
Frequency Shift Keyed

Serial communications using frequency shifts instead of voltage levels for 1's and 0's.
FSK
Frequency Shift Keyed. Serial communications using frequency shifts instead of voltage
levels for 1's and 0's.
gauge
Commonly used synonym for sensor.
GSM
Grams (per) Square Meter. Commonly used unit of basis weight.
hardware
The electrical, electronic, and mechanical equipment and components in a computer system.
Hz
Hertz. A measure of frequency in cycles per second.
IEEE
Institute of Electrical and Electronic Engineers.
I/F
Interface.
increment
To add a quantity (usually one) to another quantity.
inductance
The measure of the strength of a magnetic field created by passing a current through a
coil/conductor. Operational principle of the air-bearing caliper sensor.
initialize
To preset counters, addresses, or variables at the beginning of a process or program.
GL-6 P/N 46019100

input
Information arriving at a device for processing. Also, to enter data into the system or program.
interface
The place at which 2 systems or components meet and interact with each other. The electrical
components that allow 2 different devices to communicate.
I/O
input/output.
jack
Connector in an electrical circuit for the insertion of a plug.
keyboard
The typewriter-like unit that plugs into an operations console. Used to manually input data to
the computer during system configuration.
line conditioner
Assembly in major enclosures to terminate mill 230 VAC and convert it to 115 VAC.
Provides some filtering actions.
load
Transfer a program/data from disk or tape into memory.
loop
A sequence of instructions, written once, executed many times until a predefined condition
is met.
Machine Direction
The lengthwise direction in which the product travels through the machine.
MD
Machine Direction. The lengthwise direction in which the product travels through the
machine.
measured signal
The electrical, mechanical, pneumatic, or other variable applied to the input of a device; an
analog of the measured variable produced by a transducer.
Measurement SubSystem
A PC-based data acquisition system. Controls scanner and sensor(s) and communicates with
the host computer via a LAN.
P/N 46019100 GL-7

memory
Physical devices (chips or PCBs) that store retrievable data.
monitor
Device built around a CRT to display process information.
MSS
Measurement SubSystem. A PC-based data acquisition system. Controls scanner and
sensor(s) and communicates with the host computer via a LAN.
National Instruments
Manufacturer of measurement hardware and software.
network
An interconnected group of computers or terminals linked by a transmission medium.
NI
National Instruments. Manufacturer of measurement hardware and software.
noise
An unwanted component of a signal or variable that obscures its information content.
NRC
Nuclear Regulatory Commission.
octal
Number system in base 8. Uses numbers 0 – 7.
offline
The condition in which a system is not operational and not controlling plant processes.
offset
The steady state deviation of the controlled variable when the setpoint is fixed.
offsheet
The positioning of the heads to go off of the sheet and stop scanning.
online
The condition in which a system is fully operational and controlling plant processes.
GL-8 P/N 46019100

on/off control
The valve or final control element can only be in the open or closed position.
optimization
Industrial performance or production that consistently results in top quality, maximum rate of
output, minimum cost of operation, and minimum waste of material.
other end
The end of the scanner away from the electronics. Also called the far end.
output
Information departing a device after processing.
output signal
A signal delivered by a device, element, or system.
patch
A change inserted into a program to correct or alter the routine.
PCB
Printed Circuit Board.
peripheral
A supplementary piece of equipment that puts data into, or receives data from, the computer.
PLC
Programmable Logic Controller.
power supply
A device that takes an AC input and converts it into an AC or DC current output of varying
voltages.
power track
The device in the beams on the scanner that allows the heads to move back and forth.
process
The collective functions performed in and by the equipment in which a variable is to be
controlled. The controlled system.
process control
Automatic control of industrial processes.
P/N 46019100 GL-9

process control loop

A system of control devices linked together to control one variable of a process.
prompt
A character displayed on the terminal device to locate the input statements.
real time
Pertaining to the performance of a computation during the actual time that the related process
transpires so that results of the computation can be used in guiding the process.
real-time system
Processing data rapidly enough so that the results can influence the process being monitored
or controlled.
reference
An operation performed on Honeywell-Measurex sensors on a periodic basis to check
performance.
response
Acceptable user inputs in answer to system prompts or dialogue.
response time
The time it takes an output to reach 95% of its final value as a result of a step change in the
input variable.
RS-232
A standard for the transmission of data over a twisted-wire pair less than 50 feet. Defines pin
assignments, signal levels, and so forth for transmitting and receiving units.
RS-422
Serial communication standard of the Electronic Industries Association.
scanner
Device with an upper and lower rail placed such that the web passes between them. The
sensor heads ride on the rails and are scanned back and forth across the web. Can also be a
single rail upper or lower.
sensor
Measuring device; the basis of Honeywell-Measurex process control systems. A device that
generates a voltage or current output representative of some physical property.
GL-10 P/N 46019100

serial
Presentation of data as a time-sequential bit stream, one bit after another.
software
Programs that control the operation of a computer and its related hardware. The Honeywell-
Measurex software package includes program listings and storage media.
target
The long-term, numeric objective specifying desired product quality. Examples are weight
and thickness. In Honeywell-Measurex systems, targets are defined by code data or entered
on the monitor, and are achieved by adjusting DDC setpoints when supervisory control is
enabled.
transducer
Device that converts a measurable process quantity (pressure, temperature, flow, and so forth)
into a low-level electrical signal.
transmitter
Device that translates a transducer’s output into a higher level signal suitable for transmission
to a remote site for further processing.
turnkey
A situation where a supplier provides a fully operational system with minimal customer
involvement.
Z-Axis
A line perpendicular to CD and MD.
P/N 46019100 GL-11

GL-12 P/N 46019100

Preliminary: Model 2080-03 and 2080-13 Scanners Installation and Maintenance Manual

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Preliminary: Model 2080-03 and 2080-13 Scanners Installation and Maintenance Manual

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Model 2080-03 and 2080-13 Scanners

Installation and Maintenance Manual

July 2000 Part No. 46019100

Printed in the United States of America.

P/N 46019100 iii

5.3.1.4. Section 1 – Mounting the Heads .................................................................. 5-13

A. Scanner Installation Checklist..................................................................................................A-1

Figure 3-1. Scanner Air and Water Plumbing...................................................................................3-8

Figure 5-1. Scanner Installation (Sheet 1 of 4) .................................................................................5-3

Figure 6-1. Control Switch on the Scanner Termination Board .......................................................6-4

Table 5-1. Pass Angle Requirements ..............................................................................................5-20

Table 6-1. Manual Switches............................................................................................................6-19

1.1. Purpose and Scope

1.2. Intended Audience

P/N 46019100 1-1

1.3. Related Reading

P/N Document Title

1.4. About This Manual

Chapter 2, Understanding the Scanners, provides a brief overview of the

Chapter 4, Unpacking the Scanners, provides instructions for unpacking and

1-2 P/N 46019100

Chapter 5, Installing the Scanners, describes how to install the scanner

Chapter 6, Maintaining the Scanners and Sensors, presents maintenance

Appendix A, Scanner Installation Checklist, is used to verify the installation

Appendix B, Radiation Licensing Requirements, provides information from

Courier New 10 pt System responses are shown in this special type.

Italics In a command line or error message, words and

In text, manual titles are shown in italics.

P/N 46019100 1-3

UPPERCASE In a command line, words in uppercase letters are

lowercase In an error message, words in lowercase letters are

In a command line, words in lowercase letters

Key-1 In text, names of keys are written with initial caps;

[Key-1] In command lines, names of keys are enclosed with

[Key-1]-[Key-2] Keys pressed simultaneously are shown separated

[Key-1], [Key-2], [Key-3] Keys pressed in sequence are shown separated by

[] In command lines, square brackets signify that the

<> Angle brackets enclose commands and parameters

\ or / A slash or backslash precedes a directory

1-4 P/N 46019100

2. Understanding the Scanners

The scanners can support a number of different quality parameter sensors. A

2.1. Scanner Features

Honeywell-Measurex configures the scanners to meet each customer’s unique

P/N 46019100 2-1

Figure 2-1. Model 2080-03 Scanner with Major Features

2-2 P/N 46019100

Figure 2-2. Model 2080-13 Scanner

P/N 46019100 2-3

2.2. Installation Overview

This manual assumes that the installer is experienced at performing the

Model 2080-03 and 2080-13 Scanners are configured by Honeywell-Measurex

There are regulatory restrictions on installation and testing of Honeywell-

The scanner installation procedure includes:

• Unpacking and inspecting the equipment

• Placing and installing equipment

• Providing system utilities (air, water) as needed

• Installing and terminating interconnecting cables between system

2-4 P/N 46019100

• Verifying that the scanner is functioning correctly by completing the

• Ensuring that the applicable portions of a sensor installation and/or the

2.2.1. Scanner Installation Checklist

P/N 46019100 2-5