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January 2019

KPM KB2 Man W41100099V1.8

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Table of contents

This manual is applicable for software version V2.16 and later

Quick start-up guide ....................................................................................................... 3

1. Preparing installation .......................................................................................................... 3

2. Sensor unit installation........................................................................................................ 3

3. Display unit installation ....................................................................................................... 3

4. Start-up and tuning ............................................................................................................. 4

5. Final tuning ......................................................................................................................... 4

Description ...................................................................................................................... 2

System components ...................................................................................................... 2

Operating principle ........................................................................................................ 3

Installation ....................................................................................................................... 4

Delivery limits ................................................................................................................ 4

Display unit installation .................................................................................................. 4

Sensor head installation ................................................................................................ 5

Fiber optic cable installation .......................................................................................... 8

Wiring ............................................................................................................................. 10

Wiring and fiber optic cable connection ...................................................................... 10

– 230 VAC + power supply ......................................................................... 10

KB +24 VDC + power supply ................................................................................... 11

Operation and configuration ....................................................................................... 13

Display and operating keyboard.................................................................................. 13

Menu structure ............................................................................................................ 14

Configuration ............................................................................................................... 15

Set-up .......................................................................................................................... 19

Maintenance ................................................................................................................ 20

Parameters .................................................................................................................. 24

Start-up .......................................................................................................................... 25

Tuning sensor position ................................................................................................ 25

Reference values for Paper and Break ....................................................................... 25

Auto Limit = Configuring KB for break detection ......................................................... 25

Auto Alarm ................................................................................................................... 25

Examples ..................................................................................................................... 26

Maintenance .................................................................................................................. 27

Regular maintenance .................................................................................................. 27

Alarms ......................................................................................................................... 27

Cleaning the sensor .................................................................................................... 29

Appendix 1: Quick start-up guide ..................................................................................... 30

Appendix 2: Spare parts .................................................................................................... 32

Appendix 3: KB model selection ....................................................................................... 34

Appendix 4: Technical specifications .............................................................................. 35

Appendix 5: Settings and variables .................................................................................. 36

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Summary of Contents for KPM KB2

Page 1: ... KPM KB2 Sheet Break Detector Quick Guide ...

Page 2: ...sonell must have the necessary knowledge and training for the work to minimize risk of injury and damage All adjustments settings calibration routines and service work must be done only by specially trained personnel It is the responsibility of the supervisor to ensure that this is the case All covers must be in place during normal operation Most of the instruments have moving parts that are opera...

Page 3: ...ed pressure between 0 5 3 0 bar 7 40 psi Check that the eyelet holes are aimed at the web Check that the sensor distance from the web is 10 30 cm 4 12 Check that the measurement point distance to paper edge is about 30 cm 12 Fix position preliminary Tuning may change this slightly 3 Display unit installation Check that fiber optic conduit bushing is tight Check that fiber optic cable is connected ...

Page 4: ...reak detection signal Select the signal suggested by KPM KB2 pressing right arrow and ENTER Select Auto alarm to set the alarm signal Low High limits Drift alarm action alarm limit and direction should be set as well Activate the break relay by selecting operating mode Configuration Mode Detect en abled Check that the position memory ring is locked 5 Final tuning Final tuning should be always done...

Page 5: ... KPM KB2 Sheet Break Detector Instruction manual V1 8 ...

Page 6: ......

Page 7: ...g and fiber optic cable connection 10 3 1 1 KB 110 230 VAC power supply 10 3 1 2 KB 24 VDC power supply 11 4 Operation and configuration 13 4 1 Display and operating keyboard 13 4 2 Menu structure 14 4 3 Configuration 15 4 4 Set up 19 4 5 Maintenance 20 4 6 Parameters 24 5 Start up 25 5 1 Tuning sensor position 25 5 2 Reference values for Paper and Break 25 5 3 Auto Limit Configuring KB for break ...

Page 8: ... 40 fiber optic cable While the sensor head is exposed to high temperatures the electronics is mounted in a less hostile environment Sensor head eye holes are kept clean by purging instrument air through the sensor housing Flowing air keeps the eyelet holes clean and prevents dirt or steam from contaminating the active optic surfaces Purging air helps also to keep the sensor head temperature lower...

Page 9: ...GB IR LEDs emit pulsed red green blue or IR light onto the web surface The reflected light is received and transmitted through the fiber optic cable to the detector All light components are analyzed fast for a reliable break detection A break activates a relay which can be connected to the logic control of a paper machine The reflected light intensities are also available as optional 4 20 mA analo...

Page 10: ...r supplied components KPM KB2 sensor head tube 2 pipes with position memory 1 ea Mounting clamps 2 ea Fiber optic cable 6 m 20 9 m 30 or 12 m 40 1 ea Display unit 1 ea Flexible conduit for a fiber optic cable protection SS tubing 25 4 mm 1 OD 1 ea Options Mounting rack Analog output board Display unit installation Install the display unit to the wall outside the machine for easy access Fig 2 1 Dis...

Page 11: ...arately and are mounted together at customer site see Fig 2 2 Fig 2 2 KPM KB2 delivery The sensor head tube is delivered in 2 pieces which are mounted together at customer site see Fig 2 3 Fig 2 3 Sensor head assembly typical installation parts listed in appendix 2 The fiber optic cable is mounted to the first part of sensor head tube ...

Page 12: ...d parts together with threads Loctite 268 is already added in threads by manufacturer to seal the threads Fig 2 6 Fig 2 6 Threads with Loctite 268 4 Insert the free fiber optic cable through the flexible conduit Fig 2 7 This is easiest if the conduit is lying straight on the floor and the fiber optic cable is at room temperature If you must pull pull the fiber optic cable carefully from the outer ...

Page 13: ...mounting clamps Fig 2 8 or the rack optional Fig 2 9 or PosiEye adapter optional Fig 2 10 on paper machine s frame or other solid mounting structure Leave 20 30 cm 8 12 between the clamps It is recommended to leave option to adjust clamp height so that sensor head can be positioned optimally during the start up Fig 2 8 Mounting clamps Fig 2 9 Mounting rack option Fig 2 10 PosiEye adapter NOTE Ther...

Page 14: ... the clamp and tighten the stop screw If the sensor is removed for maintenance the memory ring ensures that the sensor head is positioned exactly in the same position as before the removal Adapters for PosiEye installations are available Fig 2 11 Position memory Fiber optic cable installation NOTE Handle fiber optic cables with care Do not pull strongly Remove protective caps before connecting to ...

Page 15: ... tighten the bushing loosely Fig 2 14 6 Insert one of the cables to the Rx slot and the other one to the RGB slot or to IR slot if IR light is used It does not matter which one of the cables is connected to the Rx slot Fig 2 14 Connecting cables to optical unit 7 Lock the cables in place with the optic block cover Fig 2 15 points A B 8 Fasten the optic block cover and tighten the cap nut of the ca...

Page 16: ...during a break In case the power is lost or turned off the Break Out On relay remains open disabled Break Out Off works in the opposite way Alarm Out Off is normally closed It opens in case the built in self diagnostics detects a failure If power is lost or turned off the Alarm Out Off is OPEN Alarm Out On works in the opposite way Fig 3 2 KPM KB2 110 230 VAC Wiring of Power Supply Break relay and...

Page 17: ...ff works in the opposite way There is 2 parallel Break Relays Break Out 1 and Break out 2 which are working simultaneously Alarm Out Off is normally closed It opens in case the built in self diagnostics detects a failure If power is lost or turned off the Alarm Out Off is OPEN Alarm Out On works in the opposite way There is 2 parallel Alarm Relays Alarm Out 1 and Alarm out 2 which are working simu...

Page 18: ... needed Fig 3 4 Fiber optic cable and optional 4 20 mA connections Analog outputs are active and KPM KB2 feeds 15 V to the current loop Analog outputs are isolated but not from each other and they all use the same filtering time Rx IR Red IR Green Blue RS 485 Shield RGB OPTIC Cables Optional 4 20 mA outputs Optics block Connect one fiber optic cable to Rx Connect another cable to Rx Receiver IR In...

Page 19: ...enus Selected line highlighted Upper right corner shows Number of lines pages in that menu Arrow shows if hidden lines Help menus in bottom Keyboard ON OFF button Switch the mains on off Arrows Scroll the menus and rows or adjust values Esc Delete changes and or return back to the previous menu Enter Accept data and input changes Sample Averages the measured values After sampling the program asks ...

Page 20: ...14 Menu structure Configuration Set up Maintenance Parameters ...

Page 21: ...limit and Auto alarm Auto limit sets the signal type for break detection detection level and direction when performed Auto alarm sets the alarm signal and alarm limits when performed Fig 4 4 Setting reference values for break levels KPM KB2 records all the signal levels in BREAK PAPER situations and stores them as reference values Measure break signal levels Press right arrow To store Break signal...

Page 22: ...gnal for break detection and puts them in a ranking list Normally the best signal is chosen for break detection by having it in display and pressing right arrow and then ENTER Then KPM KB2 sets the break trigger point Detection Limit to 50 of the difference between the web on and the break on levels for the selected signal The unit sets also automatically the detection direction Fig 4 6 Calculatin...

Page 23: ...se Alarm will go on if the signal goes below low limit default value 3 or over high limit default value 1000 Normally default values are OK Drift Alr Drift alarm is used to give alarm in case measurement signal drifts For example because of dust or dirt on top of fiber optic lens or in the opening makes it smaller There are three possibilities to use Drift Alarm Report only In case drift is detect...

Page 24: ...t light alarm in IR dryer installation Fig 4 8 Special alarm menu Measurement config uration This section determines detection speed Detect filter measurement intervall cycle light emission intensity and detector sensitivity Fig 4 9 Measurement settings Detect filter Set number of measurement cycles for break determination default 3 Number 3 means that 3 consecutive measurements are all below dete...

Page 25: ...A values are shown only if the analog output board is in stalled Fig 4 11 Analog output set up Analog output signals On optional analog board there are three 4 20 mA analog outputs You can select any of the RGB signals and their combinations to each output Menu is displayed only if board is installed Analog output limits Set the signal levels corresponding 4 mA LOW and 20 mA HIGH for each analog o...

Page 26: ...culated signals for troubleshooting NOTE Ambient light should be less than 60 When Ambient light value is higher than 60 there is too much external light which may disturb measurement Signal levels and Ambient light values can be adjusted by parameters TX Power and RX Gain which are located in Measurement Configuration menu Smaller RX Gain value will help in receiving less ambient light Values in ...

Page 27: ...nt log Event log stores changes made after start setup Also stores all boot ups Holds last 250 events Event log keeps track on breaks When the break takes place date and time information appears in the main page There is 5 minutes delay until a new break can be recoded Press ENTER for more information of the break indicates time when the break took place and when paper is back again The quantity o...

Page 28: ...his menu is used for troubleshooting and may contain a help menu how to fix problem Plus indicates time when alarm has occurred Fig 4 18 Alarms Identification Contains ID and version information Fig 4 19 Identification menus Default settings Reset to configuration settings Used e g if the settings are changed by accident ...

Page 29: ...l setting and there is no need for customer to change them Please contact ABB OY KPM for more information Fig 4 20 Factory settings Clear event log Clears the event log Factory reset Reset to factory settings Serial number Set serial number Color balance adj ustment Individual gain adjustment of R G B and IR lights Fig 4 21 Color balance adjustment ...

Page 30: ...munication port mode ScrShot Normal Analog output trim KPM KB2 sends in the edit mode 4 and 20 mA in turn to the selected analog output With S gain and Z zero offset the output can be trimmed to correspond 20 mA gain and 4 mA zero Parameters The Parameters display contains normally needed parameters and they can be modified in this display Fig 4 24 Parameters display ...

Page 31: ...per is on press SAMPLE After a short time measured values are displayed Save those numbers as reference value for paper Save as Paper level Auto Limit Configuring KPM KB2 for break detection Auto limit Calculation can be performed when above mentioned both reference values have been stored in KPM KB2 memory This procedure calculates detection limit for break detection 1 Go to Configuration Auto li...

Page 32: ...et for example 3 High alarm Limit Set for example 1000 Drift Alarm Select required action of Drift Alr recommended Report Only Drift al arm limit 103 0 70 144 8 8 70 of range between paper on and break Drift al arm dir ection Falling signal Break Limit Paper on red wire Auto limit Auto alarm values Break R 85 G 24 B 26 Paper on wire R 94 G 125 B 119 Auto limit calculation results 1 G green light g...

Page 33: ...o close to the web surface A shiny surf ace close to the sensor head A strong light beam from a nearby lamp aimed at the sensor head Reflection from the web surf ace still too high Move the sensor further away from the web or redirect the sensor eyelet holes slightly slantwise at the surface Redirect the sensor to avoid the disturbing reflection Move the disturbing light or redirect the sensor awa...

Page 34: ... Alarm goes on when signal level drops below Cleaning alarm DRIFT here limit 80 which is 70 from break 10 to Paper 110 Detection limit is set to 60 50 value between paper and break KPM KB2 informs break whenever signal drops below 60 3 1000 110 60 80 10 Cleaning alarm HIGH Cleaning alarm LOW Cleaning alarm DRIFT DETECTION LIMIT Paper Break Drift alarm ...

Page 35: ...floor 1 Release the fiber optic cable from the display unit and remove also the conduit bushing in order to get the cable to slide inside the conduit Fiber optic may be stuck on conduit 2 Remove the end plate from the sensor head by removing the two fastening screws 3 Remove the locking ring 4 Pull the fiber optic cable through the optical sensor housing 5 Wipe the lenses clean with soft fabrics o...

Page 36: ...nnected pressure between 0 5 3 0 bar 7 40 psi Check that the eyelet holes are aimed at the web Check that the sensor distance from the web is 10 30 cm 4 12 Check that the measurement point distance to paper edge is about 30 cm 12 Fix position preliminary Tuning may change this slightly 3 Display unit installation Check that fiber optic conduit bushing is tight Check that fiber optic cable is conne...

Page 37: ...t to find the best break detection signal Select the signal suggested by KPM KB2 pressing right arrow and ENTER Select Auto alarm to set the alarm signal Low High limits Drift alarm action alarm limit and direction should be set as well Activate the break relay by selecting operating mode Configuration Mode Detect enabled Check that the position memory ring is locked 5 Final tuning Final tuning sh...

Page 38: ...ead tube with eyelets H31100060V1 0 KB Back Sensor head tube 6 H41100103V1 0 Tube adapter 7 H41110025V1 0 Set collar 8 H41110043V1 0 End cap 2350011 KB 6 Conduit L 4370 2350012 KB 9 Conduit L 7370 2350013 KB 12 Conduit L 10370 A41100096V1 0 KB Sensor Head Assembly 6 m A41100097V1 0 KB Sensor Head Assembly 9 m A41100098V1 0 KB Sensor Head Assembly 12 m A41100095V1 0 KB Mounting Assembly A41100094V1...

Page 39: ...2 Measuring board 24 VDC A41100032V1 0 KB2 Measuring board 110 230 VAC 2 A41100021V1 1 KB Analog board 3 E31140033V1 0 KB Display plate assembly 300002 Graphic display board A41100027V1 0 Keyboard KB KC7 A41100102V1 0 KB2 Display Unit 90 264 VAC A41100200V1 0 KB2 Display Unit 24 VDC ...

Page 40: ...5m Sensor Head rod KB2 Display Unit 85 264VAC 2 x RELAY outputs included K B 12P KB 12 Sheet Break Detector 12 meters 40ft Fiber Optic Cable 1 5m Sensor Head rod KB2 Display Unit 24VDC 4 x RELAY outputs included Flexible Conduit for Fiber optic cable N No Conduit C Full Flexible SS316 Conduit 25mm 1 with Connectors Mounting Rack N No adjustable mounting rack only mounting clamps R Adjustable Mount...

Page 41: ...2 LED pulse frequency 1 kHz Power supply 90 264 VAC 50 60 Hz or 24 VDC Power consumption 15 W Enclosure class IP 66 Nema 4X Purge air connection Dry instrument air 0 5 3 0 bar 7 40 psi 6 4 mm 1 4 connector normal consumption 30 100l min 1 3 5 cfm Digital outputs 2 x Closing or opening contact max 250 VAC 2A 220 VDC 2 A for Break signal and Maintenance alarm Alarm output delay Min 15 ms from the ac...

Page 42: ...Limit or Break Det Limit Alarm signal Low alarm limit High alarm limit Drift Alarm Drift Alarm limit Drift Alarm direction Configuration Autolimit Autoalarm Sampled signal levels Paper Break RED GREEN BLUE IR Measurement configuration Detect filter Tx power Rx gain Set up Analog signals Low limit High limit Analog output 1 Analog output 2 Analog output 3 ...

Page 43: ...correct method of disposal ABB Oy KPM Kettukalliontie 9 E 87100 Kajaani Finland 358 10 548 7600 www prokajaani com fi kpm abb com ABB Oy KPM Kajaani Process Measurements Kettukalliontie 9 E FIN 87100 Kajaani FINLAND E mail fi kpm abb com Internet address www prokajaani com Specifications are subject to change without prior notice ABB Oy KPM reserves the right to make improvements and or changes in...

Page 44: ... ABB Oy KPM Kettukalliontie 9 E 87100 Kajaani Finland 358 10 548 7600 www prokajaani com fi kpm abb com ...

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