ABB KPM KB2 User manual

—
KPM KB2
Sheet Break Detector
Quick Guide

2
—
KPM KB2
Sheet Break Detector
Quick Guide
Edition 1.18 · 2019-01-31
Original instructions
Specifications are subject to change without prior notice. ABB reserves the right to make
improvements and/or changes in the product(s) and/or program(s) described in this
document at any time. Changes are periodically made to the information and will be
incorporated in new editions of this document. All efforts have been made to ensure the
accuracy of this document. However, should any errors be detected, ABB would gratefully
appreciate being informed of them. In case of errors in this document, ABB shall not be
liable for incidental or consequential damages in connection with or arising from such
errors. Copyright © 2018 by ABB inc.
SAFETY INFORMATION
All personell 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 operated pneumatically and/or electrically, and some incorporate sharp
edges that are capable of causing serious injury. A large part of the service work needs to
be done with the compressed air supply connected.
Always read the instructions carefully before operating the equipment. The following
notations are used to emphasize important and critical instructions:
NOTE
This label is used for instructions that are important but not related to hazards.
WARNING
This label is used to indicate potential risk of severe injury or damage if warning
is ignored.

1Quick start-up guide
This quick guide leads the way to install start-up and configure parameters in the normal
cases.
1. Preparing installation
Install fiber optic cable inside conduit. This is easier done when temperature is cool and
conduit is straight on the floor. In new devices this cable is installed.
NOTE
DO NOT PULL FIBER OPTIC CABLE STRONGLY. It may break or cut or connector
may get loose.
Connect conduit to sensor head tube.
Install sensor head mounting rack or mounting clamps.
2. Sensor unit installation
Check that dry clean purge air is connected (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 to the
optics block:
Other optic cable to RX.
Another cable to RGB or IR.
Check the wiring of the power supply.
Check the wiring of alarm signal.
Fig. 1.2. Wiring diagram for 110 –230 VAC.
Fig. 1.3. Wiring diagram for +24 VDC.
Fig. 1.1. Fiber optic cable connection.
Shield On Off Com
Shield On Off Com
FUSE
Break out Alarm out KPM Measuring board
F41100031 V1.0
90 - 264 VAC

4
4. Start-up and tuning
Preliminary tuning can be done during installation at the actual place by simulating paper on
situation with dry paper on front of sensor head. Final tuning should be always done with real
paper running situation.
Set unit to "Mode: Maintenance" in the "Configuration" menu.
Turn on the power.
Select from the "Maintenance" menu "On-line signals".
Turn the sensor head light beam so that signal levels are on their maximum values
(normally 100 - 700) when simulating paper in front of sensor. Paper sheet should be close
its correct position. Signal level can be adjusted with "TX Power" and "RX gain" in the
"Measurement config" menu. Ambient light should be < 60 %.
Simulate break: Press "SAMPLE". Store signals as "Break level".
Simulate paper: When the paper is front of the sensor close to its normal position, press
"SAMPLE". Store signals as "Paper level".
Perform "Calculate Auto-limit" 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
en- abled".
Check that the position memory ring is locked.
5. Final tuning
Final tuning should be always done with real paper running situation and real break situation.
This time paper distance to the detector is stable and temperature as normal running
temperature.
Select "Configuration" -› "Mode" -› "Maintenance" (break relay deactivated).
While the machine is running without paper press "SAMPLE" and store signals as "Break
level".
This can be done when the paper machine is warm and before paper sheet is on.
When the web (paper) is on press "SAMPLE" and store signals as "Paper level".
Perform "Calculate Auto-Limit" to find the best break detection signal.
Select the signal suggested by KPM KB2 by pressing right arrow and "ENTER".
Activate the break alarm relay by selecting operating mode ("Configuration" -› "Mode"):
"Detect enabled".

—
KPM KB2
Sheet Break Detector
Instruction manual V1.8

January 2019 KPM KB2 Man W41100099V1.8 1
Table of contents
This manual is applicable for software version V2.16 and later
1Quick 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
1Description......................................................................................................................2
1.1 System components......................................................................................................2
1.2 Operating principle........................................................................................................3
2Installation.......................................................................................................................4
2.1 Delivery limits................................................................................................................4
2.2 Display unit installation..................................................................................................4
2.3 Sensor head installation................................................................................................5
2.4 Fiber optic cable installation..........................................................................................8
3Wiring.............................................................................................................................10
3.1 Wiring 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
4Operation 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
5Start-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 detection.........................................................25
5.4 Auto Alarm...................................................................................................................25
5.5 Examples.....................................................................................................................26
6Maintenance..................................................................................................................27
6.1 Regular maintenance..................................................................................................27
6.2 Alarms.........................................................................................................................27
6.3 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

2
1Description
System components
KPM KB2 fiber optic sheet break detection system contains:
Sensor head installed above or under the web.
Fiber optic cable protected with a flexible conduit.
Display unit housing the light source, detector, and the measurement computer.
KPM KB2 is a solution to high temperature sheet break applications. The light source, detector,
and electronics are isolated from the high temperature environment by a 6 m (20'), 9 m (30') or
12 m (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 in high
temperature applications.
KPM KB2 requires clean instrument air at 0.5 –3.0 bar (7 - 40 psi), the rotameter or pressure
regulator can be used for the easy detection of airflow.
Fig. 1.1. KPM KB2 system components. Fiber optic cable can be 6, 9 or 12 m long.

January 2019 KPM KB2 Man W41100099V1.8 3
Operating principle
The KPM KB2 operates on a proven, non-contact reflection principle. The light source can be
either RGB LED (red, green, blue) or IR LED (infrared). The optical sensor is placed above or under
the web. Applications include paper or board webs, wires or felts. Thanks to the unique RGB
detection method the color of the product or the felt has no effect on the measurement
reliability. The sensor is neither affected by dirt, steam nor temperatures up to 180 °C (356 °F)
when installed according to ABB Oy, KPM specifications. There are no electronic components
located in the sensor head.
The optical sensor is connected through a fiber optic cable to the RGB/IR light source located in
the display unit. The RGB/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 analog outputs.
Fig. 1.2. Operating principle.
The self-cleaning sensor head is a 33.7 x 1500 mm (1" x 59") stainless steel tube with two holes
serving as eyelets for the fiber optics and outlets for purge air. Continuous airflow through the
stainless steel enclosure keeps positive pressure around the sensor head's eyes and keeps the
eyelets free of steam, dust or debris. The openings should be located towards the surface being
monitored.
Fig. 1.3. Sensor eyelets and purge air operation.
Optical
sensor
RGB
transmitter
or IR
Detector
Fiber optic cables
Paper sheet

4
2Installation
NOTE
Do not mount several fiber optic sensor heads side by side; a mutual
interference may occur. Infrared dryer might also interference the
measurement. Please contact ABB Oy, KPM for more information.
Delivery limits
Manufacturer 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. Display unit dimensions (mm).
340 mm
85
mm
270 mm

January 2019 KPM KB2 Man W41100099V1.8 5
Sensor head installation
The display, conduit, sensor head and mounting clamps are delivered separately 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.

6
Make the installation as follows:
1) Remove plastic support and plastic tube. They are preventing fiber optic cable from bending
during transportation (Fig. 2.4).
Fig. 2.4. Sensor head with plastic support and plastic tube.
2) Insert the free fiber optic cable through the second part of sensor head (Fig. 2.5).
Fig. 2.5. Optic cable through the second part of sensor head.
3) Attach the sensor head 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 jacket, not from the connectors.
The maximum force for pulling from 2 cables is 50 Newton (11 lbf). The minimum bending
radius is 50 mm (2").
Fig. 2.7. Fiber optic cable through flexible conduit.

January 2019 KPM KB2 Man W41100099V1.8 7
5) Connect the conduit to the sensor head tube. After that you can install the sensor head tube
to its measuring position. The sensor should be installed about 25 cm (10") inside from the
edge of the web and 15 cm (6") below or above it. Standard range is 10 - 30 cm (4 - 12").
Continue the installation as follows:
6) Install the 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
There is several lengths of the PosiEye Tube, with the longest tubes, the sensor head adapter
needs to be flipped around so that it goes inside the PosiEye tube.

8
7) Connect fiber optic cable to the display unit, see paragraph 2.4.
8) Slide the sensor tube through the mounting clamps. Rotate the eyes into a position towards
the web and semi-tighten the clamps. Final adjustment is done with the help of the signal
level display after the unit is powered up. The light beam is directed to the measured web.
9) Insert the pin of the position memory ring (Fig. 2.11) into the hole in 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 the optic block.
Route the flexible conduit with the fiber optic cable inside it to the display unit.
1. Remove the conduit bushing from the display unit.
Fig. 2.12. Removing the conduit bushing from the display unit.

January 2019 KPM KB2 Man W41100099V1.8 9
2. Guide the end of the fiber optic cable through the conduit bushing and fasten the bushing
to the flexible conduit.
3. Place the multi air seal on top of the fiber optic cables, Fig. 2.13, points A & B.
4. Insert the multi air seal inside the conduit bushing, step C.
Fig. 2.13. Multi air seal inserting.
5. Open the optics block cover, slide the cables through the bushing hole, cap nut and
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 cable bushing, points B & C.
9. Connect the instrument air 0.5 - 3.0 bar (7 - 40 psi) to the air inlet connector (point C) at the
end of the flexible conduit outside the display unit housing.
Fig. 2.15. Connecting cables to optical unit.

10
3Wiring
Wiring and fiber optic cable connection
The terminals for the electrical and fiber optic cables are located under the bottom cover of the
display unit.
3.1.1 KPM KB2 with 110 –230 VAC + power supply
The layout of the KPM KB2 110 –230 VAC measuring board is shown in Fig. 3.1.
Fig. 3.1. KPM KB2 110 –230 VAC measuring board layout.
Relays are of dry contact types. In normal operation the "Break Out On" relay is open and it closes
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 Maintenance alarm.
Break Out
Shield
Shield
On
On
Off
Off
Com
Com
Alarm Out
FUSE
Red/IR Green Blue
RS-485 Binary inputs Break out Alarm out
Shield
Analog outputs
A B
OPTIC Cable
OPTIC Cable
Shield
Shield
Shield
On
On
Off
Off
Com
Com
- + - + - +

January 2019 KPM KB2 Man W41100099V1.8 11
3.1.2 KPM KB2 with +24 VDC + power supply
Relays are of dry contact types. In normal operation the "Break Out On" relay is open and it closes
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. 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
simultaneously.
Fig. 3.3. KPM KB2 +24 VDC. Wiring of Power Supply, Break relay and Maintenance alarm .

12
Fiber optic cable is connected to the optics block. It does not matter which one of the two cables
is connected to the receiver inlet (Rx). In a normal application another cable is connected to the
RGB light source. IR light source is used in special cases such as heavy steam environment or in
an application where exceptionally strong light is 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 = Infrared LED
- RGB if RGB light in use (normally)
- IR if IR light in use
NOTE: mA outputs are not isolated.
Use isolators in DSC or PLC.
Analog outputs
A B- + - + - +

January 2019 KPM KB2 Man W41100099V1.8 13
4Operation and configuration
Display and operating keyboard
Fig. 4.1. Display and keyboard.
The display contains 7 lines, with 21 characters in a line. The main display (Fig. 4.1) shows:
Selected measurement signal for break detection.
Signal level of the selected signal.
Time.
Break status.
Alarms, if activated.
Common properties in other menus:
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 if the values will
be stored for Break or Paper Reference values or deleted.
Fig. 4.2. Main display and main menu.
ENTER
SAMPLE
ESC
ON
B
RR/B
1.83
3.05
K
K
OOFF
Katko
havaittu

14
Menu structure
Configuration
Set-up
Maintenance
Parameters