KPM KB2 User manual

2
KB
Sheet Break Detector
QUICK GUIDE

1. Quick start-up guide
This quick guide leads the way to install, start-up and configure necessary 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.
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
Rx IR RGB
OPTIC Cables
Optics block
Connect one fiber optic cable
to Rx
Connect another cable to:
Rx = Receiver
RGB = Red, green, blue LED
IR = Infrared LED
- RGB if RGB light in use (normally)
- IR if IR light in use
–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 break signal.
– Check the wiring of alarm signal.
Fig. 1.1. Fiber optic cable connection.
Break Out
Shield
Shield
On
On
Off
Off
Com
Com
Alarm Out
FUSE
Fig. 1.2. Wiring diagram.
2

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 KB 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 be 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 KB by pressing right arrow and "ENTER".
–Activate the break alarm relay by selecting operating mode ("Configuration" -› "Mode"): "Detect
enabled".
3

2
KB
Sheet Break Detector
INSTRUCTION MANUAL V1.2

Table of contents
Description 31.
System components.........................................31.1.
Operating principle...........................................41.2.
Installation 52.
Delivery limits...................................................52.1.
Display unit installation.....................................52.2.
Sensor head installation...................................62.3.
Fiber-optic cable installation.............................82.4.
Wiring 103.
Wiring and fiber-optic cable connection.........103.1.
Operation and configuration 124.
Display and operating keyboard....................124.1.
Configuration..................................................134.2.
Set-up.............................................................164.3.
Maintenance...................................................174.4.
Parameters.....................................................204.5.
Start-up 215.
Tuning sensor position...................................215.1.
Reference values for Paper and Break..........215.2.
Auto Limit = Configuring KB for break
detection.........................................................21
5.3.
Auto Alarm.....................................................215.4.
Examples.......................................................225.5.
Maintenance 236.
Regular maintenance.....................................236.1.
Alarms............................................................236.2.
Cleaning the sensor.......................................256.3.
Appendix 1: Quick start-up guide 267.
Appendix 2 288.
Spare parts.....................................................288.1.
Appendix 3 299.
KB model selection........................................299.1.
Appendix 4 3010.
Technical specifications..................................3010.1.
Appendix 5 3111.
Settings and variables....................................3111.1.
KB² Man W41100099V1.22August 2012

1. Description
1.1. System components
KB 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.
KB from KPM 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.
KB 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. KB system components. Fiber-optic cable can be 6, 9 or 12 m long.
KB² Man W41100099V1.23August 2012

1.2. Operating principle
The KB 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 Kajaani Process Measurements 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.
Optical
Sensor
RGB and IR
Transmitter
Detector
Fiber optic cables
Paper Sheet
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 eylets and purge air operation.
KB² Man W41100099V1.24August 2012

2. Installation
Note: Do not mount several fiber-optic sensor heads side by side; a mutual interference may occur. In-
frared dryer might also interference the measurement.
2.1. Delivery limits
Manufacturer supplied components:
– KB sensor head 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.
2.2. Display unit installation
Install the display unit to the wall outside the machine for easy access.
340 mm
85
mm
270 mm
Fig. 2.1. Display unit dimensions (mm).
KB² Man W41100099V1.25August 2012

2.3. Sensor head installation
The fiber-optics cable is delivered mounted to the sensor head. Feed the free fiber-optic cable through
the flexible conduit. This is easiest, if the conduit is laying straight on the floor and the fiber-optic
cable is at room temperature. Connect the conduit to the sensor head. If you pull, pull the fiber-optic
cable 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"). The sensor should be installed
about 25 cm (10") inside from the edge of the web and 15 cm (6") above it. Standard range is 10 -
30 cm (4 - 12").
Fig. 2.2. Typical installation.
Install the mounting clamps or the rack (optional) 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.
Front view
52 mm 33,7
Side view
Fig. 2.3. Mounting clamps.
Fig. 2.4. Mounting rack (option).
KB² Man W41100099V1.26August 2012

Slide the sensor tube through the mounting clamps. Rotate the eyes into a position towards the web
and semi-tighten the clamps. The groove in sensor head shows the direction of light beam (opposite
side). 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. Insert the pin of the position memory ring (fig.
2.5. ) 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.
Fig. 2.5. Position memory.
KB² Man W41100099V1.27August 2012

2.4. 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. 2.6. Removing the conduit bushing from the display unit.
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. 2.7. pointA & B.
4. Insert the multi air seal inside the conduit bushing, step C.
Fig. 2.7. Multi air seal inserting.
KB² Man W41100099V1.28August 2012

5. Open the optics block cover, slide the cables through the bushing hole, cap nut and tighten the
bushing loosely, fig. 2.8.
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. 2.8. Connecting cables to optical unit.
7. Lock the cables in place with the optic block cover, fig. 2.9. pointsA & 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. 2.9. Connecting cables to optical unit.
KB² Man W41100099V1.29August 2012

3. Wiring
3.1. 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. The layout of the KB measuring board is shown in fig. 3.1.
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
- + - + - +
Fig. 3.1. KB 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 (dis-
abled). "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.
Break Out
Shield
Shield
On
On
Off
Off
Com
Com
Alarm Out
FUSE
Fig. 3.2. Wiring of Power Supply, Break relay and Maintenance alarm.
KB² Man W41100099V1.210August 2012

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 applic-
ation where exceptionally strong light is needed.
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
RGB = Red, Green, Blue LED
IR = Infrared LED
- RGB if RGB light in use (normally)
- IR if IR light in use
NOTE: mA outputs are not
Use isolators in DSC or PLC.
isolated.
Analog outputs
A B- + - + - +
Fig. 3.3. Fiber-optic cable and optional 4-20 mA connections.
KB² Man W41100099V1.211August 2012

4. Operation and configuration
4.1. Display and operating keyboard
Break
detected
ENTER
SAMPLE
ESC
ON
B
R
R/B
1.83
3.05
K
K
OOFF
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.
KB² Man W41100099V1.212August 2012

4.2. Configuration
Fig. 4.3. Configuration menu.
(Operating)Mode:Select "Detect enabled" for normal operation. For maintenance select "Mainten-
ance" – it disables the break relay to prevent false break during the maintenance work.
Detect(ion) limit: Set the signal level trigger point for the break.
(Detect) Direction: Select, when the break is activated, if the signal level goes under ("Break <
Limit") or above ("Break > Limit") the detection limit.
Selected signal: One of the RGB-signals or combinations thereof can be selected for break detection.
The one, which gives the highest difference between the web-on (PAPER) and the web-off (BREAK)
situation is selected. In case IR light source is selected, then only IR is possible.
Auto-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.
KB 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 levels in KB memory press
"ENTER". "ESC" will escape without storing. Press "Sample" in front panel to average also signal
levels and enter this display, where break and paper values can be stored.
Measure paper (ON signal) levels Press right arrow.To store Paper ON signal levels in KB memory
by press "ENTER". "ESC" will escape without storing. Press "Sample" in front panel to average also
signal levels and enter this display, where break and paper values can be stored.
Sampled signal levels: Displays both stored signal levels (PAPER and BREAK).
KB² Man W41100099V1.213August 2012

CalculateAuto-limit menu KB calculates the web-on to web-off ratio (Paper-to-Break Ratio) when
both cases has been stored as references in memory. KB also suggests the best signal for break detec-
tion 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 KB 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. 4.5. Calculating auto-limits.
Alarm settings:
KB can alarm in situations where the signal level is very low, very high or when signal drifts a lot.
Fig. 4.6. Alarm settings.
Observed signal: Select the R, G or B signal (IR in case of IR light source) which is used to monitor
this alarm. Normally the same signal is chosen into alarm as in break detection. Only one main color
can be chosen for alarming, no combination possible.
Low/High alarm limit: If a piece of paper gets stuck on the sensor head , signal level can go very
low or very high. The low and high alarm limits are set for this case.Alarm will go on if signal goes
below low limit (3 default) or over high limit (1000 default). Normally default values are OK.
DriftAlr: 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 detected;
Alarm Relay is activated,
break detection and Break Relay continue to operate normally.
–Not in use: Drift detection is not used.
–Prev. break: In case of drift is detected;
Alarm Relay is activated,
break detection and Break Relay is not used (purpose is that KB will never give false Break output).
KB² Man W41100099V1.214August 2012

R ( G, B ) Break on and R ( G, B ) Paper: These are stored signal values during Break and Paper.
Auto limit calculation is using these values to perform detection limit and other values. These are
only for indication in this menu to help select correct alarm limits.
Measurement config(uration):This section determines detection speed (Detect filter), measurement
intervall (cycle), light emission intensity and detector sensitivity.
Fig. 4.7. Measurement settings.
Detect filter: Set number of measurement cycles for break determination, default 3. Number 3 means
that 3 consecutive measurements are all below detection limits before break relay is activated.
Meas. cycle: Set the measurement cycle time, default 20 ms. Can be between 10 and 60 ms.
Tx Power: Select light source intensity, High/Normal. High can be chosen when the measurement
distance is high, for example over 20 cm.
Rx Gain: Detector gain – normally 1 (selectable 4.0, 3.5, 3.0, 2.5, 2.0, 1.5, 1.0, 0.5). Effects directly
on signal level. Can be adjusted lower if ambient light is too high (over 60 %).
KB² Man W41100099V1.215August 2012

4.3. Set-up
Fig. 4.8. Setup displays.
–Light source: RGB (visible Red, Green, Blue) light is recommended in a normal application. IR
(Infrared) light is used in special cases, such as heavily steamy environment and/or long measure-
ment distance from the web.
–Date & time: Set date and time for data logging.
–Language: Select English/Finnish.
–Password: Set password. 000 = no password.
–Break effect: Select None, Beep, Lcd+Beep, Lcdlight (= blinking display).
–Alarm effect:Select None, Beep, Lcd+Beep, Lcdlight (= blinking display).
–Contrast: Set the display contrast (1 - 10), default = 10.
–Analog output setup: Output and mA-values are shown only, if the analog output board is in-
stalled.
Fig. 4.9. 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 output.
–Analog output filter: Select the dampening of the analog signals. The selected filtering time is
applied to all the 3 outputs.
–mA output error mode:When the self-diagnostics finds a failure the unit sets the outputs to the
selected mode. You can set the outputs to go to 22.5 or 3.5 mA, or to freeze to the last good
number, or to continue to show the measured values although they may be wrong (mode No
eff(ect)).
KB² Man W41100099V1.216August 2012

4.4. Maintenance
In "Maintenance" section you can find device indentification, measured signal values, errors, data
logging and event logging.
On-line signals:
Fig. 4.10. On-line signals, pages 1 and 2.
Fig. 4.11. On-line signals, pages 3 and 4.
Fig. 4.12. On-line signals, page 5.
You can monitore measured and calculated signals for troubleshooting.
NOTE: "Ambient light" should be less than 60%.
When "Ambient light" value is higher that 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 "Factory setting" menu. Smaller "RX Gain" value will help re-
ceiving less ambient light. ("Min %-Max %" shows the occurred extremes ambient light during one
measurement cycle).
KB² Man W41100099V1.217August 2012