Maintenance Instructions. Web Inspection System 3BSF R0101. ABB Industry Oy

ULMA NT Maintenance Instructions
Web Inspection System 3BSF 29101965 R0101
ABB Industry Oy
ULMA NT
Maintenance Instructions
ABB Industry Oy
NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment
by ABB Industry Oy. ABB Industry Oy assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Industry Oy be liable for direct, indirect, special, incidental or consequential damages of any
nature or kind arising from the use of this document, nor shall ABB Industry Oy be liable for incidental or
consequental damages arising from use of any software or hardware described in this document.
This document and parts thereof must not be reproduced without ABB Industry Oy’s written permission, and the
contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in
accordance with the terms of such license.
TRADEMARKS
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ULMA is registered trademark of ABB Industry Oy
Windows NT is registered trademark of Microsoft Corp.
Document No. 3BFS 29101965 R0101
Copyright © 1999 ABB Industry Oy. All rights reserved.

Maintenance Instructions ULMA NT i
3BFS 29101965 R0101
CONTENTS
1. BEFORE YOU BEGIN...............................................................................1
1.1. ULMA documents .....................................................................................1
1.2. Terminology used in the ULMA system .......................................................1
1.3. General information ...................................................................................3
2. General description of the ULMA system.....................................................3
3. ENVIRONMENTAL REQUIREMENTS and system conformity .......................7
3.1. Environmental requirements for use.............................................................7
3.2. Specifications of power supply....................................................................7
3.3. Vibration...................................................................................................7
3.4. Storage ....................................................................................................7
3.5. Transportation...........................................................................................7
3.6. Electrical safety ........................................................................................7
3.7. Safety of machinery...................................................................................8
3.8. Electromagnetic compatibility (EMC) ..........................................................8
4. SAFETY ASPECTS ..................................................................................8
4.1. Operational safety .....................................................................................8
4.2. Electrical safety ........................................................................................9
4.3. Protecting ESD sensitive devices................................................................9
5. PERIODIC CHECKS................................................................................ 10
5.1. RECOMMENDED PREVENTIVE MAINTENANCE...................................... 10
6. FAULT TRACING .................................................................................... 11
6.1. Introduction............................................................................................. 11
6.2. Self-diagnostics of DCS 500..................................................................... 11
6.2.1. DCS 500 fault diagnostic messages.......................................................... 11
6.2.2. HW-Fault Indications ............................................................................... 13
6.2.3. SDCS-CON-1 (control board).................................................................... 13
6.2.4. SDCS-IOB-21 (digital I/O connection board)............................................... 14
6.2.5. SDCS-IOB-3 (analogue I/O connection board) ............................................ 14
6.2.6. Other fault conditions and repair ............................................................... 14
6.3. Operator station fault diagnostic messages ............................................... 16
6.4. Camera testing ....................................................................................... 19
6.4.1. Functional check of camera ..................................................................... 19
6.4.2. Replacement of camera ........................................................................... 19
6.5. Light source beam lamp replacement ........................................................ 21
7. OPERATION........................................................................................... 21
7.1. Principles of design and operation............................................................. 21
7.2. Power supply cabinet .............................................................................. 22
7.2.1. Assembly of power supply cabinet ............................................................ 22
7.2.2. DCS 500 Converter module ...................................................................... 24
7.2.3. Control Board SDCS-CON-1..................................................................... 24
7.2.4. Communication board SDCS-COM-1......................................................... 25
7.2.5. Power supply board SDCS-POW-1 ........................................................... 26
7.2.6. Digital connection board SDCS-IOB-2x...................................................... 27
7.2.7. SDCS-IOB-3 Analogue I/O connection board.............................................. 29
7.2.8. Incremental encoder connections.............................................................. 31
7.2.9. Connections between I/O-boards .............................................................. 31
7.2.10. I/O Interface, UNS 0863 ........................................................................... 32
7.2.11. Extended I/O-interface board UNS 867A-P................................................. 35
7.3. Operator station ...................................................................................... 36
7.3.1. Introduction............................................................................................ 36
7.3.2. Main components.................................................................................... 36
7.3.3. Camera Interface Module (CIM) inside the Master PC-unit........................... 36
7.4. Camera .................................................................................................. 38
7.4.1. Introduction............................................................................................. 38
7.4.2. CCD-unit ................................................................................................ 38
7.4.3. Signal processing unit ............................................................................. 38
7.4.4. Power Supply Module (PSM).................................................................... 39
7.4.5. The Camera Processor Module (CPM) ...................................................... 39
7.4.6. The video processing module (VPM) and video interface module (VIM) ......... 41
7.4.7. Optical coupler........................................................................................ 41
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7.4.8. Fiber optic connection boards: optimult..................................................... 41

7.4.9. Power supply box ................................................................................... 42
7.4.10. Light intensity control.............................................................................. 43
7.5. Output devices ....................................................................................... 43
7.5.1. Light panel ............................................................................................. 43
7.5.2. Audible alarm ......................................................................................... 43
7.5.3. Spray colour marker................................................................................ 43
7.6. Beam lifter ............................................................................................. 45
7.7. Fan ....................................................................................................... 46
8. CONTROL SIGNALS AND THEIR EFFECTS ............................................. 46
8.1. External control signals........................................................................... 46
8.2. Fan running............................................................................................ 46
8.3. Web break ............................................................................................. 47
8.4. Remote OFF command........................................................................... 47
8.5. Remote ON command............................................................................. 47
8.6. Reel change........................................................................................... 48
8.7. Light-source beam temperature from the Pt-100 sensor.............................. 48
9. Software INSTALLATION ......................................................................... 48
ILLUSTRATIONS
Figure 1. ULMA NT system...................................................................................................................................................... 3
Figure 2. Operator station with built-in PC, monitor and keyboard ............................................................................. 4
Figure 3. Table-top PC ............................................................................................................................................................ 5
Figure 4. Tower PC with tabletop monitor and keyboard ................................................................................................ 5
Figure 5. Example of ULMA NT system configuration....................................................................................................... 6
Figure 6. Terminals of thyristor module TT25N16KOF...................................................................................................16
Figure 7. Lens focusing curves by Curve program...........................................................................................................20
Figure 8. Bending lamp strip................................................................................................................................................21
Figure 9. Power supply cabinet ...........................................................................................................................................22
Figure 10. Main diagram of power supply.........................................................................................................................23
Figure 11. Dimensions of converter.....................................................................................................................................24
Figure 12. Layout of the control board SDCS-CON-1 and Extended I/O board UNS0867 .....................................25
Figure 13. SDCS-COM-1 TC link communication board...............................................................................................25
Figure 14. Power supply board SDCS-POW-1 (revision B or later) layout and jumper coding instructions. .....26
Figure 15. Lay out of the digital connection board SDCS-IOB-2x. ..............................................................................27
Figure 16. Terminal connection of the SDCS-IOB-2 board............................................................................................28
Figure 17. Coding and lay-out of the SDCS-IOB-3 board..............................................................................................29
Figure 18. Connection terminals of the SDCS-IOB-3 board..........................................................................................30
Figure 19. Pulse encoder connection principles..............................................................................................................31
Figure 20. Ribbon cable connections between I/O-boards and SDCS-CON-1...........................................................31
Figure 21. I/O-board UNS 0863..........................................................................................................................................32
Figure 22. Digital Inputs.......................................................................................................................................................33
Figure 23. Relay Outputs.......................................................................................................................................................34
Figure 24. Example: Input 112-122 isolated.....................................................................................................................35
Figure 25. Extended I/O.........................................................................................................................................................35
Figure 26. CIM board layout................................................................................................................................................36
Figure 27. Camera and CCD board ....................................................................................................................................38
Figure 28. Camera signal processing unit.........................................................................................................................39
Figure 29. CPM -board layout.............................................................................................................................................40
Figure 30. Optimult daughter board...................................................................................................................................41
Figure 31. Optimult mother board.......................................................................................................................................42
Figure 32. Light intensity control........................................................................................................................................43
Figure 33. Control of spray colour marker........................................................................................................................44
Figure 34. Control of the colour marker retraction motor.............................................................................................45
Figure 35. Beam lifter control ..............................................................................................................................................45
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3BFS 29101965 R0101
1. BEFORE YOU BEGIN
1.1. ULMA documents

This manual (Maintenance Instructions, 3BFS 29101965) covers the maintenance and fault tracing of ULMA
NT system. Additional information is provided by the following documents. The manuals are also available in
Adobe Acrobat ® PDF-format.
Document Description
Installation Instructions 3BFS 120 29101981 Installation instructions and environmental

requirements
Installation Instructions, 3BFS 120 29103267 Installation instructions and environmental

requirements for North-American customers
Operator’s Instructions, 3BFS 120 29118825 Basic manual covering the daily use of the system
Document binder Customer specific drawings for each system
1.2. Terminology used in the ULMA system

Designation Item Description
GA1 OPERATOR STATION Contains PC-unit, monitor and keyboard
GA2 POWER SUPPLY Main Supply is connected here. Supplies the whole ULMA system
CABINET
GA3 POWER SUPPLY Camera power supply
BOX
GA4 DETECTOR BEAM Cameras are mounted here
GA5 LIGHT BEAM Light source beam
GA6 PULSE TACHOMETER Protection card, isolates tacho voltages and ULMA system
PROTECTION UNIT
GB1 PULSE TACHOMETER Pulse tachometer, or tacho pulses from another source
GH1 HORN Alarms according to program configuration
GH2 LIGHT PANEL Alarms according to program configuration
GH3 COLOUR MARKER Is situated nearby Colour Marker
CONTROL BOX
GH4 COLOUR MARKER Marks detected defects in paper
GH5 BEAM LIFTER Is situated nearby Beam Lifter
CONTROL BOX
GH6.1 BEAM LIFTER Lifts Light Beam when threading on, if beam lifting is attached in
system.
GH6.2 BEAM LIFTER Pneumatics box. is used, if pneumatic lifter cylinder
PNEUMATIC BOX
GM1 COOLING FAN For cooling Light and Detector Beams
CQ1 SAFETY SWITCH Service switch for safety switching cooling fan off
GP1 MONITOR for table-top installation
GP2 KEYBOARD for table-top installation
GP3 PRINTER for table-top installation
GP4 REMOTE ADAPTER for long distances keyboard, mouse and parallel printer connection
Aux. boards connected to converter unit

A09 SDCS-IOB-21 Digital I/O connection board 24...48V d.c. 8 DI, 8 DO
A10 SDCS-IOB-3 Analogue I/O connection board 5 AI, 3 AO, 1 pulse.
A99 UNS 0863 Extended I/O board 24V d.c. 16 DI, 18 DO, 2 AI, 2 AO
CIM Camera Interfacing Module (a PC board)
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A98 The Optimult system inside GA2

A1 The Optimult system inside the Camera Beam
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1.3. General information

The Maintenance Instructions are used for servicing and locating any faults in the ULMA NT system. The only
regular maintenance required by the ULMA NT system consists of some inspections and cleaning as
described in Section 4, Periodic Checks. Faults of the ULMA NT system are easy to locate and repair, as the
system automatically reports many types of faults, and repairs are effected by replacing the entire
malfunctioning unit.
This manual describes various fault conditions, their likely causes and the necessary repair action. Although
even some rare cases are included, these instructions do not necessarily cover every conceivable situation.
In addition to this manual, you will need the document binder included in the shipment, which contains the
other necessary drawings and manuals, such as the Operating Instructions.
2. GENERAL DESCRIPTION OF THE ULMA SYSTEM

Figure 1 shows the equipment included in a complete ULMA NT system.
The actual measuring head consists of detector and light-source. A fan is located near the beams, normally
on the drive side. The fan cools the measuring head beams and prevents the entry of dust. The power supply
box is located near the detector beam.
The entire system is powered through a power supply cabinet, usually installed in a separate electrical
equipment room. The power supply cabinet also houses the process interface modules.
Figure 1. ULMA NT system
The ULMA operator station is located either at the machine or in the control room. Figure 2 shows the
operator station with built-in PC, video display unit (monitor) and keyboard. The PC, monitor, and keyboard
can also be located as separate tabletop models in a control room (Figure 3). The PC can also be a so-called
tower PC standing on the floor (Figure 4).
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The colour marker is usually installed near the measuring head beams at the web. The light panel and audible
alarm device are installed on the tender side, well visible to the operator. The web speed is measured by a
pulse tachometer installed on a motor shaft.
ULMA NT
Figure 2. Operator station with built-in PC, monitor and keyboard
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Figure 3. Table-top PC
Figure 4. Tower PC with tabletop monitor and keyboard
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Advant 520 X-station

DCS-OP-station
Ethernet
Client PC Client PC Client PCs

Windows 4.0 Windows 4.0 0-10 pc. Master PC PC Windows NT
Windows NT 4.0 X-server
Database
optical cable MAX 500 M
DCS DCS Detector beam Detector beam

500 500
beam1 beam2
Mains supply
digital I/O Mains
analog I/O Light
supply
beam Light beam Light beam
supply I/O
pulse tacho pulse tacho Light beam supply
colour marker(s) colour
marker
alarms
alarms
Power supply cabinet
Figure 5. Example of ULMA NT system configuration
An example of ULMA NT network configuration is shown in Figure 5. A CIM -board (Camera Interface Module)
connects the Main PC to the camera beam and the power supply cabinet through optical links. The ULMA
system can be controlled not only by the main PC but also by client PCs (max. 10 pcs). The PCs are
connected to each other through Ethernet network running TCP/IP protocol stack.
In addition, DCS systems can have acces to ULMA by X Window technique. DCS terminal has to conform to
R11.5 or higher protocol. A separate X server will be needed in the network. It must have Windows NT
operating system and WinDD supplement software packaged to enable X windowing. It is recommended not
to open more than three X windows form one X server. If more X windows are needed, an additional X server
should be installed.
ULMA system can use also traditional serial links to interface with other equipment. The following serial
protocols are supported by the system:
- serial Siemens RK3964 -protocol; current loop or RS232
- serial ULMA -protocol; current loop or RS232
- serial ABS -interface (special protocol); current loop or RS232
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3. ENVIRONMENTAL REQUIREMENTS AND SYSTEM CONFORMITY
3.1. Environmental requirements for use

The environment where the system is used must comply with the set of environmental class combinations
IE33 (IEC 721-3-3). The exceptions are given below:
Temperature range: 10 ... 55 °C (table top monitor 10 ... 35 °C)
Humidity range: 10 ... 90 % (noncondensing)
Lower temperatures mean increased system reliability and availability.
The lifecycles of wet, electrolytic capacitors and most semiconductors are greatly reduced if the maximum
permitted temperatures are exceeded.
The cooling air must not contain aggressive gases or carbon dust.
3.2. Specifications of power supply

- Supply voltages: 3-phase 400...600 V
- Supply voltage deviation: ±10 % continuous, ±15 % short time
- Rated frequency: 50 or 60 Hz
- Static frequency deviation: ±2 %
- Dynamic frequency range: 45 ... 65 Hz
- Dynamic df/dt: 17 % / s
3.3. Vibration
This concerns especially operator station, power supply cabinet and beams. The vibration should be
considered when the detector beam mounting location is determined. The cabinets must stand on a stable
floor, deck or supporting structure, free from vibrations.
If the system equipment is installed in a place adjacent to large machinery such as Pope reeler, where
frequent major vibrations occur, shock absorbers or an isolation pad may be required to protect the system
equipment. Shock absorbers normally protect the equipment from sustained low-level vibrations (vibrations
that are perceptible, but not excessive). If vibrations or shock are a major problem, consider more extreme
measures to alleviate the problem.
3.4. Storage
The system must be stored in a weather-protected shelter which fulfills the requirements or the set of
environmental class combinations IE11 (IEC 721-3-1).
3.5. Transportation
When leaving the factory the systems are packed taking into accordance the way of shipment. There are two
main types of packaging: for land/air shipment and for sea freight. The sets of environmental class
combinations are IE21 and IE22 (IEC 721-3-2) accordingly.
3.6. Electrical safety

The system complies with the requirements of Council Directive 73/23/EEC for electrical safety. The relevant
standards are IEC 1010-1, IEC 664-1, and IEC 529.
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3.7. Safety of machinery

The system complies with the requirements of Council Directive 89/392/EEC for safety of machinery. The
relevant standards are EN 60204-1, EN 292-1, EN 292-2, EN 418 and EN 563.
3.8. Electromagnetic compatibility (EMC)

The system conforms with the EMC protection requirements of Council Directive 89/336/EEC. The relevant
standards are EN 50081-2 and EN 50082-2.
4. SAFETY ASPECTS
4.1. Operational safety

When correctly operated, the ULMA NT equipment is not dangerous to the user in any way.
The system does not interfere with the paper making process during normal operation or in case of faults, as
the measurement is performed without contacting with the web.
Moving parts are used in the light source beam equipped with a beam lifter and in the colour marker.
If a beam lifter is used, it is usually fitted to the light source beam on the tender side. The light source beam
may also have a beam lifter at both ends.
The purpose of the beam lifter is to move the beam (or beams) normally 500 mm away from the web to
facilitate the threading of the web.
The light source beam moves automatically to the measuring position, when the ULMA is switched ON. If the
ULMA is switched OFF or there is a web break, the beam moves automatically away from the measuring
position.
Commonly 50 mm/s, the speed of the pneumatic beam lifter is adjustable. The slow movements do not
endanger the operating staff. For increased safety, the beam lifter control box is provided with an
EMERGENCY STOP switch for stopping the movement.
The colour marker movements to and away from the web are equally slow, approximately 9 mm/s.
The light source beam contains incandescent lamps, which emit both visible and infrared radiation. The lamps
burn brightly on when the measurement is in progress. At web break the light is dimmed. When the web is
thick, the light is bright, and looking directly into it at close distance should be avoided. The operation of the
system does not require looking at the light.
Although the beam is continuously cooled, the temperature of the glass and the side plates may be over 100
o
C; be careful not to touch these hot parts.
The lamps are dimmed at web break, but the beam remains warm until cooled down by the fan. The light
source beam temperature is continuously monitored with a temperature sensor. If the temperature exceeds
the warning limit, the system alerts, and if the alarm limit is exceeded, the light source beam supply voltage
is automatically switched off.
Strictly no standing or walking on the light source beam!
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4.2. Electrical safety

It is absolutely necessary that these safety instructions are read before any work on the equipment.
WARNING!
The equipment is alive as soon as the main switch Q01 in the power supply cabinet is closed. Lock
the main switch Q01 in the OFF position for major maintenance operations.
ULMA power supply cabinet, power supply box, and light source beam use dangerous voltages and if handled
improperly, the system may cause a risk of death or serious injury to persons or damage to environment.
All relevant safety regulations must be observed during installation, commissioning and maintenance work.
After the supply voltage is disconnected by means of the main switch, always ensure by voltage
measurement that no part of the system has voltage or the system is protected before servicing or making
main circuit connections. Measure between terminals L1 - L2 - L3 - PE. The meter must be capable of
withstanding 1000 VAC. See the circuit diagrams of supplies before any action.
There may be live terminals inside the drive cabinet even after the supply voltage has been disconnected from
the main switch, e.g. incoming supply cables itself or external auxiliary power supplies. Note also separate
supply to cooling device in operator station and a possible UPS supply!
Do not make any voltage withstand tests on any part of the unit.
4.3. Protecting ESD sensitive devices

CAUTION!
All electronic devices are sensitive to ESD (electrostatic discharge) effect.
Observe the following safety rules:
• Avoid discharges of static electricity by grounding both yourself and tools before handling circuit
boards and other parts of the equipment.
• Use, if possible, a grounded wristband and a grounded working surface when handling parts of the
system. Wrist strap has to have built-in protective resistor.
• Handle the circuit boards carefully, particularly those, which contain MOS components, which can be
damaged by static electricity discharges.
• Use, as far as possible, a grounded wristband when handling boards not stored in envelopes of
conductive plastic. This gives optimum protection against static electricity discharges.
• Hold the circuit boards from sides, don't unnecessarily touch components, wires, terminals or folio.
• Always store circuit boards in envelopes of conductive plastic.
• Always switch off the voltage before extracting a board which cannot be exchanged while under
voltage. Wait a sufficient time for the capacitors to discharge.
• Switch off voltage to the system and withdraw all boards at least 20 mm before electrical welding is
performed near the system.
• Damaged electronics boards are to be handled with the same caution.
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5. PERIODIC CHECKS
5.1. RECOMMENDED PREVENTIVE MAINTENANCE

Weekly (2 mhrs)
1. Review the alarm page for software/hardware discrepancies.
2. Discuss with production personnel all operational alarms.
3. Check color marker fully operational (dye level, reservoir, nozzle, edge follower setting).
4. Inspect printer.
5. Check that the beams air supply to filter (at the cooling fan) is clear of obstacles.
6. Clean light source glasses and camera port covers.
7. Check that all lamps light up.
Monthly (2 mhrs)
8. Remove and clean beam air filter (at the cooling fan).
9. Clean color marker nozzle by flushing with warm water (connect water to the dye line).
10. Review camera Video Levels and compare with previous values (using test page inspect condition of lens
and lamps). Any “loose” pictures on the curve?
11. Verify defect delectability by making artificial defects on the web. E.g., holes can be made by shooting
with airgun, light spots by dropping water or oil, dark spots by dropping small pieces of paper, and
coating streaks by pressing paper gently with a spike after the coating station.
12. Verify tachometer speed display accuracy
Semi-annual (8 mhrs)
13. Remove camera lens and clean with lint free cloth.
14. Clean CCD element with optical cleaning solution.
15. Clean light beam gold reflectors with a water damp cloth. No solvents.
16. Read and document system voltages. (system must be on-line with web)
A. Power supply cabinet: mill power supply (e.g., 575 Vac)
220 Vac
+24 Vdc (±10 %)
lamp power
B. Power supply box: 3 x 400 Vac
+48 Vdc (±10 %)
17. Inspect camera video levels (system on-line with web)
Annual (5 mhrs)
18. Secure main power and purge all cabinets of dust . Using static ground wrist strap clean circuit boards.
19. Clean camera body circuit boards. Check that all addresses are correct.
20. Inspect wiring for discoloration and termination.
21. Bearings of the DCS 500 fan motor should be checked and the fan should be replaced if the bearings are
not in good condition.
22. Change all lamps every fifth year.
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6. FAULT TRACING
6.1. Introduction
All applicable electric safety regulations must be observed while maintening the ULMA equipment. When a
fault is observed, the repair time can be appreciably shortened by immediately investigating the effects of the
fault. A person sufficiently familiar with the ULMA will often find it quite easy to localize the fault. In most
cases, the diagnostic displays can be used for preliminary tracing of the fault location and the fault resetting
can be done without opening the door of the controller cabinet. In some rare cases it may be necessary to
check all functions of the system in a systematical way.
WARNING!
The equipment is live as soon as the fuse-disconnector Q01 in the power supply cabinet is closed. Lock Q01
in the OFF position for major maintenance operations.
6.2. Self-diagnostics of DCS 500

General
In preliminary fault tracing, the possible fault location is generally traced on the basis of the fault message on
the DCS 500 module.
External fault sources are, for example:
- Supply
- Control circuit connections
- Light beam and tachometer cables
- Load of the light beam
- CIM-communication fault
- Incremental encoder
Internal fault sources are, for example:
- Circuit boards
- Power semiconductors
- Flat cables
- Cooling fan
In most cases, it is possible to reset the fault message. A fault can be reset by switching the mains voltage
off for a while. Try to restart DCS 500 before proceeding to a more accurate fault tracing. If the fault has been
removed, the DCS 500 will resume normal operation.
Before the fault is assumed to be in DCS 500, it must be checked carefully that the fault code is not referring
to any outside fault or disturbance.
In case of a fault or an alarm occurrence the indication is done by the seven segment display of the SDCS-
CON-1 board.
6.2.1. DCS 500 fault diagnostic messages
There are three different types of signals:

- Fault which causes tripping and prevents to run.
- Alarm which warns about the fault but does not prevent or stop the run.
- Status shows the state of the drive.
Every fault and alarm/status signal is coded as an individual error code.
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Signal Definition Type of Mode of Reset

Code [Fault text] Signal Action Method
0 No faults or alarms
99 Resets all resettable faults Reset
1 Auxiliary voltage fault Fault Trips To be reset
[Auxil. undervoltage]
2 Overcurrent Fault Trips To be reset
4 Measured overtemperature of converter Fault Trips To be reset
[Converter overtemp.]
5 [Earth fault] Fault Trips To be reset
14 Speed measurement fault Fault Trips To be reset
[Speed meas. fault]
17 Type coding fault Fault Trips Can't be reset
[Type coding fault]
18 Parameter backup fault Fault Trips Can't be reset
[Backup read fault]
20 COM – SCS 500 Fault Parameter To be reset
[Comm. error] dependent.
28 Armature DC over voltage Fault Trips To be reset
[Armature overvoltage]
29 Main supply undervoltage Fault Trips To be reset
[Mains undervoltage]
30 Main AC supply overvoltage Fault Trips To be reset
[Mains overvoltage]
34 Armature current ripple Fault Trips To be reset
[Arm. current ripple]
38 Phase sequence fault Fault Trips To be reset
[Phase sequence fault]
41 Missing main contactor acknowledge Fault Trips To be reset
[No main cont. ack]
44 A fault that is caused by missing I/O-board Fault Trips Can't be reset
[I/O-Board not found]
101 Switch ofr prevention of unexpected start Status Prevents start Resets when
has been switched ([START INHIBIT] 908) up released
[Start inhibition]
105 Alarm of converter module temperature Alarm Alarm Self reset
measurement indicator
[Conv. overtemp. alarm]
106 Current Regulator is blocked Alarm Status Self reset
[Current reg blocked] indicator
108 Backup failure of RAM memory Alarm Alarm Self reset
[RAM-backup failed] indicator (after first run)
115 Armature current ripple Alarm Alarm Self reset
[[Arm. current ripple] indicator
118 Main supply under voltage Alarm Alarm Self reset
[Mains underv.alarm] indicator
120 Armature current deviation Alarm Alarm Self reset
[Arm.curr.dev.alarm] indicator
129 Type code changed during power shut Alarm Alarm Self reset
down indicator
[Type code changed]
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Signal Definition Type of Mode of Reset

Code [APC alarm/status texts] Signal Action Method
130 Initial values read from fprom-memory Alarm Alarm Self reset
[Init values read, S2] indicator
132 Parameter set 2 is missing Alarm Alarm Self reset
[Param set 2 missing] indicator
134 Saving of the parameters and connection Alarm Alarm Self reset
points not allowed indicator
[Backup not allowed]
136 Saving of the parameters and connection Alarm Alarm Self reset
points failed indicator
[Write backup alarm]
138 Initial values read from the fprom memory Alarm Alarm Self reset
[Init values read] indicator
6.2.2. HW-Fault Indications
Power supply cabinet boards

The boards of the ULMA power supply cabinet can be divided into the following functional groups:
– Converter unit DCS 500 U01
– Other interface units:
– Digital I/O board SDCS-IOB-21 A09
– Analog I/O board SDCS-IOB-3 A10
– Extended I/O board UNS0863 + UNS1867 A99
6.2.3. SDCS-CON-1 (control board)
There is one seven-segment display on the board SDCS-CON-1. The display might blink by the cycle 0.7 s.
The blinking is coded as shown in the table below.
Code Description
0.7 s 0.7 s
. Normal situation, no fault no alarm
L During downloading (PC->drive) sequence
8 Program is not running
E 1 ROM memory test error
E 2 RAM memory test error
E 3 No TC link board
E 4 Bad TC-link board
E 5 No control program in memory
E 6 Incompatible hardware
Alarm, same number as in Fault logger, shown only if no fault is
A XX
active
F XX Fault, same number as in fault logger
E.g. The display shows 0.7 s E, 0.7 s 0 and 0.7 s 1. After this the sequence start again from E. The meaning
of display is ROM-test error.
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6.2.4. SDCS-IOB-21 (digital I/O connection board)
LED’s on the SDCS-IOB-21 board shows the state of the digital inputs and outputs.
- V1 - V8 are lit when inputs (DI1 - DI8) are high
- V43 - V50 are lit when outputs (DO1 - DO8) are high.
6.2.5. SDCS-IOB-3 (analogue I/O connection board)
LED’s on the SDCS-IOB-3 board shows the following:

- V17 is lit when the encoder supply is OK
- V17 is blinking if a short circuit has occurred between X5:7 - X5:8
- if the auxiliary voltage of encoder is 5 V it is possible that the V17 is lit though there is a short
circuit somewhere in the cable of the encoder (according to the impedance of cable).
6.2.6. Other fault conditions and repair
Main fuses are blown

In case of burned main fuses there is a high possibility of short circuit in the main circuit SDCS-PIN-XX
(bridge).
Measure the main circuit to find out the fault source. Never change the fuses without measuring the condition
of main circuit!
Main fuses can be changed as well as measurements of the semiconductors can be done when the
converter is disconnected from the AC-supply by means of the fuse disconnector Q01 and the zero voltage
is measured with a voltage meter between L1 - L2, L1-L3, L2-L3, L1 - PE, L2 - PE and L3 - PE. Check the
connection from delivery documents.
General instruction how to replace boards
The main voltage must be disconnected when replacing circuit boards.
Remove all ribbon cables and/or screw terminal blocks from board. Remove all screws holding the board.
Compare that new and old boards have the same type designation or that the new board can replace the old
one. Check the jumper settings, components on solder posts and scaling (or burden) resistors of the old
board and ensure that the jumpers, components on solder posts and scaling (or burden) resistors are set in
the same way on the new board.
How to replace the SDCS-CON-1 board
Ensure that the spare board is compatible with the old board and take care that the parameters will be
correct after replacing.
If the program version of new board is the same as the old version then the possibilities to load parameters
are:
- Change the FLASH-memory D35 from the old board to the new board. Note! Install the circuit to the
correct position into the board using suitable tool.
- Download the parameters.
If the program version of the new board is different than the old version it must be checked that those versions
are compatible.
If the program version (circuits D33 and D34) will be changed from a old board to the new board it must be
checked that the hardware of new board is compatible with the new program version.
In indistinct cases contact to the nearest ABB Service representative.
Measuring of the semiconductors
Short circuits can be detected by a multimeter measurement. Don't open the semiconductors before
measuring. See Fig. 6.
The resistance between A (anode) - K (cathode) - G (gate) must be measured from every thyristor.
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Note: Use always low ohm measuring equipment (not Megger).

When resistance between K - G is measured the trigger pulse connections from SDCS-PIN-XX board must be
removed.
If the short circuit is found the light beam cable (L+ or L-) must be disconnected before the broken thyristor or
RC-circuit can be located.
The resistance values are according to used type of multimeter and used type of thyristors. Compare the
results with each other’s.
Exact values can't be given but some typical resistance values are about:
- A - K > 10 kΩ
- A - G > 10 kΩ
- (K - G) 10Ω < K - G < 100Ω
General instructions for handling the semiconductors
Thyristor modules have to be mounted to right torque using torque screwdriver.
To avoid confusion with "good" components, always mark clearly suspected damaged components after
removing them from the circuit.
When dismounting the damaged semiconductor, note which way it was installed in the heat sink.
Compare that new and old components have the same type designation or that the new component can
replace the old one. The semiconductor can be replaced by the different manufacturer's compatible
semiconductor according to the code in the table later on.
Semiconductor components are precision products. All unnecessary tools and articles constitute a needless
danger to the easily dented and scratched mounted surfaces and to the semiconductors in general.
1. Keep new semiconductors as long as possible in their original packages.
2. Use protective gloves if necessary.
3. Clean table and hands frequently.
4. Use good lighting.
Installation of thyristor module
In order to keep the operating temperature of the semiconductor module low, the joint between the heat sink
and the module should have a good heat conducting ability. The electrical conductivity of the connectors must
also be good. For this reason the following instructions must be observed with particular care.
1. Preparation of the heat sink. If the area is clean spread out the remaining heat conducting compound
with a rubber spatula or similar. If the area is dirty, wipe the heat sink surface clean with tissue
paper.
2. Cleanse the mounting surfaces with an appropriate solvent (for example Grafol fluid) and spread heat
transfer grease on the base of the module.
3. Mount the module on the heat sink and tighten the clamping screws until the screw heads touch the
bottom of the module.
4. Then tighten the screws to pretorque (50 % from nominal torque).
5. Tighten the screws.
Fig. 6 shows a thyristor modules. The terminals of the module are also stamped or marked by sticker to the
module.
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A K AK
2 4 1 3
TT25N16KOF
4
2
3
1
Figure 6. Terminals of thyristor module TT25N16KOF
6.3. Operator station fault diagnostic messages

The table below shows the hardware faults reported by the monitor.
Hardware fault Probable cause Corrective action
CAMERA DOES Camera error Replace camera

NOT RESPOND
CAMERAS DO Failure in connection to Replace CIM board in the

NOT RESPOND camera beam PC-unit
Replace Optimult board in the
camera beam
CAMERA VIDEO Camera beam or light source Clean the glass at the affected
LEVEL beam glass dirty camera
LIGHT SOURCE BEAM Light source beam glass dirty Clean the light source beam
TEMPERATURE glass
ALARM
LIGHT SOURCE Light source beam glass dirty Clean the light source beam
INTENSITY LIMITS glass
DCS DOES NOT Optical link, CIM board or Replace the board
RESPOND Optimult board
FAN STOPPED Safety switch Close the switch
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SYSTEM ALARMS
------------------------------------------------------------------------------------------------------------------------------------
Alarm # Explanation / Corrective procedure
------------------------------------------------------------------------------------------------------------------------------------
0 CAMERA XX DOES NOT RESPOND
Supply voltage to the camera is missing
– check the supply voltage LED's of camera xx:
all three LED’s should be on. If not, change the camera power supply board.
Camera xx does not communicate
– check the fiber connectors on the camera and on the optimult board
– visually check that the camera-receiving fiber is lit. If not, the problem is on the
optimult board or optical fiber.
Wrong address
– check the address of camera xx in the beam:
the camera should match with the camera number in the beam.
Camera HW failure
– verify LED’s of the camera digital board
– write down how the LED’s differ from normal operation
– replace the camera and attach description of the LED’s to the camera.
1 CAMERAS DO NOT RESPOND
After this alarm appears the system goes automatically into yellow ON status.
Possible cause:
No supply voltages to the cameras

– check the 48V voltage in the power supply box
Cameras do not communicate
– check the communication on the CIM-2CH-board, both the LED’s above the optical
cable connectors should be lit
– if both LED’s are off the CIM-2CH-board is not sending inquiries:
check that the cameras are in ON-condition at the operator station
– if cameras are ON and both CIM-2CH LED’s OFF, CIM-2CH-board is not
communicating: first reset PC and if no help, replace CIM-2CH-board
– if transmitting LED is ON but receiving LED OFF, the cameras do not answer to
inquiries: check the receiving optical path from the optimult to the CIM-2CH
– check that both LED’s on the optimult board are ON
– check the supply voltage to the optimult board (48V)
– replace the optimult board
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SYSTEM ALARMS, cont.

2 CAMERAS XX VIDEO LEVEL
This alarm is not significant if it does not appear all the time, e.g. in case of web break, video alarms
may appear. If the alarm is continuous for some cameras, actions should be taken.
The video level of the camera XX deviates more than +/-200 (hex) which is +/-20 % from the average
video level of all the cameras
- the light source beam glass at camera XX is dirty:
clean the glass
- the light source beam lamp has failed:
replace the lamp
- the lens aperture is closed too much:
adjust the lens aperture (f stop)
- some obstacle between paper web and camera or
paper web and light source (e.g. peace of paper)
- camera HW failure:
replace the camera.
3 LIGHT INTENSITY CONTROL LIMIT

The light source beam has reached the maximum level
– the light source beam glass is dirty:
clean the glass
– the set point of the automatic light control is too high:
set the value in range 35 ... 45 %.
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6.4. Camera testing
6.4.1. Functional check of camera
Shooting a hole into the paper web with an air gun can also test the operation of a camera. The output
devices should then register a hole.
The ability of a camera to detect a streak can be tested by inserting an opaque wire between the camera
beam and the web. The output devices should register a dark streak.
6.4.2. Replacement of camera
– Disconnect the two optical cables from the camera.

– Disconnect auxiliary voltage cable.
– Unscrew the four knurled-head screws.
When installing a new camera frame, the following items should be checked:
– Ensure that the lens and that there is air blowing on top of the camera board raid.
– The address of the new camera, which is to be selected the same as on the camera being
replaced.
When installing a CCD module, the following items should be checked:
– Lens aperture (f-stop) and focusing, which must be the same as on the camera, being replaced.
– CCD module alignment.
Focusing
Measure the video signal and focus the lens using the Curve program running in a laptop that is connected
with the DSP-MON adapter to the camera. Normal light intensity should be used during the inspection. The
web must be in place or there must be a sheet of corresponding type between the light source beam and the
camera beam.
Video signal (ODD or EVEN) is used for focusing the camera lens. When the sheet is in place, a piece of
thread is placed on the sheet so that it shows in the video signal. The lens-focusing ring is turned until the
thread produces maximum signal, and the focusing ring is locked with a screw in this position. Figure 7
shows the two curves produced by the Curve program while focusing the camera. The upper curve is obtained
when the lens is well focused. The lower curve corresponds the situation when the lens is still slightly out-of-
focus.
Alignment
Monitor the signal with the curve program. Place the tip of screwdriver exactly at the center of the light beam,
± 2-mm from the center lone. Adjust the tilt of the module with the thumbscrews so that you see the tip of the
screwdriver in the curve.
Thumb screws
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E00
C00
A00
800
600
400
200
E00
C00
A00
800
600
400
200
Figure 7. Lens focusing curves by Curve program
One line on the scales represents 200H = 160mV. The edge indicator is a vertical line on the curve.
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6.5. Light source beam lamp replacement

Switch off the supply to the light-source beam at fuse-disconnector Q01 in the controller cabinet.
Do not remove the lamp's protective paper until you are finished with the installation.
Remove the light source beam glass covering the lamp. Remove the screws and take out the lamp. Cut and
bend the metal strip of the new lamp to match that of the old lamp. If the bulb has been touched with bare
hands, it must be wiped clean with a solvent such as alcohol.
Figure 8. Bending lamp strip
Then fixed to the aluminum bracket be sure of that there is a force F pressing the lamp base against the
bracket. This leads the heat from the lamp base to the aluminum bracket.
The condition of the reflectors should be checked once a year and wiped off with a dry cotton cloth.
7. OPERATION
7.1. Principles of design and operation

Power is supplied to the system from the power supply cabinet. The power supply cabinet contains not only
1-2 converter unit(s) but also all DI/DO and AI interfaces.
The operator station contains a microcomputer and other peripherals, such as the video monitor, the
keyboard and the trackball or the mouse.
The actual measuring part of the ULMA system consists of two beams spanning the web. The beams are on
different sides of the web for through-the-web scanning, or on the same side of the web for reflection
scanning. One of the beams, the light source beam, emits wide spectrum light. Defects in the web material
cause variations in the light, and these are detected and classified beam into various defect categories by the
cameras in the camera.
The signals from the camera beam are transferred via an optical cable to the fibre optics distribution unit, and
from there to the operator station. The camera beam receives auxiliary supply voltages from the power supply
box near the beams.
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7.2. Power supply cabinet
7.2.1. Assembly of power supply cabinet
All the voltages required for the ULMA system are supplied from the power supply cabinet connected to the
mill's power supply.
The fuse-disconnector in the controller cabinet can be used for making the complete ULMA system dead.
Note! There can be a separate UPS control voltage supply, too.
The power supply cabinet:
– provides a supply voltage of 230V ± 10 V at 50 or 60 Hz to the operator station, colour marker and beam
lifter, regardless of the mains supply available, by means of transformer T01
– provides the desired voltage to the light-source beam by means of the thyristor bridge;
– protects the peripherals by means of the contactors and relays;
– turns off all power from the system when the disconnecter is actuated.
The assembly of a power supply cabinet is shown in Figure 9.
Figure 9. Power supply cabinet
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Figure 10. Main diagram of power supply

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7.2.2. DCS 500 Converter module
Figure 11. Dimensions of converter
Figure 11 shows the dimensions of the DCS 500 converter module. The converter modules supply the dc-
power to the light source beam. It also comprises different I/O-boards needed to interface the system the
process, e.g. to measure the paper machine speed and light source beam temperature, to read digital input
signals such as reel change, and to control peripheral devices like color marker. The converter module is
connected to operator station via optical link.
The different boards of the converter unit are described in the following chapters.
7.2.3. Control Board SDCS-CON-1
The control board SDCS-CON-1 is based on the 80C186 microprocessor and the ASIC circuit DC94L01. CPU
clock frequency is 16 MHz. The layout of the board is shown in Figure 12.
Memory circuits and the back-up
The system program has been downloaded to Flash PROM’s D33 and D34. Application parameters are saved
in the Flash PROM D35. During normal operation application parameters are in static RAM circuits which
have a back up capacitor of 1 F, which lasts minimum 8 hour, typically several days.
It takes about 30 minutes to charge the backup capacitor.
Most of the measurements and control functions of the DCS 500 are done in the ASIC (Application Specific
Integrated Circuit):
- measurement
- watchdog function
- A/D and D/A-conversion control
- thyristor firing pulse generation
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S3 Selection
Enable erasure and
S2 Selection programming of FPROMs
Normal start (parameter and system)
Start with initial Disable erasure and
X37 parameters
X14
programming of FPROMs
2 4 2 4
S2 1 3 A1 1 3
All supports
B1
S3 are metallic
X15 A1 Back up
1 X33 B1 X37 capacitor
1 CPU
X18 H1
1
2
X21 X11 D33 D34
A1
B1 21 21
X17 D35
UNS0867A-P ASIC
2
X12
1 X3
1 1
2
X13 X4 SDCS-COM-1
1
X34 X16 B1 B1
A1 X2 A1 X1
Figure 12. Layout of the control board SDCS-CON-1 and Extended I/O board UNS0867
As the board has memory backup that lasts for 8 hours there is a way to reset the memory instantly.
7.2.4. Communication board SDCS-COM-1
The communication board SDCS-COM-1 has three separate HDLC channels 1.5 Mbits/s to communicate
with a PC on Ch1, CIM-board on Ch2, and possibility to communicate as MASTER/FOLLOWER link on Ch3
between the two modules. The layout of the board is shown in Figure 13.
The CIM board controller can drive 1...4 modules simultaneously and therefore each module must be
identified by means of jumper S1 on the board.
The SDCS-COM1 is connected on top of the SDCS-COM-1 into X11. All fixing screws with spacers must be
used.
V3
RxD
SDCS-COM-1
TC Link CH 2 X11
to CIM V4
TxD
S1
V1 RxD 1234 Converter Coding for
CMT/DCS500 number channel 2
CH 1
Tool PC
V2 TxD D8 D11 1 S1
1234
V5 RxD
Master/ 2 S1
CH 3 2 8
Follower 1234
V6 TxD S2
Link Internal 3 S1
1 7
X1.1 +24 V 1234
X1 Setting for
4 S1
X1.2 0V external
supply for
(S2:1-2,7-8)
Ch3: 1234
Figure 13. SDCS-COM-1 TC link communication board.
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7.2.5. Power supply board SDCS-POW-1
The SDCS-POW-1 board is an integrated power supply for DCS 500 converter module. It makes all necessary
DC voltages for the SDCS-CON-1 and the I/O boards. The input voltage can be selected either to 230 V a.c.
or to 115 V a.c. (or 190 V d.c. ... 350 V d.c). Figure 14 shows the board lay-out with the instructions for the
selection of AC input voltage and for the selection of encoder supply voltage.
MAIN CONTACTOR 230 V/115 V These AC Supply

CONTROL supporbe metallic
should
X96 X99 F1
2 1 N L
110 V 220 V Fuse:
T3.15A 250V
DO8
SW1
Input
selection
voltage
Backup
supply
for SDCS-POW-1
SDCS-POW-1 +
-
X95
M1
Encoder supply
selection X5, X4, X3
A
5 V B AB 15V
24V
A A 15V
12 V B B 24V
A A 15V
24 V B B 24V
26 14
A A 15V
X37 B B 24V
1 13 X5 X4 X3
Figure 14. Power supply board SDCS-POW-1 (revision B or later) layout and jumper coding instructions.
The SDCS-POW-1 has got one output relay that is controlled as DO8. In the ULMA NT this relay controls the
Main contactor K01. The encoder feature is not in use.
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7.2.6. Digital connection board SDCS-IOB-2x
The Digital connection board SDCS-IOB-2x has 8 digital inputs and 8 digital outputs and it is used with the
SDCS-IOB-3 board. The layout is shown in Fig. 15. Inputs are filtered and galvanically isolated. Input voltage
level can be selected with resistors R1...R8. Inputs can form two galvanically separated groups (one is always
grounded to the converter frame) The board is connected to the SDCS-CON1
There are three different types of SDCS-IOB-2x boards depending on the input voltage level:
SDCS-IOB-21 24...48V d.c.
SDCS-IOB-22 115 V a.c.
SDCS-IOB-23 230 V a.c.
The terminal connections of the board are shown in Figure 16.
SDCS-IOB-2x
1
DO1
K1 X3 Conductive
X4 K2
DO2
support
K3
DO3 s
DO4
K4
DO5
K5
1
X1
DO6
X5 DO7
DO8
K8
R1 DI1
1
W1 W2
Filter selection 10 ms
R2 DI2
W3 W4
R3 DI3 Filter
W5 W6
X6 R4 DI4 2ms 10ms

W7 W8
12 12
R5 DI5 S7
W9 W10
R6 DI6 DI7 34 34
W12 12
W11 12
R7 DI7 S8
W13 W14
1 DI8 34 34
R8 DI8
X7 W15 W16 1 2 12
S8 S7
3 4 34
Figure 15. Lay out of the digital connection board SDCS-IOB-2x.
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3BFS 29101965 R0101
8 digital outputs:
X4.1 Color Marker 1 ON/OFF Ch 1-5, 8 galvanically isolated

DO1
X4.2 with relays, contact
X4.3 Color marker Mark rating 250 V a.c. / 3A
DO2
X4.4
X4.5
DO3
Color marker 2 ON/OFF
X4.6
X4.7 Color marker Mark
DO4
X4.8
X5.1 Free
DO5
X5.2
X5.3
DO6
Beam Lifter
X5.4 Ch 6, 7 optocoupler
X5.5 Audible Alarm (50 mA , 48 V d.c.)
DO7
X5.6
X5.7
DO8 Not used
X5.8
8 digital inputs:
681 V1 +
X6.1 R1
100n
+
681 Reserved
- DI1
W1 W2
X6.2 R2
DI2
Reserved Input voltage:
W3 W4 24V...48V("21") R1-R8 = 4.7kΩ
X6.3 R3
DI3
Reserved 115V AC ("22") R1-R8 = 22kΩ
W5 W6 230V AC ("23") R1-R8 = 47kΩ
X6.4 R4 Splice
DI4
W7 W8
X6.5 R5 State of main contactor Filter time constant:

DI5
W9 W10 DI1 - DI6: 10ms
X6.6 R6 Detection ON/OFF DI7 and DI8:
DI6
W11 W12 S7 and S8: 1-2 (10 ms), 3-4 (2 ms)
X6.7 R7 Web break
DI7
W13 W14
X6.8 R8 Reel change

DI8
W15 W16
100n
Earthing capacitor
X7:1 GNDI
X7:2 GNDE Power supply for digital inputs 48V, 50mA
X7:3 +48V
X7:4 +48V
Figure 16. Terminal connection of the SDCS-IOB-2 board.
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7.2.7. SDCS-IOB-3 Analogue I/O connection board
The SDCS-IOB-3 board contains the following channels:

- 5 analogue inputs of which one is used for temperature measurement
- 3 analogue outputs, one is dedicated for actual current. This controls the possible fluorescent light
beams.
- one pulse encoder interface
Figure 17 shows the board layout and jumper positions. The connection terminals are shown in Figure 18.
All SDCS-IOB-3 Switch

Gain=1 Gain=10 Earth fault
Ch Input area: Input area: Input area: measuring
0/4...20 mA -10V..+10V -1V..+1V selected
supports 1 A1 B1
are 2 8 AITAC S1:1-2
conductive X3 S2 1 26 X1
7 pin
AI1 S1:3-4
2 8
S3 A1 B1
AI2 S1:5-6
1 7 1
12
2 S2:1-2
S1 X2
1 2 1 2
1 2
13 14 S2:3-4 3 4 3 4 3 4
1 26
6 5 6
R110 pin S2:5-6
5 6 5
7 8
7 8 7 8
X4 S5 3 1 1,5 mA 5 mA S2:7-8
3 1 31
4 2 AI3 S1:7-8
4 2 4 2
2 S3:1-2 1 2 1 2
1 2
12 1 3 Encoder supply
S10 ok. S3:3-4 3 4 3 4 3 4
1 V17 5 6 5 6 5 6
22
23
24 S3:5-6 7 8
7 8 7 8
X5 S3:7-8
S4 T1
11 1
AI4 S1:9-10
12 2
S1:11-12
10 S1:13-14
AI4 S1:9-10
S1:11-12
Incremental encoder supply S1:13-14
S4:
Incremental Encoder Interface
Single ended Differential ended
24V Ch Term. S10 S10
5V 12/24 V 5 V 12/24 V 13 mA
A+ X5:1 5-6 2-3 4-5 1-2
12V A- X5:2 n.c.
B+ X5:3 11-12 8-9 10-11 7-8
B- X5:4 n.c.
5V Z+ X5:5 17-18 14-15 16-17 13-14
Z- X5:6 n.c.
Figure 17. Coding and lay-out of the SDCS-IOB-3 board.
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3BFS 29101965 R0101
100k 1 00k
X3.1 - 1
1n Di 5 HIGH OHMIC ANALOGUE INPUTS:
S1 100k 1n 1 00k AITAC
X3.2 +
2
Resolutions:
X3.3 - Channel AITAC and AI1: 12 bit + sign
3
4 1 AI1
X3.4 + Channel AI2...AI4: 11 bit +sign
X3.5 -
10 V : S 2= 1-3 - - , 6-8
1 V: S2 =1 -2 , 3-4 ,5 -6 , 7 -8
5
6 1 AI2
X3.6 + Input range:
10 V: S3 1-3, 2-4,5-7, 6-8
X3.7 - 1 : 3 1 -2, 3 -4 ,5-6, 7 -8 Channel 1...5 -10V...+10V and
7
8 1 AI3
X3.8 +
0/4 mA...20 mA
X3.9 - 9
10 1 AI4 Channel 3 and 4 also -1V...+1V
X3.10 +
S1
12
11
14
13
CMR is +40 V, except in range +1 V +10V
X3.11
Earth fault
X3.12
100u 4 7.5
X4.1 +
100n
AO1 2 ANALOGUE OUTPUTS:
X4.2 0V
100u 4 7.5
Resolutions: Channel 1 and 2 11 bit + sign
X4.3 +
100n
AO2 Output range: -10V...+10V
X4.4 0V
-10..10V
R110 Maximum load: +5 mA
X4.5 + Iact (- + V) Analogue output of actual current (Iact)
X4.6 0V
X4.7 +10V
Default 10V = IN (converter)
X4.8 GND
Adjustable gain 0.5...5 by R110
-
X4.9 -10V
Voltage reference +10 V / 5 mA
1.5 mA 5mA
X4.10 1.5/5mA 10 0u 5
X4.11 0 V 5 Current source for PT100 elements is 5mA
X4.12 Spare Current source for PTC resistor is 1.5 mA.
X5.1 Ch A
X5.2 Ch A
INCREMENTAL ENCODER INPUTS
X5.3 Ch B Inputs are isolated.
X5.4 Ch B Input current a.13 mA/channel (24V mode)
X5.5 Ch Z Max. frequency is 30 kHz (encoders with
X5.6 Ch Z differential outputs)
X5.7 U
X5.8 U = (incremental encoder power supply)
X5.9 5V/0.2A, 12V/0.2A and 24V/0.2A.
X5.10 0VE
Figure 18. Connection terminals of the SDCS-IOB-3 board.
The constant current source is used to supply current for the light source beam temperature sensor PT –100.
In this case the current is selected with the jumper S5 in position 3-4.
The actual voltage is connected to input 3.
If the machine speed shown in the status display shows a very high speed then connect a 100 nF capacitor
from X5/10 to chassis ground.
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7.2.8. Incremental encoder connections
There is a galvanically isolated power supply for the incremental encoder on the SDCS-IOB-3 board. The
following supply voltages can be selected: +5 V, +12 V and +24 V ( by S4). When LED indicator (V17) is lit,
the supply is OK.
Two different incremental encoder connections are available (Figure 19):
- differential connection with either voltage or current connection (the upper diagram in Fig. 19)
- single-ended (push pull) voltage connection (the lower diagram in Fig.19)
SDCS-I OB-3 +
CH+ X5:_
S10 +
CH- X5:_ +24V
+U
SDCS-I OB-3 +
CH+ X5:_
S10 +
CH- X5:_ +24V
-U
Figure 19. Pulse encoder connection principles.
Three differential inputs are reserved for connecting the incremental encoder. CH A and CH B are the normal
pulse channels having nominal 90° phase shift between the channels. CH Z is the zero pulse channel which
can be additionally used if the encoder has an output giving one "zero" pulse per revolution. The incremental
encoder connection is isolated with optocouplers.
7.2.9. Connections between I/O-boards
Figure 20 shows ribbon cables used to connect the standard I/O-boards to the Control Board.
SDCS-IOB-2 <2m SDCS-CON-1

X1 X1
X3
<1 m flatcables (26 pins)
X3
X2
X2
SDCS-IOB-3 <2m
Figure 20. Ribbon cable connections between I/O-boards and SDCS-CON-1.
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7.2.10. I/O Interface, UNS 0863
The optional I/O-interface board UNS 0863 is used if the capacity of the standard I/O-boards is not sufficient.
The board contains 16 galvanically isolated digital inputs for 24 Vdc nominal voltage and
18 output relays with switchover contacts for 250 Vac/dc. There are also test points available for checking the
analog actual values of the UNS 1860. The board lay-out is shown in Figure 21.
UNS 0867
TWIN 1 1
X41 X12
X31
TP1...49
X42
1 1
X11 X32
N Y I/O Interface UNS 0863

R100 R100 R100 R100
1 2 3 4
2-CH
Digital inputs
Relay outputs Analog I/O
12 14 22 182 184 19 20 21 35 36 12 22 162
X4 X5 X6
11 11 21 181 181 1 2 3 17 18 11 21 161
Figure 21. I/O-board UNS 0863
The discrete input connections and relay output connections of this board are shown in the figures 22 and 23
respectively.
Digital Inputs:
Number: 16 digital inputs for 24Vdc; galvanically isolated.
The +24Vdc interrogation voltage for the 16 external customer contacts is provided by the power supply unit
UNS 0861. The LED’s IN 1 ... 16 indicate activated inputs. Each input is galvanically isolated by means of an
optocoupler. In the basic configuration of the device, all digital inputs have the same reference potential, i.e.
all soldered bridges X1001 ... X1016 are connected to each other. If independent inputs are required (e.g. from
SPS drivers), the corresponding inputs can be configured by disconnecting (cutting out) the reference
potential connection.
The + 24VDC supply voltage for the optocouplers is provided by the output (6,7) of the power supply unit UNS
0861, which is decoupled by means of a diode. This allows redundant voltage supply for 2-channel
configurations.
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X6:
11
I1 X41/42:
+24V 4
X1 00 1 ON IN 1
0V 12
I2
21 5
X1 00 2 OFF
22
I3
31 6
X1003
32
I4
41 7
X1004
42
I5
51 8
X1005
52
I6
61 9
X 1 00 6
62
I7
71 10
X 1 00 7
72
I8
81 11
X1008
82
I9
91 12
X1009
92
I10
101 13
X1010
1 02
I11
111 14
X1 01 1
112
I12
121 15
X1 01 2
1 22
I13
1 31 16
X 1 01 3
132
I14
1 41 17
X1014
142
I15
151 18
X1015
152
I16
161 19
X 1 01 6 IN16
162
ZB
23/24
+24V
25/26
Figure 22. Digital Inputs
Each of the 16 inputs can be used to give remarks in the defect map. If used, a text has to be given in the
Configuration/Display configuration/Digital Inputs, for example: “Coating On” and “Coating OFF”
If the inputs are to be used, +24V has to be wired from terminals 100…120 through a switch and return to
X6/11..161. The GND should be wired from 121…140 to X6/12…162.
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+ N
X41:34 1 CH 2 FAIL
TCHFN2 Y
X32:34
2 CH
X42:34 1 CH 1 FAIL
X4:
TCHFN1
X31:34 12
CH 1+2FAIL
11 , 11
X31/X32: 14
TRIP
33 22
TRIP
21 , 21
EXC. TRIP
24
O3
32 32
OUT3
31 , 31
34
O4
31 42
OUT4 4 1, 41
44
O5
30 52
OUT5 51, 51
54
O6
29 62
OUT6 61 , 61
64
O7
28 72
OUT7
71, 71
74
O8
27 82
OUT8 81 , 81
84
O9
26 92
OUT9
91 , 91
94
O10
25 10 2
10 1, 101
OUT 10
10 4
O11
24 11 2
11 1, 111
OUT 11
11 4
O12
23 12 2
12 1, 121
OUT 12
12 4
O13
22 13 2
13 1, 131
OUT 13
13 4
O14
21 14 2
14 1, 141
OUT 14
14 4
O15
20 15 2
OUT 15 15 1, 151
15 4
O16
19 16 2
OUT 16 16 1, 161
16 4
O17
18 17 2
17 1, 171
OUT 17
17 4
O18
17 18 2
ALARM
OUT18
18 1, 181
18 4
ZB
15
Figure 23. Relay Outputs
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Relay Outputs
Number: 18 relays with changeover contacts.
The LED’s OUT 3 ... OUT 18 indicate activated relays.
Reference potential of the digital inputs
Only one return conductor can be used for digital inputs with the same reference potential. In the basic
configuration, the bridges X1001 ... X1016 are connected with one another. If separate input channels are
required, these are to be separated from the others.
X6: X41/42:
I11
111 14
X1011 IN11
112
I12
121 15
X1012 IN12
122
I13
131 16
X1013 IN13
132
Break connection
Figure 24. Example: Input 112-122 isolated.
7.2.11. Extended I/O-interface board UNS 867A-P
The I/O-board UNS 863 is interfaced to the SDCS-CON board via the extended I/O board UNS0867A-P
provides. The board includes 16 digital inputs, 19 digital outputs. The board is plugged into the connector X21
of the SDCS-CON board and is supplied with power from connector X37 via a flat cable (Fig. 25).
UNS 086 7
SDCS-CON-1
X37
X21 X11
X3 X4
UNS 08 63
X31 X41
X32 X42
Figure 25. Extended I/O
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7.3. Operator station
7.3.1. Introduction
The purpose of the operator station PC is to process the defects detected by the camera beam and to output
them to selected output devices. The keyboard of the operator station can be used e.g. to adjust the
detection sensitivity and to select the desired output devices.
7.3.2. Main components
The cabinet model operator station comprises the following components:

– an industrial PC-unit,
- containing the CIM board connected to ISA-bus
- Ethernet network board (option)
– power supplies
– monitor and keyboard
The monitor, keyboard, and defect report printer may also be located outside the operator station.
7.3.3. Camera Interface Module (CIM) inside the Master PC-unit
The CIM -board is communicating with the cameras and with the DCS500 -controller through the optical
quartz fiber links. The link to the cameras is 2 Mbit/s (channel A) and to the DCS500-unit 1,5MBit/s (channel
B). Both of these links use HDLC-protocol.
Figure 26. CIM board layout
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The CIM -board is connected to the ISA-bus in the Main PC and is communicating with PC-application
program via PC’s I/O -port. CIM-board drawing is shown in figure 26.
The serial communications unit CIM (figure 26) is provided with two serial communication channels; a fast
channel with optical fibre connector and an RS232 channel. Equipped with two parallel connections, the
optical fibre connector is suited for plastic fibre and glass fibre. The connection is used for communicating
with the cameras in the camera beam using the so-called polling method. The RS232 channel is used for
testing.
CPU: AMD 29240EH running at 25 Mhz.
Memory: Dynamic memory, 1 to 64 Mbytes
Serial communication controller:
Siemens ESCC2, DMA usage, HDLC protocol
PC Interface: 512 x 16 BIFIFO, 16 bit bidirectional latch, Interrupt.
Interface between PC and CIM

Board addressing
Four possible base addresses selected by jumpers J1 and J2 (see Fig. 26):
J2 J1 Base address
0 0 0x0220
0 1 0x0240
1 0 0x0320
1 0 0x0340
In addition up to four boards can share the same base address (Fig. 26).
J4 J3 Board Number Final Address
0 0 0 Base Address + 0x00000
Notes: 0 indicates Jumper not installed.
IRQ selected by jumpers J5-J12

J5 IRQ 3
J6 IRQ 4
J7 IRQ 5
J8 IRQ 6
J9 IRQ 7
J10 IRQ 10
J11 IRQ 11
J12 IRQ 12
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7.4. Camera
7.4.1. Introduction
The CCD -camera contains two main parts:

- CCD -unit
- signal processing unit with 4 electronic modules and mother board where the modules are
connected.
7.4.2. CCD-unit
The CCD-unit contains a CCD-board, objective lens (35 or 50 mm) and lens adjustment mechanism (see Fig.
27). The CDD unit is connected through a flat cable to VPM-board located in the signal processing unit. The
CCD-unit can be detached separately.
The CCD board contains a CCD-element (Charge-Coupled Device) which comprises 2048 or 1024 light-
sensitive areas, called pixels, with a size of 13 µm x 13 µm each.
The light emitted by the light source beam passes through the lens onto the CCD which converts the light into
two video signals. The video signals are amplified in a transistor stage and transmitted over 20-wire ribbon
cable to the analog board.
Figure 27. Camera and CCD board
7.4.3. Signal processing unit
The signal processing unit consists of a board rack with mother board (MOM) and four electronics boards
located in the rack:
– power supply module (PSM)
– camera processor board (CPM)
– video interface module (VIM)
– video processor module (VPM)
The face of the rack is shown in Figure 28.
Mother Board (MOM)
There are four female connectors on the mother board where the modules connect. The connectors are
identical in pin order. The recommended order of boards is from left to right PSM, empty slot ,CPM,
VIM&VPM .
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V4 TENS
D17
S1
V3
ONES
V2 S2
V1
D7
S1
D13
X2 X6
+
-
X1
PSM CPM VIM VPM
Figure 28. Camera signal processing unit
7.4.4. Power Supply Module (PSM)
The power supply module produces the stabilized auxiliary voltages required by the boards in the camera.
The power supply box near the end of the beams supplies + 48 V DC to the unit (see acceptable range in the
table below). The front plate of the board is shown in Fig. 28 (module PSM). D17 is green LED lamp
indicating power OK. Switch S1 is power ON/OFF switch. Connector X2 is used for 48 V power supply to the
module.
The + 48 V supply is converted into the + 5 V auxiliary voltage required by the logic circuits. The green LED
lamp should be burning all the time. If the maximum current draw is exceeded (short circuit , or some other
cause) the green LED will go off and PSM automatically restricts the current to 4 amps for the +5V line.
Voltage specifications:
Input voltage ................................36-72V DC
Output voltage 5V/4A................... 5.0-5.2V (digital part)
Output voltage 5V/0.6A............... 4.9-5.2V (analog –”– )
Output voltage -5V/0.6A............. -5.1...-5.3V (–”–)
Output voltage 16/20V/0.6A.........16.4-19.5V (analog part)
7.4.5. The Camera Processor Module (CPM)
The Camera Processor Module communicates with the operator station through OPTIMULT - buffer board and
optical fibers. CPM has also all the camera SW -programs in the 256 kbyte EPROM. The programs for the
DSP processor are transferred during the restart process. Layout of the board is shown in Fig. 29..
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3BFS 29101965 R0101
Figure 29. CPM -board layout
The camera processor module has two high performance processors:

- AMD 29240 RISC
- TMS 320C50 signal processor
– The defect processor (AMD29240RISC) reads the defect data coming from the analog board, calculates the
size of the defects and transmits to the operator station only the defects exceeding the preset minimum
sizes.
– The streak processor (TMS320C50) reads the pixel-specific data from the dual-port RAM circuit, compares
them with the detection levels set at the operator station and sends the pixel-specific streak data exceeding
the detection levels to the main processor board.
The front plate of the CPM module can be seen in Fig. 28.
X1 is the connector of a serial port used for SW-debugging of both processors. X1 is used also to show video
curve on PC screen running Curve-program (CURVE.EXE). In that case PC parallel port LPT1 or LPT2 is
connected through the curve-adapter module to the port X1.
Each CPM has unique number which is the camera number ranging 1... 99. The switches TENS and ONES
are used to set the tens and ones of a two digit number. Two cameras should not have the same number.
Number 0 is reserved for production test purpose.
The cameras are interchangeable. However, the address of the camera must be set to correspond to the
location, and the focusing must checked and adjusted.
CPM has 4 LED lamps for the camera status/diagnostics. In normal operation the status of the LED - lamps
should be as follows:
V1 streak detected, LED is on
V2 hole or spot detected by the camera
(flashes once)
V3 blinking when SW-programs are running
V4 CIM communication LED, blinking very
fast when communication is working
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7.4.6. The video processing module (VPM) and video interface module (VIM)
The video-processing module (VPM) and video interface module (VIM) are attached to each other and have
only one common connector to the motherboard (MOM). The CCD -board is connected to the VPM with a flat
cable through the connector X6. Most of the video signal processing is made in these two modules.
The video signals coming from the CCD units are distributed on the video interface board for detection of
defects and streaks. For detection of defects, the DC component is removed from the video signals, and the
corrected video signal are analyzed into different types of defects, such as hole, light spot or dark spot. After
this the defects exceeding the reference level are digitized, and data on location and size are added to them.
For detection of streaks the video signal is digitized and the pixel-specific location is added to it.
7.4.7. Optical coupler
The optical coupler is located in the support column of the beam or in the beam. The + 48 V supply for the
board is taken from the power supply box.
The optical coupler distributes the data from the operator station to the cameras, and combines and transmits
the data from the cameras to the operator station.
There are two LED’s on the board, which indicate the state of received and transmitted.
7.4.8. Fiber optic connection boards: optimult
The camera has two plastic fiber connectors (transmit and receive) which are connected to the Optimult board
installed inside the camera beam.
Figure 30. Optimult daughter board
The Optimult daughter board is shown in the Figure 30. Max. 5 cameras can be connected to one Optimult
board. The board is connected to Optimult motherboard where 6 optimult -2 boards can be connected. One
motherboard can handle 5x6=30 cameras. If there are more than 30 cameras, second motherboard is
required. Optimult motherboard is shown in figure 28.
The LED-lamp on the motherboard is lit when the communication is working from the CIM-board. The LED-
lamp on the Optimult board is lit when the communication to that board is working. CIM is inquiring the data
from the cameras regularly when the system is ON and the LED-lamps should be lit when the communication
starts.
The power voltage for the Optimult motherboard is 48V DC (figure 13). A regulator on the board is converting
the voltage into +5 volts.
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Figure 31. Optimult mother board
On the Optimult motherboard there are two pairs of optoreceiver-transmitters. The outermost connectors are
used for the connection to the CIM -board. The optical fiber from the Optimult motherboard to CIM is quartz
fiber with two cables inside the same shell.
7.4.9. Power supply box
The power supply box (GA3) provides the auxiliary voltages + 48 V for the cameras. The auxiliary voltages are
so called unstabilized raw voltages. The 3-phase supply for the box is taken from the controller cabinet.
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7.4.10. Light intensity control
The CIM-board in the ULMA operator station controls the intensity of the light-source beam in accordance
with a set point value by varying the DCS 500-converter module output voltage. The set point is obtained from
the parameter display, and the actual value from the cameras. The control loop uses a PI algorithm with a
time constant in the order of seconds.
Figure 32. Light intensity control
7.5. Output devices
7.5.1. Light panel
The purpose of the light panel is to give visual alarm indication when a defect is detected. There are five 26V,
3 W indicator lamps in the panel. The lamps are driven by the digital output unit A99, using the + 24 Vdc
voltage. The length of the alarm and the defect type can be selected on the parameter pages.
7.5.2. Audible alarm
An audible alarm is provided by a horn when a web defect occurs. The duration of the signal and the defect
types to generate an alarm can be selected on the parameter display.
7.5.3. Spray colour marker
The purpose of the colour marker is to mark the paper edge with a streak of dye, about 10 mm wide, where a
defect has been detected. Visible as a ring on the side of the reel, the mark makes it possible to find the
defect when unwinding.
The spray colour marker consists of the following components:
– Actuator (linear motor)
– Nozzle (1 or 2)
– Dye tank (1 or 2)
– Dye tank level switch
– Waste dye tank
– Solenoid valves (2 or 4)
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– Edge follower sensor

– Pressure reducing valve
– Control box
When the switch S2 on the control box GH3 is in the AUTO position (figure 20), the DCS 500 module controls
the solenoid valves of the colour marker through the digital output unit. The length of the mark can be selected
in meter’s on the parameter display. The colour marker actuator, which moves the marker onto the web and
away from it, is controlled either by the digital output unit or by the edge follower sensor. The digital output
unit drives the colour marker off the web during a web break. The edge follower sensor controls the colour
marker to make it track the web edge during normal running. At reel change, a dye mark is sprayed onto the
web, whose length is determined by a parameter selection.
When the switch S2 on the control box GH3 is in the MAN position, the operation of the colour marker can be
tested with the switch S1. Dye is sprayed by turning the MARK switch towards 1. Position 2 of the MARK
switch is used for controlling the 2nd colour of a 2-colour marker. The ON/OFF function of the switch S3 can
be used for controlling the retraction motor, when the switch S2 is in the MAN position.
The figures 33 and 34 show the circuit diagrams of the colour marker.
Figure 33. Control of spray colour marker
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Figure 34. Control of the colour marker retraction motor
7.6. Beam lifter

The pneumatic beam lifter moves the detector beam away from the measuring position during a web break.
The beam lifter is controlled by a digital output unit, when switch S2 on the control box GH5 is in the position
AUTO (Figure 35).
Figure 35. Beam lifter control
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The beam lifter control diagram is shown in Figure 35. The control signal is supplied from the control box GH5
to the coils of the solenoid valves in the pneumatics box GH6.1. When coil Y1 is activated, the beam moves
to the measuring position, and when coil Y2 is activated, the beam moves away from the measuring position.
Compressed air supply is connected to the shut-off valve of the pneumatics box, and from there through a
pressure reduction valve to the non-return valves. These valves control the supply of air to the beam lifter
cylinder. When air is supplied to the (+) connection, the beam moves to the measuring position, and when
the (-) connection is pressurized, the beam moves away from the measuring position. The speed of the beam
moving towards the measuring position is adjusted with the throttle valve S2 at the (-) connection, and valve
S1 at the (+) connection controls the speed of the beam moving away from the measuring position. The end
dampening is adjusted with screws installed at the ends of the cylinder.
The air hoses between the pneumatics box and the cylinders are fitted with snap-on connectors. To
disconnect a hose, push in the collar at the end of the hose and at the same pull out the hose. The hose
locks on automatically when pushed into the connector.
The air supply can be taken from a normal compressed air network. The minimum supply pressure is 4.5 bar
and the maximum pressure is 10 bar. The recommended operating pressure is 6 bar.
The beam lifter can be stopped with the switch S1 (EMERGENCY STOP) on the control box. The switch is
released by turning in the direction of the arrows.
When the control box switch S2 is in the MAN position, the beam lifter can be controlled manually by turning
the switch S3 towards ON or OFF.
If the light source beam is fitted with two pneumatic lifters, each cylinder has its own pneumatics box, and
the cylinders are operated parallel suing the same control box.
7.7. Fan
The purpose of the fan is to provide cooling of the light-source and detector beams and to create a pressure in
the detector beam in order to prevent clogging of the camera lenses.
The fan is started when the fuse disconnector Q01 in the power supply cabinet and the protective switch are
closed. A protective switch is placed close to the fan, with which the fan can be stopped for replacement of
the filter. The fan branch has its own motor cut-out switch F03 (F03 and F04 if two fans are used). The cut-
outs provide the fan RUNNING signal to the digital I/O unit A09 of the controller station.
8. CONTROL SIGNALS AND THEIR EFFECTS
8.1. External control signals

The following external control signals are received by the ULMA through digital inputs in the form of contact
closure:
– Fan running (RUNNING)
– Web break (BREAK)
– Reel change (RC)
– Detection ON/OFF (DETECTION) or coating ON/OFF (coaters)
The following control signals are received through analog inputs:
– Light-source beam temperature signal from Pt-100 sensor (PT100)
8.2. Fan running

The RUNNING signal is 0 V if the fan motor cut-out has tripped. The signal is accepted if the ULMA is in the
green ON state, i.e. if measurement is in progress.
When accepted, the signal has the following effects:
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3BFS 29101965 R0101
– Basic functions as when the ULMA goes to the OFF state.

– The monitor indicates the interruption of measurement with a yellow ON/OFF field, i.e. the yellow
ON state.
– When the fan stops, a blinking alarm field appears on the screen. When the field is clicked, the
message FAN STOPPED along with the time the fan stopped are displayed on the alarm page.
8.3. Web break

The BREAK signal is accepted if the ULMA is in the green ON state, i.e. if measurement is in progress.
When accepted, the signal has the following effects:
– Basic functions as when the ULMA goes to the OFF state.
– The monitor indicates the interruption of measurement with a yellow ON/OFF field, i.e. the yellow
ON state.
– The web break is output to the defect map of the status display.
– The web break is reported on the active computer link as a message containing the current reel
length.
8.4. Remote OFF command

The OFF signal is accepted unless the ULMA is in the OFF state. When accepted, the signal has the same
effects as pressing the OFF key in the operator keyboard:
– The detector beam moves away from the measuring position, i.e. the LIFTER signal goes from + 24 V to ±
0 V and the beam lifter control relay drops
– The light-source beam is extinguished by setting the thyristor bridge control voltage CFU to
-10 V.
– The MAINS signal goes from + 24 V to ± 0 V and the main contactor control relay in the controller cabinet
drops. The main contactor opens and the thyristor bridge control pulses are removed.
– The colour marker moves off the web, i.e. the colour marker control signal OFF1 goes from
+24 V to ±0 V, and the colour marker actuator control relay K1 in the edge follower control box operates. If
two colour markers are used, the 2nd marker is controlled with the OFF2 signal.
– Length counting and defect registering are discontinued.
– The monitor indicates the interruption of measurement with a red ON/OFF field and the text OFF.
8.5. Remote ON command

The ON signal is accepted unless the ULMA is in the green ON state, i.e. unless measurement is in
progress. When accepted, the signal has the same effects as pressing the ON key in the operator keyboard:
– The beam moves into the measuring position, i.e. the LIFTER signal goes from ± 0 V to + 24 V and the
beam lifter control relay operates.
– The light-source beam is turned on by setting the thyristor bridge control voltage CFU to the value
specified for the delay state (the blinking green ON state).
– If the ULMA is in the red OFF state, the MAINS signal goes from ± 0 v to + 24 V and the control relay for
the main contactor in the controller cabinet operates. This causes the thyristor bridge firing pulse
suppression to be released and the main contactor to operate. (If the ULMA is in the yellow ON state, the
main contactor control signal, i.e. the MAINS signal is already + 24 V, the firing pulses are enabled, and
the thyristor bridge control voltage CFU is at the value corresponding to the yellow ON state.)
– The colour marker moves onto the web, i.e. their control signal OFF1 goes from ± 0 V to + 24 V and the
colour marker actuator control relay K1 in the edge follower control box drops. If two colour markers are
used, the 2nd marker is controlled with the OFF2 signal.
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3BFS 29101965 R0101
– Length counting starts.

– The ULMA starts measurement after a delay determined by the appropriate parameter. Flashing green
colour in the ON field indicates the delay period. After the delay the ULMA goes to the measurement
status and the ON field shows a steady green colour.
8.6. Reel change

The RC signal is accepted if the ULMA is in the green ON state and if the reel length exceeds the relevant
parameter setting. When accepted, the signal has the following effects:
– The number, length and defects of the previous reel and their longitudinal and cross-machine locations are
stored.
– The reel number is incremented by a parameter-defined constant.
– The defect counters and length counter of the reel are cleared.
– The reel change is output to the status display defect map.
– The colour marker sprays a mark whose length is defined by the relevant parameter.
– The report printer outputs a reel summary and starts a new reel report.
– The reel change is reported on the active computer link as a message containing the reel number and reel
length.
– The reel change is followed by a dead distance set by a parameter, during which the ULMA does not
register web defects.
8.7. Light-source beam temperature from the Pt-100 sensor

The converter module measures the temperature of the light source beam with the aid of Pt-100 sensor.
When the temperature rises, the following takes place:
– When light source beam temperature drops below the minimum alarm limit selected with a parameter, the
temperature display field turns red.
– When the temperature of the light source beam exceeds the maximum alarm limit, the temperature
display field turns red.
– When the temperature of the light source beam exceeds the tripping limit, the ULMA goes to the yellow
ON state, which also results from a fan failure or a web break. The monitor displays a blinking alarm field.
The ULMA cannot be restarted until the temperature is below the trip limit again.
9. SOFTWARE INSTALLATION
It is possible to connect several independent operator stations to the ULMA. One of the PC:s is the so-called
master station and the other are clients, connected to each other using Windows socket (TCP/IP-protocol).
Master and Client software are different software packages.
For training purposes it is possible to install demo version to separate PC, Stand Alone Station software can
be installed to PC with Windows NT 4.0, Master/Client demo installation requires WfW 3.11/Windows NT 4.0
and TCP/IP socket. ABS connection can also be proved.
For the software functions and installation instructions see the Operator’s Instructions manual.
17.05.01
ABB Industry Oy 3BFS 29118825 R0101
Pulp & Paper
Web Inspection Systems
P.O. Box 94
FIN-00381 HELSINKI
Finland
Tel. +358 10 22 2000

Telefax +358 10 22 22842

Maintenance Instructions. Web Inspection System 3BSF R0101. ABB Industry Oy

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ULMA NT Maintenance Instructions

Web Inspection System 3BSF 29101965 R0101

Adobe Acrobat is a registered trademark of Adobe Systems Incorporated

Document No. 3BFS 29101965 R0101

Copyright © 1999 ABB Industry Oy. All rights reserved.

7.4.8. Fiber optic connection boards: optimult..................................................... 41

1. BEFORE YOU BEGIN

1.1. ULMA documents

Installation Instructions 3BFS 120 29101981 Installation instructions and environmental

Installation Instructions, 3BFS 120 29103267 Installation instructions and environmental

Document binder Customer specific drawings for each system

1.2. Terminology used in the ULMA system

Aux. boards connected to converter unit

A98 The Optimult system inside GA2

1.3. General information

2. GENERAL DESCRIPTION OF THE ULMA SYSTEM

Figure 1. ULMA NT system

Figure 2. Operator station with built-in PC, monitor and keyboard

Figure 4. Tower PC with tabletop monitor and keyboard

Advant 520 X-station

Client PC Client PC Client PCs

optical cable MAX 500 M

DCS DCS Detector beam Detector beam

Figure 5. Example of ULMA NT system configuration

3. ENVIRONMENTAL REQUIREMENTS AND SYSTEM CONFORMITY

3.1. Environmental requirements for use

3.2. Specifications of power supply

3.6. Electrical safety

3.7. Safety of machinery

3.8. Electromagnetic compatibility (EMC)

4.1. Operational safety

Strictly no standing or walking on the light source beam!

4.2. Electrical safety

4.3. Protecting ESD sensitive devices

5.1. RECOMMENDED PREVENTIVE MAINTENANCE

6.2. Self-diagnostics of DCS 500

6.2.1. DCS 500 fault diagnostic messages

There are three different types of signals:

Signal Definition Type of Mode of Reset

Signal Definition Type of Mode of Reset

6.2.2. HW-Fault Indications

Power supply cabinet boards

6.2.3. SDCS-CON-1 (control board)

6.2.4. SDCS-IOB-21 (digital I/O connection board)

6.2.5. SDCS-IOB-3 (analogue I/O connection board)

LED’s on the SDCS-IOB-3 board shows the following:

6.2.6. Other fault conditions and repair

Main fuses are blown

Note: Use always low ohm measuring equipment (not Megger).

Figure 6. Terminals of thyristor module TT25N16KOF

6.3. Operator station fault diagnostic messages

CAMERA DOES Camera error Replace camera

CAMERAS DO Failure in connection to Replace CIM board in the

FAN STOPPED Safety switch Close the switch

No supply voltages to the cameras

SYSTEM ALARMS, cont.

3 LIGHT INTENSITY CONTROL LIMIT

6.4. Camera testing

6.4.1. Functional check of camera

6.4.2. Replacement of camera

– Disconnect the two optical cables from the camera.

Figure 7. Lens focusing curves by Curve program

6.5. Light source beam lamp replacement

Figure 8. Bending lamp strip