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TRANSCRIPT
Experion MX MSS & EDAQ Data Acquisition
System Manual
6510020381 Rev 03
System Manual
April, 2015
Confidentiality Statement
This manual is a product of Honeywell. It is intended for use only by Honeywell and customer personnel in connection with
Honeywell products. It is strictly prohibited to copy this manual or any part thereof or to transfer this manual or any part
thereof to any non-Honeywell person or entity, except customer personnel for use in connection with Honeywell products.
Persons employed by a third-party service company shall not have access to this manual.
Notice
All information and specifications contained in this manual have been carefully researched and prepared according to the best
efforts of Honeywell, and are believed to be true and correct as of the time of this printing. However, due to continued efforts
in product improvement, we reserve the right to make changes at any time without notice.
Trademarks
All trademarks and registered trademarks are the properties of their respective holders.
Copyright
© 2015 Honeywell International
www.honeywellprocess.com
All rights reserved. No part of this publication may be reproduced or translated, stored in a database or retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior
written permission of Honeywell.
P/N 6510020381 Rev 03 4/1/15 i
Contents
Introduction ............................................................................................................................................ xiii
Audience ............................................................................................................................................... xiii
About this manual ............................................................................................................................... xiii
Related reading ......................................................................................................................................xv
Conventions ............................................................................................................................................xv
1. System Overview ............................................................................................................................... 1-1
1.1. Q4000 EDAQ and MSS ............................................................................................................ 1-2
1.2. 408x scanner EDAQ and MSS.................................................................................................. 1-4
1.2.1. Differences in the MSS hardware ................................................................................. 1-5 1.2.2. Differences in the EDAQs ............................................................................................ 1-5
1.2.3. Safety interlock and watchdog functions ...................................................................... 1-5
1.3. 4036 Metals and 4283 rubber thickness measurement EDAQs and MSS ................................ 1-6 1.3.1. Differences in the MSS hardware ................................................................................. 1-6
1.3.2. Metals system radiation safety interlocking .................................................................. 1-7 1.3.3. Rubber Caliper retract mechanism ................................................................................ 1-7
1.4. Q309x EDAQs and MSS .......................................................................................................... 1-8
1.4.1. Differences in the MSS ................................................................................................. 1-8 1.4.2. Differences in the EDAQs ............................................................................................ 1-9
1.5. Software Releases ................................................................................................................... 1-11
2. Network Architecture ....................................................................................................................... 2-1
2.1. Scanner network ........................................................................................................................ 2-1
2.2. Metals C-Frame network .......................................................................................................... 2-3
2.3. Q309x scanner network ............................................................................................................ 2-4
2.4. IP addresses ............................................................................................................................... 2-5
2.5. Ethernet switch information ...................................................................................................... 2-7
2.6. Network Configuration ............................................................................................................. 2-8
2.6.1. New Interface ................................................................................................................ 2-8
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2.6.2. Old Interface ............................................................................................................... 2-12
2.7. Ethernet cable redundancy ...................................................................................................... 2-14 2.7.1. Setup Q4000 Ethernet cable redundancy .................................................................... 2-15
2.7.2. MSS-server cable redundancy .................................................................................... 2-18
3. MSS .................................................................................................................................................... 3-1
3.1. Hardware Overview .................................................................................................................. 3-1
3.2. Q4000 MSS hardware ............................................................................................................... 3-3 3.2.1. Advantech UNO-2182 model ....................................................................................... 3-3
3.2.2. NexCom model ............................................................................................................. 3-5
3.3. CWS 408x scanner, rubber and metals thickness MSS hardware ............................................ 3-6
3.3.1. Fit-PC2i model .............................................................................................................. 3-6
3.4. Q309x MSS hardware ............................................................................................................... 3-7 3.4.1. Advantech ARK-1122 model ....................................................................................... 3-7
3.5. Initial factory software installation ........................................................................................... 3-8
3.6. Setting the MSS type, IP address and time ............................................................................. 3-12
3.7. MSS software upgrade ............................................................................................................ 3-13
3.7.1. Procedures ................................................................................................................... 3-13
3.8. Replace the MSS with a spare ................................................................................................ 3-19
3.9. MSS troubleshooting .............................................................................................................. 3-21
3.9.1. No MSS-RAE communication ................................................................................... 3-21 3.9.2. Disk drive errors ......................................................................................................... 3-24
3.10. Alternate partition boot ..................................................................................................... 3-25
3.11. MSS wireless capabilities ................................................................................................. 3-28
4. Back up and Clone the MSS ............................................................................................................ 4-1
4.1. Create a self-booting MSS installation USB flash drive .......................................................... 4-2
4.2. Back up the MSS hard drive ..................................................................................................... 4-3
4.2.1. Create a Clonezilla USB flash drive ............................................................................. 4-4 4.2.2. Create a backup image of the MSS hard disk ............................................................... 4-5
4.2.3. Create a self-booting restoration image ...................................................................... 4-11 4.2.4. Copy image to DVD or USB flash drive .................................................................... 4-12 4.2.5. Restore MSS from USB flash drive ............................................................................ 4-12
4.3. Clone the MSS to a virtual machine ....................................................................................... 4-12
5. EDAQ ................................................................................................................................................. 5-1
5.1. Physical layout .......................................................................................................................... 5-3 5.1.1. Hardware status information ......................................................................................... 5-4
5.2. EDAQ reset ............................................................................................................................... 5-5 5.2.1. EDAQ boot sequence.................................................................................................... 5-5
5.3. EDAQ sensor identification and IP addressing ........................................................................ 5-6
5.4. Upgrade EDAQ software .......................................................................................................... 5-7
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5.5. Replace EDAQ with a spare ................................................................................................... 5-15
5.6. Upgrade the spare EDAQ ....................................................................................................... 5-16
6. Obtain Status Information ............................................................................................................... 6-1
6.1. Experion MX platform .............................................................................................................. 6-1
6.2. MSS and EDAQ web pages ...................................................................................................... 6-3 6.2.1. Access to the web page ................................................................................................. 6-3 6.2.2. Main MSS page overview ............................................................................................. 6-4 6.2.3. Detailed EDAQ information ......................................................................................... 6-7
6.2.4. EDAQ, MSS, and FC scanner log files ......................................................................... 6-9 6.2.5. MSS data logger .......................................................................................................... 6-12
7. EDAQ Position and Function Code Overrides ............................................................................... 7-1
7.1. Symptoms of an identification failure ....................................................................................... 7-1
7.2. Override procedures .................................................................................................................. 7-3 7.2.1. Check present function and codes ................................................................................. 7-3
7.2.2. Identify a configured override....................................................................................... 7-4 7.2.3. Edit the position and/or function code .......................................................................... 7-5
7.3. Determine sensor type override codes ...................................................................................... 7-8 7.3.1. Connect an EDAQ to the sensor network ................................................................... 7-10
7.4. Sensor position numbers in the Q4000 ................................................................................... 7-11
7.5. Sensor position numbers in Q309x scanner ............................................................................ 7-11
7.6. Recalibrate the position and function resistance measurement .............................................. 7-12
7.6.1. Recalibration procedure .............................................................................................. 7-12
Error! Cannot open file referenced on page i
9. Tasks ................................................................................................................................................... 9-1
9.1. Verify EDAQ connections ........................................................................................................ 9-1
9.2. Verify EDAQ ID ....................................................................................................................... 9-2
9.3. Verify EDAQ process health .................................................................................................... 9-3
9.4. EDAQ self-test .......................................................................................................................... 9-4
9.5. Increase RTDR limits................................................................................................................ 9-5
9.6. Improve head cooling................................................................................................................ 9-6
9.7. Verify HMI panel operation ...................................................................................................... 9-6
9.8. Verify red light .......................................................................................................................... 9-7
9.9. Inspect head gap ........................................................................................................................ 9-9
9.10. Inspect HMI panel ............................................................................................................... 9-9
9.11. Check time synchronization processes ............................................................................. 9-10
9.12. Check ethernet cable ......................................................................................................... 9-11
9.13. Check MSS CPU ............................................................................................................... 9-13
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9.14. Check temperature measurement ...................................................................................... 9-14
10. Experion Alarm Based Troubleshooting .................................................................................. 10-1
10.1. EDAQ I/O Not Ready ....................................................................................................... 10-1
10.2. EDAQ I/O Timestamps .................................................................................................... 10-1
10.3. EDAQ PCB Head Temp High .......................................................................................... 10-2
10.4. Amber Light Not Lit ......................................................................................................... 10-2
10.5. Red Light Not Lit .............................................................................................................. 10-3
10.6. Lost LAN Connection ....................................................................................................... 10-3
10.7. Lost Connection to Alley EDAQ ...................................................................................... 10-4
10.8. Heads are Split .................................................................................................................. 10-4
10.9. EDAQ Time Synchronization Error ................................................................................. 10-4
10.10. EDAQ FPGA Error ........................................................................................................... 10-4
10.11. EDAQ GPIO Watchdog.................................................................................................... 10-5
10.12. MSS emss SW Version ..................................................................................................... 10-5
10.13. MSS Redundant Ethernet.................................................................................................. 10-5
10.14. MSS CPU Core Temperature High .................................................................................. 10-5
10.15. MSS Reboot Required ...................................................................................................... 10-6
10.16. MSS TCP Retransmission Rate Too High ........................................................................ 10-6
10.17. MSS TCP Loss Ratio Too High ....................................................................................... 10-6
10.18. Temperature Measurement Deviations ............................................................................. 10-7
11. EDAQ Error Messages ............................................................................................................... 11-1
12. EDAQ Failure Diagnostic Process ............................................................................................ 12-1
12.1. Completed board failures .................................................................................................. 12-1
12.2. I/O sub-component failures .............................................................................................. 12-2 12.2.1. Caliper frequency readings unstable ........................................................................... 12-2
13. Storage, Transportation, End of Life ........................................................................................ 13-1
13.1. Storage and transportation environment ........................................................................... 13-1
13.2. Disposal ............................................................................................................................ 13-1
13.2.1. Solid materials ............................................................................................................ 13-2
14. Glossary ....................................................................................................................................... 14-1
A. Part Numbers ....................................................................................................................................A-1
Experion MX MSS & EDAQ Data Acquisition Contents
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List of Figures Figure 1-1 Color Measurement Module ................................................................................................... 1-1 Figure 1-2 Color Backing Module ........................................................................................................... 1-2
Figure 1-3 Color Sensor Schematic Diagram .......................................................................................... 1-3 Figure 1-4 Wiring Communication Principles ......................................................................................... 1-4 Figure 1-5 Color Measurement Module (front view) .............................................................................. 1-4 Figure 1-6 Color Measurement Module (top view) ................................................................................. 1-5 Figure 1-7 Color Measurement Module (right view)............................................................................... 1-5
Figure 1-8 Color Measurement Module (back view)............................................................................... 1-6 Figure 1-9 Color Measurement Module: Dark Solenoid ......................................................................... 1-7 Figure 1-10 CMM Interface Module: Indicator LEDs ............................................................................. 1-8
Figure 1-11 Color Backing Module (front top view) ............................................................................... 1-9 Figure 1-12 Color Backing Module (front view) ................................................................................... 1-10 Figure 1-13 Color Backing Module (left view) ..................................................................................... 1-10 Figure 1-14 Color Backing Module: Tile Wheel, and 4 Tiles ............................................................... 1-12
Figure 1-15 Color Backing Module Indicator LEDs ............................................................................. 1-14 Figure 1-16 Color Backing Module Indicator LEDs Status List ........................................................... 1-15
Figure 1-17 Flow From Reflectance to Color and Appearance Measurements ..................................... 1-16 Figure 2-1 Color Space Window Display ................................................................................................ 2-2 Figure 2-2 Color Spectrum Display: Production Mode ........................................................................... 2-6
Figure 2-3 Color Spectrum Display: Maintenance Mode ........................................................................ 2-7 Figure 2-4 Color Spectrum Difference Display ....................................................................................... 2-9
Figure 2-5 Download Configuration Display ........................................................................................ 2-10
Figure 2-6 Color diagnose Display ........................................................................................................ 2-12
Figure 2-7 Color FW Errors Display ..................................................................................................... 2-16 Figure 2-8 Product tuning Display ......................................................................................................... 2-18
Figure 2-9 Recipe maintenance Display: Color Code00 ....................................................................... 2-19 Figure 2-10 Recipe maintenance Display: COLOPR11 Calibration Table00 ....................................... 2-20 Figure 2-11 Sensor Maintenance Display: Production Mode ................................................................ 2-21
Figure 2-12 Sensor Maintenance Display: Maintenance Mode ............................................................. 2-23 Figure 2-13 Sensor Reporting Display: COLORP Standardize Report ................................................. 2-24 Figure 2-14 Scanner Sensor Status Display ........................................................................................... 2-25
Figure 2-15 MSS Setup Diagnostics Display (MSS PnP Setup pop-up) ............................................... 2-26 Figure 2-16 MSS Card IO Point Monitor .............................................................................................. 2-27 Figure 3-1 Lower Configuration Board G ............................................................................................... 3-3
Figure 3-2 Wiring Communication Principles ......................................................................................... 3-4 Figure 3-3 MSS Card IO Point Monitor: Digital Inputs Of the Color Sensor ......................................... 3-8 Figure 3-4 MSS Card IO Point Monitor: Digital Outputs of the Color Sensor ....................................... 3-9 Figure 4-1 Color Sensor Installation (relative to the moving web) ......................................................... 4-2
Figure 4-2 Top Installation ...................................................................................................................... 4-4 Figure 4-3 MSS Card IO Point Monitor Display ..................................................................................... 4-9 Figure 6-1 Reflectance Graph of UV-excluded and UV-included Reflectances ..................................... 6-3 Figure 6-2 Fluorescence Suppressed Measurements ............................................................................... 6-7 Figure 7-1 Measured Apparent Reflectance: Effect Of YSTD .................................................................. 7-5
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Figure 7-2 Measured Apparent Reflectance: Effect of Fluor Std: Fluorescent Strength (FI) ................. 7-6
Figure 8-1 Reflectance and Fluorescence Emission E(|D65) ................................................................ 8-2
Figure 8-2 (|S)Std-White .......................................................................................................................... 8-4
Figure 8-3 (|S) ..................................................................................................................................... 8-4 Figure 8-4 FS Color Measurement (raw pixel spectral data to FS) ......................................................... 8-6
Figure 8-5 R()white
and R()black
: White Copy Paper ............................................................................. 8-7
Figure 8-6 1-R()black
/ R() ................................................................................................................... 8-8
Figure 8-7 Types of FS Spectrum, UV Excluded Types ......................................................................... 8-9 Figure 8-8 Raw Pixel Spectral Data to FS Brightness Measurement .................................................... 8-10 Figure 8-9 Pixel Spectral Data to FC Color Measurement .................................................................... 8-11
Figure 8-10 Fluorescence Emission Strength and Shape of E(|S): White Copy Paper ....................... 8-12
Figure 8-11 R() and R'(|D65) ......................................................................................................... 8-13 Figure 8-12 Raw Pixel Data to FC Secondary Color Measurement ...................................................... 8-14 Figure 8-13 Raw Pixel Data to FC Brightness Measurement ................................................................ 8-15 Figure 8-14 Measurement Calculations ................................................................................................. 8-16 Figure 8-15 CIELAB Color Space In 3D .............................................................................................. 8-17 Figure 9-1 UVM: Primary Illuminant Effect On FC Spectrum ............................................................... 9-3 Figure 9-2 UV Excluded (FS) Measurement Types ................................................................................ 9-4 Figure 10-1 Kubelka-Munk: Backing Corrector Effect on FS Spectrum, Reflectance ......................... 10-3 Figure 10-2 Kubelka-Munk: Opacity Corrector Effect on FS Spectrum, Reflectance .......................... 10-4 Figure 10-3 Kubelka-Munk Opacity FC Effect ..................................................................................... 10-5 Figure 10-4 Pre-sorting .......................................................................................................................... 10-7 Figure 10-5 Moisture Dependency of the Fluorescent Emission ........................................................ 10-16 Figure 12-1 CMM Window and Lenses (green): Air Barrel Removed ................................................. 12-2
Figure 12-2 QTH Cable Assembly ........................................................................................................ 12-4 Figure 12-3 CMM Power Switch .......................................................................................................... 12-5 Figure 12-4 UV LED Cable Assembly .................................................................................................. 12-7 Figure 12-5 CMM Interface Module Without Cables ........................................................................... 12-8 Figure 12-6 Support Bracket of CMM Interface Module ...................................................................... 12-9 Figure 12-7 Support Bracket and UV LED Holder Assembly .............................................................. 12-9 Figure 12-8 UV LED Holder Assembly .............................................................................................. 12-10
Figure 12-9 Dark Solenoid Assembly ................................................................................................. 12-11 Figure 12-10 Dark Solenoid Removal Direction ................................................................................. 12-12 Figure 12-11 Matched Spectrometers .................................................................................................. 12-13 Figure 12-12 Cable From Signal Board To sbRIO .............................................................................. 12-16 Figure 12-13 Cables From CMM Interface Module, Power Cable, and Ground Cable, to Color Processor
..................................................................................................................................................... 12-16 Figure 12-14 Color Processor Support Bracket With Air Assembly .................................................. 12-17
Figure 12-15 Core Body Of CMM Without Color Processor Board and Support Bracket ................. 12-17 Figure 12-16 Unplugged Cables From Spectrometers ........................................................................ 12-18 Figure 12-17 The Spectrometers On Table .......................................................................................... 12-18 Figure 12-18 Conical Mirror and Spectrometers ................................................................................. 12-19 Figure 12-19 Detector/spectrometer Identification .............................................................................. 12-20 Figure 12-20 Conical Mirror Assembly............................................................................................... 12-21 Figure 12-21 Remove the sbRIO ......................................................................................................... 12-22
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Figure 12-22 Place Spectrometers On Table ....................................................................................... 12-23 Figure 12-23 Remove Barrel................................................................................................................ 12-23 Figure 12-24 Window Assembly With Conical Mirror Visible .......................................................... 12-23
Figure 12-25 Trapezoid Mirror Assembly With Mounting Plate ........................................................ 12-25 Figure 12-26 Conical Mirror and Spectrometers ................................................................................. 12-26 Figure 12-27 Conical Mirror and Trapezoid Assembly ....................................................................... 12-27 Figure 12-28 Barrel .............................................................................................................................. 12-27 Figure 12-29 Window Assembly ......................................................................................................... 12-28
Figure 12-30 Trapezoid Assembly ....................................................................................................... 12-28 Figure 12-31 Color Processor Board With Cables............................................................................... 12-29 Figure 12-32 Cables To the Color Processor ....................................................................................... 12-31 Figure 12-33 CMM Signal Board PCB................................................................................................ 12-32
Figure 12-34 Signal Board Without Cables ......................................................................................... 12-34 Figure 12-35 CMM Interface Module ................................................................................................. 12-35
Figure 12-36 CMM Interface Module Without Cables ....................................................................... 12-37 Figure 12-37 FTP Transfer Settings..................................................................................................... 12-39
Figure 12-38 FileZilla FTP Program ................................................................................................... 12-40 Figure 12-39 Adjust Backing Tile Height............................................................................................ 12-43 Figure 12-40 Bezel Speed Adjustment ................................................................................................ 12-45
Figure 12-41 White Tile ....................................................................................................................... 12-49 Figure 12-42 Wheel Detent Solenoid Assembly .................................................................................. 12-51
Figure 12-43 Disconnect Hoses and Cables (wheel detent solenoid assembly shown in blue) ........... 12-53 Figure 12-44 Loosen Screws................................................................................................................ 12-53 Figure 12-45 CBM Without Wheel Detent Solenoid Assembly.......................................................... 12-54
Figure 12-46 Bezel Solenoid 4-way Assembly.................................................................................... 12-55 Figure 12-47 Disconnect Hoses and Cables (bezel solenoid 4-way assembly shown in blue) ........... 12-56
Figure 12-48 Loosen Screws................................................................................................................ 12-57 Figure 12-49 CBM Without Bezel Solenoid 4-way Assembly............................................................ 12-58
Figure 12-50 Bezel Position Switch..................................................................................................... 12-59 Figure 12-51 Bezel Position Switch Cable (shown in blue) ................................................................ 12-61 Figure 12-52 Bezel Position Switch: Height Adjusting Screws (left); Support Bracket (right) .......... 12-61
Figure 12-53 Stepper Motor ................................................................................................................. 12-63 Figure 12-54 Disconnect Cables (shown in blue) ................................................................................ 12-64 Figure 12-55 Color Backing Processor ................................................................................................ 12-65 Figure 12-56 Hub Clamp On Motor Gear ............................................................................................ 12-65 Figure 12-57 Timing Belt Service Kit ................................................................................................. 12-67
Figure 12-58 Tile Wheel Assembly and Barrel ................................................................................... 12-68 Figure 12-59 Color Backing Processor Removed................................................................................ 12-70 Figure 12-60 Bezel Position Switch: Height Adjusting Screws (left); Support Bracket (right) .......... 12-70 Figure 12-61 Hub Clamp ..................................................................................................................... 12-71
Figure 12-62 Stepper Motor in Place (left) and Removed (right)........................................................ 12-71 Figure 12-63 T-piece Air Connector Removed ................................................................................... 12-72 Figure 12-64 CBM With (left), and Without (right), Wheel Detent Solenoid Assembly .................... 12-72 Figure 12-65 Housing Mounting Screws ............................................................................................. 12-73 Figure 12-66 CBM In Two Parts: Housing and Base .......................................................................... 12-73 Figure 12-67 Wheel Shaft/axel Locking Screws ................................................................................. 12-74
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Figure 12-68 Retaining Ring Locking Wheel Shaft/axel .................................................................... 12-74 Figure 12-69 Wheel Shaft/axel Out ..................................................................................................... 12-75 Figure 12-70 Tile Wheel and Wheel Shaft/axel Removed .................................................................. 12-75
Figure 12-71 Remove Mounting Plate ................................................................................................ 12-76 Figure 12-72 Barrel and Bezel Block .................................................................................................. 12-76 Figure 12-73 Adjusting Backing Tile Height ...................................................................................... 12-77 Figure 12-74 Processor Board LED Indicator Numbering .................................................................. 12-79 Figure 12-75 Color Backing Module Processor .................................................................................. 12-82
Figure 12-76 CBM Without Color Backing Processor ........................................................................ 12-83 Figure C-1 Color Sensor In 4000 Scanner .............................................................................................. C-1 Figure C-2 Installation of Color Measurement Module Into 4000 Scanner ........................................... C-2 Figure C-3 Installation of Color Backing Module Into 4000 Scanner ................................................... C-3
Figure C-4 Color Measurement Module Assembly ................................................................................ C-4 Figure C-5 Main Assemblies of the Color Measurement Module .......................................................... C-5
Figure C-6 Schematic of the Color Measurement Module Electronics .................................................. C-6 Figure C-7 Schematic of the Color Measurement Module Wiring, Color Measurement Module Interface
Module In the Connector J2 and PWR In ....................................................................................... C-7 Figure C-8 Color Backing Module Assembly (1 of 4) ........................................................................... C-8 Figure C-9 Color Backing Module Assembly (2 of 4) ........................................................................... C-9
Figure C-10 Color Backing Module Assembly (3 of 4) ....................................................................... C-10 Figure C-11 Color Backing Module Assembly (4 of 4) ....................................................................... C-11
Figure C-12 Schematic of the Color Backing Module Electronics ...................................................... C-12 Figure C-13 Schematic of the Color Backing Module Wiring in Connector J1................................... C-13 Figure C-14 Wiring Schematic For the Top Color Measurement Module With the PCI-PCDAQ Board C-
14 Figure C-15 Wiring Schematic For the Bottom Color Measurement Module With the PCI-PCDAQ
Board ............................................................................................................................................. C-15
List of Tables Table 1-1 Q4215-11 Color Sensor Specifications ................................................................................. 1-17 Table 4-1 Estimated Power Consumption ............................................................................................... 4-7 Table 4-2 Nominal Ranges of Standardization and Reference Readings .............................................. 4-13
Table 4-3 Standardization Check Limit Values ..................................................................................... 4-13 Table 4-4 Standardization and Reference Limit Values in the Firmware ............................................. 4-14
Table 5-1 Color Sensor Standardization Report ...................................................................................... 5-4 Table 5-2 Firmware Error Messages ....................................................................................................... 5-7 Table 6-1 Color Code Parameters ............................................................................................................ 6-4 Table 6-2 COLORP## Configuration ...................................................................................................... 6-5 Table 6-3 COLORP## MSS Setup .......................................................................................................... 6-8
Table 7-1 COLORP## Calibration Parameters ....................................................................................... 7-1 Table 7-2 YSTD Parameters ...................................................................................................................... 7-5
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Table 7-3 Changing Fluorescent Standard ............................................................................................... 7-6 Table 7-4 COLORP## Configuration Parameters ................................................................................... 7-7 Table 7-5 COLORP## Calibration Parameters ........................................................................................ 7-8
Table 7-6 MMS Spectrometer and Tile Serial Numbers and Values ...................................................... 7-8 Table 8-1 Tristimulus values Xn, Yn and Zn of the CIE Standard Illuminant with Corresponding
Observer ......................................................................................................................................... 8-18 Table 8-2 Tristimulus Values: Corresponding Observer ....................................................................... 8-19 Table 8-3 Chromaticity Values: Corresponding Observer .................................................................... 8-20
Table 9-1 UV-adjust Parameters (UVM: Primary Illuminant) ................................................................ 9-3 Table 11-1 Preventive Maintenance Internal Checklist ......................................................................... 11-1 Table 12-1 Processor Board LED Indicators ....................................................................................... 12-79 Table 12-2 CBM Processor Board LED Statuses ................................................................................ 12-80
Table 12-3 Criteria for Medium-term Repeatability of the Standardization ....................................... 12-91 Table 14-1 Storage and Transportation Parameters ............................................................................... 14-1
Table A-1 Part Numbers: Color Measurement Module .......................................................................... A-1 Table A-2 Part Numbers: Color Backing Module .................................................................................. A-2
Table B-1 Color Process Study ............................................................................................................... B-1
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Introduction
The purpose of this manual is to provide an introduction to Q4215-11 Color
Measurement.
The terms Color Measurement sensor, and Color sensor, refer to the Color
Measurement. These terms may be used interchangeably in this manual.
Audience
This manual is intended for use by engineers or process engineers and assumes
that the reader has some knowledge of the operation of a paper machine and a
basic understanding of mechanical, electrical, and computer software concepts.
This manual also assumes the reader is familiar with basic operations such as
using the Da Vinci system to control the scanner, maintain the paper recipe
database, and other related tasks.
About this manual
This manual contains 16 chapters and three appendixes.
Chapter 1, System Overview, describes operating principles of the color
sensor.
Chapter 2, Displays, describes color sensor displays and other displays
relevant for the color sensor available under other display tabs.
System Manual Introduction
4/1/15 P/N: 6510020381 Rev 03 xiv
Chapter 3, Infrastructure and Configuration, describes the principles of
required supporting hardware and how to setup top, bottom, and two-sided
color measurements.
Chapter 4, Installation, describes installation and set up tasks of the color
sensor.
Chapter 5, Operation, describes internal operation of the color sensor.
Chapter 6, Configuration, describes color configuration parameters.
Chapter 7, Calibration, describes color calibration parameters.
Chapter 8, Introduction to Measurements, describes the principles and
procedures of measurement.
Chapter 9, Static Cross-adjustment, describes principles and procedures for
static cross-adjustment.
Chapter 10, Dynamic Cross-adjustment, describes principles and procedures
for dynamic cross-adjustment.
Chapter 11, Preventive Maintenance, provides a schedule for recommended
ongoing preventive maintenance tasks.
Chapter 12, Tasks, describes procedures for maintenance, diagnostic, and
troubleshooting tasks.
Chapter 13, Troubleshooting, describes symptoms, alarms, possible causes,
and links to associated diagnostic or troubleshooting tasks.
Chapter 14, Storage, Transportation, End of Life, describes methods for
storing, transporting, and disposing sensor components.
Chapter 15, Glossary, describes the terms and acronyms used in this manual.
Appendix A, Part Numbers provides a list of part numbers for color sensor
components.
Appendix B, Coloring Process Study provides the Coloring Process Study
checklist.
Appendix C, Drawings provides some installation and color sensor-specific
drawings.
Introduction Related reading
P/N 6510020381 Rev 03 4/1/15 xv
Related reading
The following documents contain related reading material.
Honeywell Part Number
Document Title / Description
46028700 Color and Coloring of Paper Reference Manual
6510020200 Precision Platform 4000 Scanner System Manual
6510020192 Da Vinci Operator Manual
6510020199 Honeywell Radiation Safety Training Manual
6510020197 Honeywell Radiation Safety Manual for Customers
6510493041 Honeywell Technical Bulletin
Conventions
The following conventions are used in this manual:
Text may appear in uppercase or lowercase except as specified in these conventions.
Boldface Boldface characters in this special type indicate your input.
Special Type Characters in this special type that are not boldfaced indicate system prompts, responses, messages, or characters that appear on displays, keypads, or as menu selections.
Italics In a command line or error message, words and numbers shown in italics represent filenames, words, or numbers that can vary; for example, filename represents any filename.
In text, words shown in italics are manual titles, key terms, notes, cautions, or warnings.
Boldface Boldface characters in this special type indicate button names, button menus, fields on a display, parameters, or commands that must be entered exactly as they appear.
lowercase In an error message, words in lowercase are filenames or words that can vary. In a command line, words in lowercase indicate variable input.
Type Type means to type the text on a keypad or keyboard.
Press Press means to press a key or a button. [ENTER] or [RETURN]
[ENTER] is the key you press to enter characters or commands into the system, or to accept a default option. In a command line, square brackets are included; for example: SXDEF 1 [ENTER]
[CTRL] [CTRL] is the key you press simultaneously with another key. This key is called different names on different systems; for example,
[CONTROL], or [CTL].
[KEY-1]-KEY-2 Connected keys indicate that you must press the keys simultaneously; for example,
[CTRL]-C.
System Manual Introduction
4/1/15 P/N: 6510020381 Rev 03 xvi
Click Click means to position the mouse pointer on an item, then quickly depress and release the mouse button. This action highlights or “selects,” the item clicked.
Double-click Double-click means to position the mouse pointer on an item, and then click the item twice in rapid succession. This action selects the item “double-clicked.”
Drag X Drag X means to move the mouse pointer to X, then press the mouse button and hold it down, while keeping the button down, move the mouse pointer.
Press X Press X means to move the mouse pointer to the X button, then press the mouse button and hold it down.
The attention icon appears beside a note box containing information that is important.
The caution icon appears beside a note box containing information that cautions you about potential equipment or material damage.
The warning icon appears beside a note box containing information that warns you about potential bodily harm or catastrophic equipment damage.
P/N Rev 03 4/1/15 1-1
1. System Overview
For the next generation of Experion MX scanners in both the paper and CWS
industry, a new data acquisition architecture was developed. The new hardware
consists of a Measurement Sub System (MSS, also referred to as the PMP in
CWS), and an intelligent data acquisition (signal processing) card called the
Ethernet Data Acquisition (EDAQ) board.
This is a common platform of hardware, but implemented differently in the
Q4000 series scanner than the CWS 4080/4084 scanners (referred to here as the
408x series) and Q3090/Q3091 scanners (referred to here as the Q309x series). It
is also used in the 4283 rubber caliper and the 4036 metals C-Frame
measurements (using 092249XX x-ray sensors).
The EDAQ boards perform all the digitization for the sensors, and pass data via
Ethernet to any other client on the network. All EDAQs are identical in all
applications and contain the same software. This means that every EDAQ
contains the code for all sensors and all applications – the appropriate code is
loaded at start time by detecting the type of attached sensor or scanner.
In the Q4000 scanner, the EDAQs may have some sensor dependent local
programming to provide interlocking, signal conditioning or communication with
partner sensor modules.
In the 4080x scanners, the EDAQs are not aware of the sensor type connected to
them and mostly just pass digitized data back and forth to the MSS.
The rubber (4283) and metals (4036) thickness systems fall somewhere in
between. Some interlocking logic is handled by the EDAQ rather than the MSS.
In addition, the metals fast control voltage signal (CRSP) code is running on the
EDAQ CPU.
The rubber caliper has a single EDAQ capable of controlling up to three calipers.
For the metal systems, every 2249 gauge has its own MSS and two EDAQs. One
EDAQ predominantly processes receiver signals and the other processes source
signals.
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The Q309x scanner is the latest addition to the Experion Mx scanner family. This
scanner uses a wireless network for MSS-EDAQ communication. The upper and
lower parts of the head are independently driven and are not mechanically
coupled. EDAQs connected to the first sensor perform motion control tasks to
keep the heads aligned, in addition to the generic I/O processing and sensor
interlocking functions.The MSS is a generic CPU that collects all the sensor data
and bins the signals before transmission to the QCS server. This data is largely
compatible with what a previous generation MSS would be providing. However,
the older MSS generation also performed motion control. In the new architecture,
an EDAQ and an associated I/O expansion board (together referred to as the
Frame-Controller FC) now perform this task. The physical hardware used in the
Q4000-80 scanner for the MSS is a more powerful processor than for the CWS
scanner, rubber and metals systems, but the software, and disk content, are the
same. The MSS and EDAQ all run web servers and generate log files with
detailed information on the state of the system.
Regardless of the scanner type, the MSS and EDAQ software is released using a
single software release called Experion Mx Scanner Software.
All relevant software components are loaded during the startup of the MSS and
EDAQ to perform the task specific to the scanner or sensor. The scanner type is a
configuration item in the MSS. EDAQs use two resistors in the harness called
function and position resistors, which are used to decode function and position
codes by the EDAQ startup script. Function code identifies the sensor connected
to the EDAQ and position code idenfiy where and in which scanner the EDAQ is
mounted.
Section 1.1 and Section 1.2 detail some of the differences on how the new MSS
and EDAQs are used. Most of the chapters in this manual apply equally to all
applications. Prominent exceptions are information related to the user panel
interface (Q4000 series only), the radiation interlock, and the power track.
Software installation, upgrading, maintenance tasks, and web interfaces are
identical.
1.1. Q4000 EDAQ and MSS
The Experion MX Q4000-80 scanner is the first scanner in a new line that uses
local smart data acquisition cards and a generic MSS.
With each sensor having its own EDAQ board, the power track is reduced to
Ethernet, power, and some special signals such as the hardwired green light safety
signal and infrared (IR) chopper synchronization signal.
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In addition to the sensor EDAQs, the Q4000-80 has two alley EDAQs, one in
each head to control and interface with generic head functions and signals.
The new architecture has the following advantages:
sensors can be added more or less plug and play to the scanner head
new signals from sensors can easily be added to system and/or
retrofitted
much simpler endbell scanner cabling (especially with respect to
radiation interlocks)
increased diagnostics
For most sensor types, the EDAQs typically:
collect data from all sub-systems (ADC, DIO, USB, Serial, and so on)
time-stamp the data (with 50 microsecond absolute precision)
make data available to anyone on the network (not only MSS) using
the EDAQ data acquisition layer and software communication layer,
EDAL.
listen to requests from anyone to control digital outputs and analog
outputs
run a local Web server
New tasks performed by the EDAQs:
for radiation sensors, the EDAQs deal with low level interlocks, for
example, checking whether the state of the shutter matches observed
signal in the receiver, checking the state of the red light, and so on
perform PID control for the head temperature (sheetguide, air wipes)
convert to engineering units some of the auxiliary signals, such as
temperatures and so on
act as a converter board for RS-485 serial signals to Ethernet (for
example in the color sensor, FotoForm, FotoFiber, and so on)
For example, the upper head alley EDAQ:
reads signals from the Z-sensor
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reads signals from the Sheet Temp sensor if it is configured in the
system
controls the clutch (actuator) to split the heads using a digital output
reads head aligned magnet signal
reads accelerometers from the head power distribution board
performs PID loop control on the sheetguide and air wipe heaters
The upper head alley EDAQ publishes the state of the head aligned switch to any
of the other EDAQs that need to know the state. In this case, all nuclear and X-ray
sensors will subscribe to this data from this EDAQ so that they can make the
appropriate interlock decision. Data subscription is how EDAQs make data
available to other clients on the network. The EDAQs can publish the same ADC
data simultaneously to any number of other clients (such as the MSS, other
EDAQs, or debugging software running on a Windows® PC).
The EDAQ I/O functions consist of digital inputs and outputs, analog inputs and
outputs, a frequency counter, R232 and RS485 serial interfaces, USB interface
and temperature measurements.
To allow data from various EDAQs to be binned according to the position of the
scanner, each EDAQ has a clock that has to be highly synchronized with the
MSS. This is achieved by implementing the IEEE1588 Networking
Synchronization Standard [2002]. Each EDAQ board receives clock data packets
from the MSS, which acts as the master clock for the system. This signal arrives a
few times per second and keeps all EDAQ system clocks the synchronized to the
MSS. An accuracy of 50 microseconds or better is expected at all times.
1.2. 408x scanner EDAQ and MSS
Most of the information in this manual was written for the Q4000 series scanner,
but much also applies to the Q4000 and the 408x scanners.
In the Q4000-80 scanner, the EDAQs are mounted at each sensor position and
digitize the signals in the head.
In the 408x scanners, the EDAQs are not dedicated to a particular sensor, but act
as generic data acquisition (DAC) cards similar to the previous generation of
National Instruments DAQ cards.
System Overview 408x scanner EDAQ and MSS
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1.2.1. Differences in the MSS hardware
The Q4000 series scanner uses a more powerful processor due to the large amount
of sensor data it needs to process. The PC used in the 408x scanners, a FitPC2i at
this time, has more modest specifications. However, the software and operating
system running on both is the same.
The same base installation image is applied to both PCs, and the same MSS
updates (as described in Chapter 3) are applicable to both unless explicitly
notified by Honeywell Engineering. The intent is to keep the systems 100%
compatible and interchangeable. This MSS is capable of operating as a wireless
access point, which allows both monitoring of the MSS and EDAQs (through
their web pages) as well as remoting to the desktop of the MXProLine server
while at the scanner.
1.2.2. Differences in the EDAQs
The EDAQ hardware used in the 408x scanners consists of one or two EDAQs at
the endbell to digitize the sensor signals, and an additional EDAQ used as an FC-
EDAQ. The latter consists of an EDAQ mounted on an I/O expansion board. All
three EDAQs are identical in software and hardware, and may be freely inter-
changed. All EDAQs should automatically identify their function in the scanner
and load appropriate firmware and application code. The EDAQs can be
interchanged between the 408x and the Q4000 series scanners. For details on the
automatic identification, see Chapter 7.
1.2.3. Safety interlock and watchdog functions
In the paper Q4000 scanner the EDAQs can run dedicated code depending on the
sensor function detected at start up time. For example, the radiation sensors have
sophisticated safety interlocking which is processed on the EDAQ. These EDAQs
will check for the status of the red light, the head aligned switch, and the receiver
signals before allowing the command to set a digital output to be processed.
Details may be found in Basis Weight Measurement System Manual (p/n
6510020331). In the 408x scanners this functionality is handled by the MSS and
some dedicated hardware at the endbell.
The EDAQs in the 408X scanner do not run code specific to the type of sensors
mounted on the scanner. In other words, they operate as non-intelligent DAC
cards, running generic EDAQ code that does not inhibit commands from the
MSS. This code is identical to the code that is running on IR sensor-associated
EDAQs that have no interlocking functionality.
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As an additional layer of safety against failure, a software watchdog is
implemented on the 408x endbell EDAQs. Because the logic to operate the
nuclear shutters runs on the MSS, and the connection between the EDAQs and the
MSS could potentially fail (or be unplugged), the EDAQs will turn off all digital
outputs if no stay-alive message is received from the MSS in a specific time
period. The time period is in the order of a few seconds and may be changed in
the RAE database.
Do not configure higher than the default setting for radiation safety, as the radiation safety
interlocks are run in the MSS for 408x scanners.
Advanced users find this in the RTDR area under the sensor job set/setup record
with the name ./Setup/EDAQ Watchdog Timeout Sec. Also, see the RAE alarm
information in Chapter 10.
1.3. 4036 Metals and 4283 rubber thickness measurement EDAQs and MSS
Most of the information in this manual was written for the Q4000 series scanner
but much applies to all systems. In the metals and rubber caliper the new MSS
and EDAQs were introduced to simplify the set up, reduce the end user cost, and
provide some additional diagnostics but otherwise operate the same as the
previous National Instruments based system.
The EDAQ I/O functions consist of digital inputs and outputs, analog inputs and
outputs, a frequency counter, several serial interfaces, and USB and temperature
measurements. In the metals systems, only the analog I/O, digital I/O and
Ethernet are used. Two EDAQs are required to process all the signals from a
metals sensor. Signal descriptions can be found in the Metals C-Frame Scanner
System Manual, Honeywell p/n 6510020493.
1.3.1. Differences in the MSS hardware
At this time, a small form factor FitPC2i from CompuLab is used. However, the
software and operating system running on all MSS and EDAQ applications is the
same. The same base installation image is applied to both PCs, and the same MSS
updates (as described in Chapter 3) are applicable to both unless explicitly
notified by Honeywell Engineering. The intent is to keep the systems 100%
compatible and interchangeable.
System Overview 4036 Metals and 4283 rubber thickness measurement EDAQs and MSS
P/N 6510020381 Rev 03 4/1/15 1-7
The actual hardware is likely to change as vendors update their products. This
MSS is capable of operating as a wireless access point, which allows both
monitoring of the MSS and EDAQs (through their web pages) as well remoting to
the desktop of the MXProLine server while at the sensors.
1.3.2. Metals system radiation safety interlocking
Details of the interlocking system can be found in the Metals C-Frame Scanner
System Manual, Honeywell p/n 6510020493 but a brief overview is given here
because it helps to clarify the function of the EDAQs.
The green light (shutter in position switch) has remained the same and
is a hard-wired connecting that does not involve and software or
EDAQ hardware.
The amber light is an indication that the x-ray system has power. It is
turning on when the keyswitch is in the on position and the enable
button is pressed.
There are a number of conditions that can cause the EDAQ to turn off
power (and amber light) – these include LAN failure between it and
the MSS, interlock board failure, and amber light failure.
Interlock board 65805000109 acts as a failsafe mechanism for the
EDAQs. It generates the +24 V for the sensor (which turns on the
amber light) if it receives a pulse train from an EDAQ digital output
and if source cover interlock switch and the thermostat switch are
closed.
The red light indicates the shutter was commanded to open, relayed by
the MSS to the EDAQ. The EDAQ may turn off the shutter (or refuse
to open it in the first place) based on criteria including, Low Open
Receiver Volts, red lamp failure, LAN connection failure and receiver
saturated failure.
Any state change in the EDAQ IO, or the unexpected signals that lead to an
interlock failure are reported in human-readable log files stored on the MSS disk
drive. Chapter 6 details how to access and download these files.
1.3.3. Rubber Caliper retract mechanism
There is a primitive interlock system in the rubber caliper retract mechanism. The
switch and enable buttons are used by the EDAQ to determine whether to process
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the insertion command from RAE (through the MSS). The EDAQ reports the
reason for failure to insert, both to RAE and in the MSS log files.
1.4. Q309x EDAQs and MSS
The Q309x scanner is very different from other scanner types. The two major
differences are the complete absence of the power track and the introduction of
independently driven heads.
The Q309x uses a wireless network to carry out the communication between MSS
and EDAQs. A brush assembly that slides over a power rail is used to provide
24V power to the EDAQs and sensors. A small compressor is mounted inside the
head produces compressed air for operating sensor shutter and flags. These
choices entirely eliminate the need for power track between MSS and the heads.
The upper and lower parts of the heads are fitted with separate stepper motor
drives. There will be two or four EDAQs inside a Q309x scanner head depending
on whether it is a single or dual sensor head. EDAQs connected to the first sensor
performs motion control tasks and keep the heads aligned.
1.4.1. Differences in the MSS
The Q309x scanner MSS is fitted with an internal PCI wireless card for
implementing wireless sensor LAN. MSS software configures a bridged network
using the wireless LAN interface and the eth1 wired network interface. This
means EDAQs can communicate with MSS either using wired or wireless
connection. Typically, a wired connection is used for initial configuration and
synchronization. It can be also used for recovery operations if the wireless
authentication information is lost. MSS and EDAQ communicate using secure
wireless network during normal operation of the scanner.
Another difference in the Q309x MSS is that the Frame Controller runs as a
software application in the MSS. This application interfaces the new EDAQ
motion control applications to the motion control jobsets running in the MSS.
Since Frame Controller assembly is eliminated, the HMI panel is directly
connected to a serial port in the MSS computer. Mill I/O connections such as scan
enable, sheet break, line speed etc. are terminated to the I/O interface in the HMI
panel. A new HMI server application running in the MSS interfaces the HMI
panel to the Frame Controller and to the MSS application.
Currently, Advantech ARK series embedded computers are used as MSS in
Q309x scanners. Note that specific wireless cards qualified by Honeywell
Engineering are required for the wireless sensor LAN.
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1.4.2. Differences in the EDAQs
EDAQs in Q309x scanner is fitted with a USB wireless dongle. These EDAQs are
assigned with special position codes – 127 to 131 in lower head and 227 to 231 in
upper head. EDAQ startup scripts initializes wireless sensor LAN interface only if
the position code falls in this range. Note that specific USB wireless dongles
qualified by Honeywell Engineering are required for the operation of wireless
sensor LAN.
Sensor specific software in Q309x scanner is similar to those in Q4000 scanner.
However, the I/O channel mapping is different and the communication takes place
using wireless network. In addition, the EDAQ connected to the first sensor is
runs a new motion control application for controlling the movement of the heads.
Motion control runs in master mode in the upper head and in follower mode in the
lower head. These two applications works with the frame controller application in
MSS to execute the scanner motion commands.MSS Web Interface
The MSS web interface is the focal point for EDAQ, FC, and MSS configuration
and information. Many of the EDAQ, FC, and MSS diagnostics are displayed on
the MSS web interface. The MSS IP address and time are set here, and all the
devices are upgraded through this interface. High speed analog signals from the
sensor can be displayed as can numerous other functions. MSS web interface can
be accessed in several different ways:
From the QCS server or thin client operator station, navigate to the
MSS Diagnostic tab, click MSS Monitor, choose the appropriate
MSS, and click MSS Web page.
Open a browser on any computer connected to the QCS server level
network and using the URL http://192.168.10.101 or the IP address set
up for the MSS.
Opening a browser on any computer connected to the scanner endbell
LAN switch and use http://192.168.0.1 as URL.
Log on to the MSS computer native console by connecting a monitor,
keyboard and mouse, open the web browser and use localhost as URL.
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By default, the MSS web interface can only be accessed by devices on either the
server LAN or the sensor LAN, but not on separated networks. For example,
operator stations connected on a separate (possibly FTE) network do not see the
MSS IP addresses and cannot access the web page. This issue can be fixed if the
RAE server is set up to forward HTTP requests (see Section 8.7). Thin-client
operator stations are effectively run from the RAE server and can see with the
MSS IP address.
Figure 1-1 Q309x MSS Web Interface Home Page R20x Release
Figure 1-1 above shows the home page of a Q309x scanner MSS. The home page
in previous R10x releases are slightly different. The main difference is the user
name and password texboxes in the top left corner for logging into administrator
mode which enables advanced functions. This is login process is eliminated from
R200.1 release and all functions are listed in the left menu. In addition, the
command buttons for updating MSS and EDAQ software are grouped together in
the top of the menu for easy access.
Figure 1-2 below shows R10x style home page from a Q4000 scanner MSS.
User name: administrator
System Overview Software Releases
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Password: hmxresult
Used for logging into administrative mode.
Figure 1-2 Q4000 MSS Web Interface Home Page R10x Release
The MSS web interface uses Javasripts to display and hide user interface elements
as different options are chosen.
Ensure that active scripting is enabled in the security settings of the browser for the
proper display of MSS web interface.
1.5. Software Releases
MSS and EDAQ software releases are done together in a single release called
Experion Mx Scanner Software Release. Scanner software releases are done
independent of theExperion MX/RAE server software. However, each scanner
software release may have some dependency on the Experion MX/RAE server
release. Refer to the scanner software release notes for the supported Experion
MX/RAE releases. Release notes page can be displayed by clicking the “Release
Notes” button in the left menu under “Scanner Functions” in MSS web interface.
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Scanner software releases are named in the format “Experion Mx Scanner
Software Rabc.n”. The release image is a zip file which contains the following
components.
Table 1-1 Scanner Software Release Components
Component Description File Name
MSS Image File for updating MSS software mss-filesRabc.n.SVNpqrs.tar.z
EDAQ Image File for updating EDAQ software edaq-filesRabc.n.SVNpqrs.tar.z
GPL Files All GPL licensed source files used for building this release
GPL-files.Rabc.n.SVNpqrs.tar.z
Rabc.n is the short name or the release number identifying the release. The .n
releases are updates to the Rabc release to distribute mainly bug fixes. The b and
or c numbers are updated when new functionality is included in the release. For
example, when a new sensor or scanner type is introduced. The a number is
updated when there is a major platform change that may force incompatibility
with previous builds. Always refer to the release notes and the software change
notice for compatibility and upgrade instructions.
The pqrs number in SVNpqrs refers to the revision number in the source code
management system used for archiving the scanner software. The pqrs number
should be same for all components in a release.
The MSS image file and EDAQ image files are used to upgrade the MSS and
EDAQs respectively using the MSS web interface. GPL Files are included as part
of the release to comply with software licensing requirements. This deliverable is
not required for updating the scanner.
It is important to stop the scanner before starting the software upgrade process.
Command the scanner offsheet and press the scanner stop button on either end of
the scanner.
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2. Network Architecture
The basic network layout is the same for all applications, but the number of
EDAQ and network switches involved differs.
Physically the simplest system is the rubber caliper, where the MSS connects to
the MXProLine server and the EDAQ connects to the second MSS Ethernet port.
The metals system has one Ethernet switch to join two EDAQs and the MSS.
Q4000 scanners have multiple switches and up to 15 EDAQs, but LANs are
configured the same way as for the simpler metals and rubber systems.
Q309x scanners also have the same network architecture as all other scanners but
uses wireless technology to implement the sensor LAN. The wireless access point
software running the MSS functions the role of a switch eliminating the need of a
physical sensor LAN switch.
2.1. Scanner network
Figure 2-1 shows the scanner network for a Q4000 paper scanner. The
architecture is the same for the 408x scanners except that the EDAQs are not
physically with the sensors (as shown in the Figure) but at the endbell.
All other information in this chapter applies to both scanner types.
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Figure 2-1 Scanner Network and IP Architecture (upper and lower head
alley EDAQ not shown)
The MSS has two network cards. As shown in Figure 2-1, one card is part of the
scanner network and always has an address of 192.168.0.1. Also shown is the FC,
with fixed address 192.168.0.2. This Q4000 scanner has two EDAQ boards in the
top and bottom heads, with addresses assigned through their position in the head
(position 202/102 as shown in Figure 2-1, resulting in IP addresses 192.168.0.102
and 192.168.0.202.). See Section 5.3 for more information on location numbers
and IP addresses. The structure and IP assignments inside the scanner network are
fixed and should not be changed at installation.
In addition to the scanner devices, Figure 2-1 shows a laptop plugged into the
network. The local DHCP server (inside the scanner network) assigned it the
temporary address 192.168.0.38. Because the MSS is configured to act as a
network router, this laptop has access to both the scanner network and the
network at the next level up (that of the MSS-RAE server network, shown in
Figure 2-2.). This means that remote desktop applications on the laptop may
access the QCS server. In the example network shown in Figure 2-2, access the
server using the address 192.168.10.1.
Network Architecture Metals C-Frame network
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Figure 2-2 MSS and Server Network for a Two-Scanner System
2.2. Metals C-Frame network
Figure 2-3 shows how the same architecture applies to the metals C-Frame
sensors. The MSS has two network cards.
One of the MSS Ethernet cards is connected to the C-Frame network and always
has an address of 192.168.0.1. There are two EDAQs in this network, one
processing primarily x-ray source signals and processing x-ray receiver signals.
Both of these have fixed IP addresses, as shown on the main MSS web page. The
structure and IP assignments inside the C-frame network are fixed and should not
be changed at installation.
The second Ethernet card connects the MSS to the RAE server. The assigned IP
address defaults to 192.168.10.101 at factory time but it can be changed to any
address as long as it matches the address setup in the server. The change must be
made through the MSS Main web page and requires a reboot of the MSS.
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There is a local DHCP server inside the C-Frame network and it will provide an
IP address to any network device plugged into the switch. The MSS is configured
to act as a network router, so that any laptop plugged into the Ethernet switch has
access to both the scanner network and the network at the next level up (that of
the MSS-MxProLine server network). This means that remote desktop
applications on the laptop may access the MXProLine server.
Figure 2-3 Network configuration for a typical 4036 c-frame scanner
2.3. Q309x scanner network
The Q309x scanner MSS has three network interfaces – two wired and one
wireless. One of the wired interface is used as server LAN interface as in other
scanners. The other wired and the wireless interface are configured in bridged
mode to function as the sensor LAN. Wireless sensor LAN interface is used for
the normal operation of the scanner and the wired sensor LAN interface is used
for initial configuration, synchronization and recovering EDAQs with
mismatched authentication settings.
The EDAQs in the Q309x scanner has two network interfaces – regular on-board
wired interface and an external wireless interface using a dongle connected to the
USB port. During normal operation, sensor LAN is initialized using the wireless
interface and the wired interface is configured with a fixed 192.168.2.1 address.
This interface is used for connecting network devices locally to the EDAQ. For
example, foto sensors use this interface to connect camera module to the scanner.
Network Architecture IP addresses
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Figure 2-4 Network Configuration for Q309x scanner
MSS functions as the wireless access point and the EDAQs connect to the MSS as
wireless client devices. Standard 802.11a technology operating 5 GHz range is
used to implement the wireless network and operates in secure encrypted mode
using standard WPA2 security configuration. Default Q309x configuration has no
sensor or server LAN switch installed by default. However, a server LAN switch
is required to interface multiple Q309x scanners to the same server. Sensor LAN
switch may be used temporarily for wiring EDAQs or debugging devices to the
MSS wired sensor LAN interface.
EDAQ network configuration must match with MSS network configuration and
security settings. A rotory switch on the head power distribution board is used for
this purpose. Refer to section 2.6 Network Configuration for more detailed
description of MSS and EDAQ network configuration.
2.4. IP addresses
Within the scanner network, the MSS Web pages may be accessed using the
scanner address http://192.168.0.1/.
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Each EDAQ may be directly accessed using the IP address, for example,
http://192.168.0.102 for the lower head EDAQ and http://192.168.0.2 for the
Frame Controller EDAQ.
The following tables illustrate the fixed IP addresses in the subnet for the various
MSS/EDAQ applications:
Table 2-1 Fixed MSS and EDAQ IP addresses in a Q4000 series scanner
MSS 192.168.0.1
Frame Controller (FC) 192.168.0.2
Upper Alley EDAQ 192.168.0.200
Lower Alley EDAQ 192.168.0.100
Table 2-2 Fixed IP addresses for the 4080 scanner
MSS 192.168.0.1
Frame Controller (FC) 192.168.0.2
Sensor EDAQ 1 192.168.0.3
Sensor EDAQ 2 192.168.0.4
Table 2-3Fixed IP addresses for the 4036 metals system
MSS 192.168.0.1
Receiver EDAQ 192.168.0.3
Source EDAQ 192.168.0.4
Table 2-4 Fixed IP addresses for the Q309x scanner
MSS 192.168.0.1
First sensor source EDAQ (Master Motion Controller) 192.168.0.227
First sensor receiver EDAQ (Follower Motion Controller) 192.168.0.127
Second sensor source EDAQ 192.168.0.228
Second sensor receiver EDAQ 192.168.0.128
EDAQ local wired interface (all wireless EDAQs) 192.168.2.1
Figure 2-2 also indicates the function of the MSS as a Web proxy server. Any
device on the MSS-RAE network can access the EDAQ Web pages by appending
the network name to the address.
The MSS-RAE network is the next level up and typically connects all the
scanners at site to the server. The network cards in the MSS server segment may
have default addresses from the factory, but they may be changed on-site without
restrictions. There is no DHCP server on this network segment, although it can
easily be added on request.
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Figure 2-2 shows two scanners, where the second MSS was assigned IP address
192.168.10.102 at installation, and the first MSS retained its default address.
Laptops connected into this network segment can access the MSS Web pages
using their addresses (http://192.168.10.101 and http://192.168.10.102/). Also
indicated in Figure 2-2 is the optional forwarding of port 22 on the QCS server to
the same ports on the MSS. This will allow technical support direct access to the
MSS and hence to the EDAQs in each scanner.
2.5. Ethernet switch information
All scanner devices are auto-negotiating their speed and duplex mode so all the
scanner switches are set up for auto mode only. For any switch connected directly
to the MSS, it is important to avoid setting it to 100 Mb/s full duplex.
Ethernet switches directly connected to the MSS must be configured to use auto-
negotiation.
According to the Ethernet standard, when an auto-negotiating device detects a
non-auto-negotiating device it will revert to half-duplex mode. A 100 Mb/s full-
duplex set switch will force the MSS to half-duplex, causing large amounts of re-
transmitted and, eventually, lost data.
Aside from the auto-negotiation, there is no particular required feature of switches
between the MSS connection and the RAE server. You can set duplex rates on the
switch port connecting to the server (assuming the server is also set to fixed
rates), but not on the port connected to the MSS.
The scanner Ethernet switches are not generic switches and cannot be easily
replaced. The MSS communicates time synchronization data to all EDAQs over a
high-priority VLAN tagged packet. Timing synchronization fails if the switch:
does not recognize VLAN tags
does not have priority queuing set up by default
In this event, the EDAQ date changes to January 1st, 1970 at start up. The RAE
system will send user notifications that the data time stamp on the EDAQs is
incorrect. There are many managed switches that support the items listed above,
but they must be set up properly.
There are few switches on the market that have both features enabled off the
shelf. You cannot remote install the MSS (remove from endbell) and insert a
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booster switch in between to get long cable distances, another Phoenix Contact
switch such as is in the endbell.
See Section 2.6 for information about redundant Ethernet connections.
2.6. Network Configuration
Scanner network configuration is done using the MSS web interface. Since
network configuration depends on the scanner type, MSS Type or scanner type,
configuration should be done with the network configuration.
2.6.1. New Interface
Starting with R200.1 release, a single MSS Configuration page supports all
network and scanner type configurations. Select the Configure MSS button in the
left menu to naviage to the network configuration page.
Figure 2-5 MSS Configuration Web Page
The MSS Type drop-down listbox selects the scanner for which MSS is
configured. The MSS Power Supply listbox specifies the mounting location of
the MSS. Mounting location is used to define the operation of the MSS when
scanner is shut down by pressing the scan and offsheet buttons together in the
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scanner HMI panel. If the MSS is mounted on the scanner, the scanner shutdown
will result in normal shutdown of the MSS. A power cyle is required to restart a
shut down MSS. If the MSS is mounted remotely, scanner shutdown will result in
a reboot and the MSS will back running automatically.
Figure 2-6 MSS Type & Power Supply Selections
Default network configuration changes depending on the MSS type selection. All
scanners except Q309x, defaults to wired eth0 interface for server LAN and eth1
interface for sensor LAN. Q309x scanner will default to eth1-wlan0 bridged
interface for the sensor LAN. Other scanner types can enable wireless by
configuring either the server or sensor LAN interface in wired-wireless bridged
mode, if the MSS hardware has wireless interface card installed.
Regardless of the scanner type, wireless can be enabled in the MSS only in
bridged mode.
The term MSS IP address refers to the IP address of the MSS server LAN
interface. By default, it is 192.168.10.101 and 192.168.10.1 is used as the default
server IP address. These along with the netmask has to be configured to match the
actual QCS server network configution. The sensor LAN (192.168.0.*) and the
MSS sensor LAN interface address (192.168.0.1) are fixed and cannot be
changed.
Wireless network configuration selections are displayed only if the wireless is
enabled by configuring one of the interfaces in bridged mode. Depending on the
channel selection, MSS wireless operates in standard 802.11n (2.4GHz channels)
or 802.11a mode (5GHz channels).
The chosen wireless network channel must comply with the local government
regulations and rules regarding the operation of wireless networks.
MSS wireless operates in a secure encrypted mode using standard WPA2 security
configuration.Wireless client devices are required to authenticate by specifying
the network name and password paraphrase to join to the MSS wireless network.
Default network name: ExperionMxScanner
Default password paraphrase: Hmxresult1#
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If there are more than one MSS wireless networks in close proximity, wireless
network names must be changed to uniquely identify each network. Also, it is
highly recommended to configure each MSS to operate in different wireless
channels to avoid interference.
Broadcasting of the wireless name can be enabled or disabled using the Hide
Wireless checkbox.
New additions to the interface
Used to update the MSS configuration on the local hard drive.
Configuration changes only take effect after rebooting the MSS.
Sets default settings for all selections depending on the currently selected MSS.
Ignores any changes after the last save.
The MSS web interface displays these options after an updated configuration is saved.
If any wireless EDAQs are connected to the MSS, click the Reboot Later option especially if either the network name or password is modified from the defaults.
Post-poning a reboot allows the system to synchronize the updated authentication settings to the EDAQ before the changes take effect.
This option is used to synchronize the EDAQs with the MSS.
Reboot the EDAQs and the MSS after synchronization is complete to open the network with the updated configuration.
Updated MSS configurations must be rebooted to take effect..
If there are wireless EDAQs connected to the MSS, synchronize the updated
wireless configuration to the EDAQs before rebooting the MSS.
Wirelss client devices other than EDAQs can be connected to the MSS wireless
network just like connecting to any other WiFi network. Create a new connection,
enter MSS wireless network name as SSID, select WPA2-Personal security
settings and enter the password paraphrase.
Only the Q309x scanner supports EDAQs in wireless mode. The EDAQ position
code has to be in the Q309x position code range (127 through 131 or 227 through
231) for the wireless to be enabled. WLAN selector switch on the Q309x head
power distribution board sets up the EDAQ wireless operation mode as described
in the table below.
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Table 2-5 EDAQ WLAN Selector Positions
Position 1 EDAQ uses wired interface for sensor LAN. The wireless network is not initialized.
Position 1 allows EDAQ recovery if the authentication settings synchronizated are no longer valid.
Position 2 EDAQ uses USB wireless interface for sensor LAN with default network name and password. Wired interface is assigned with address IP 192.168.2.1.
Position 3 EDAQ uses wireless interface for sensor LAN with network name and password paraphrase previously synchronized with the MSS. Wired interface is assigned with IP address 192.168.2.1.
Position 4 Reserved.
After synchronizing wireless configuration, set the WLAN selector switch to
match the MSS settings and then reboot the EDAQs.
Power cycle the EDAQ after changing the WLAN selector to position 1 and use
an Ethernet cable to connect the EDAQ to the MSS wired sensor LAN interface.
The wireless configuration can now be synchronized and wireless connection can
be restored upon restarting the EDAQ in WLAN selector position 3.
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2.6.2. Old Interface
Figure 2-7 Network Configuration R107.x Release
Button Use
Network Settings Used to configure the MSS IP address and server IP address.
Ethernet Settings in previous R10x
versions.
Set IP Address Saves changes to the configuration.
Factory Default Used to set the MSS IP address and server IP address.
Default MSS IP: 192.168.10.101
Default server IP: 192.168.10.1
Set MSS Type Used to configure the MSS type and specify if it is mounted locally to the MSS or if it is mounted remotely.
The MSS must be reset by selecting Restart MSS from menu for the new
configuration to take effect.
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The R10x release also supports configuring the MSS wireless by logging into the
administrator mode in the web interface.
Figure 2-8 MSS Wireless Configuration R107.x Release
To enable administrator mode:
1. Use the following credentials:
Login: admin
Password: hmxresult
2. Click on Configure Wireless.
The wireless network is configured with 192.168.5.x as subnet address and the
ESSID is derived automatically from from the MSS IP address. All supported
wireless channels are in 2.4GHz range.
Configuring the wireless for EDAQ-MSS and MSS-RAE communication in R10x
release is for demonstrative purposes only. These configurations are not validated
for normal production operation.
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R10x MSS wireless are configured for local diagnostics only.
2.7. Ethernet cable redundancy
This option applies to MSS software revision R107 or higher only, which
configures the managed switches. Do not connect multiple (redundant) Ethernet
cables to EDAQ/MSS switches when running older software revisions or
without configuration.
The switches used in conjunction with the EDAQ and MSS network allow for
multiple cables to connect between the same points, using the Rapid Spanning
Tree protocol. There are two redundant cable configurations:
Q4000 series scanner: each power track has two Ethernet cables that
can be used as a redundant pair. When redundancy is enabled in the
software, the cables will alternate (with a fixed period) and any
failures are reported to the RAE system and the MSS web pages.
In addition, all applications (rubber caliper and x-ray metals included)
could use two sets of cat-5 cable to connect between the MSS and the
RAE (Experion MX or MXProLine) server. This requires the use of an
additional Phoenix Contact smart switch chosen for the Q4000
scanner. The MSS is connected to this switch with one cable and two
cables run from the switch to another (unmanaged, generic) Ethernet
switch near the RAE server. In this case, the switch automatically
selects one cable until it fails and then switches over. Failures are also
reported to RAE and the MSS web pages.
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Figure 2-9 Example configuration for redundant communication to the
server
2.7.1. Setup Q4000 Ethernet cable redundancy
Ethernet redundancy is only available in EDAQ/MSS software revisions R107.X
or higher.
In software revisions older than R107, do not connect both Ethernet cables in the
power tracks to the Ethernet switches. This will result in network failures because
the switches, when not configured properly, are not expecting two paths to the
same destination.
Using R107.X or higher and following the provided instructions, the switches will
be automatically programmed by the MSS to handle the double paths.
For the MSS to provide correct failure information, the power track cables must
be plugged in the specific ports on the endbell switch as indicated in Table 2-4.
Table 2-6 Switch port number assignment for the Q4000 endbell switch
Usage Switch Port
MSS 5
Upper PT CAT-5 cable 1 1
Upper PT CAT-5 cable 2 2
Lower PT CAT-5 cable 1 3
Lower PT CAT-5 cable 2 4
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Figure 2-10 Ethernet redundancy status page
Figure 2-10 shows the main cable redundancy page that can be accessed through
the Cable Status button
Documentation is provided by clicking Help.
To configure a normal, redundant operation:
1. Ensure only the MSS cable is connected to port 5 and one of the upper
and lower power track cables is connected to ports 1 and 3
respectively.
2. Enable the diagnostics on lower and upper cable.
3. Disable the RAE alarm on both cables.
4. Set Active Cable Selection to Periodic Swap.
5. Click Update Configuration.
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It takes up to a minute for the diagnostic script to configure sensor
LAN switch.
6. Refresh the web page until Upper/Lower Cable 2 not connected is
displayed in the status message.
7. Connect both upper and lower cable 2 to the switch. Wait and refresh
the web page until the status message displays No error detected.
8. Enable RAE alarm on both cables and click Update Configuration
again.
The various options are described in detail in the online documentation accessible
through the Help button.
As follows is a summary of the configuration options:
Diagnostics: The MSS enables the main monitoring scripts to interrogate
the switches, checking for failure and monitoring the packet
retransmission rates on the lines
RAE Alarms: When unchecked, the scripts runs, but alarms are not
generated. This can be used to disable nuisance alarms but still maintain
the monitoring function.
Active Cable Selection: Under normal conditions the MSS periodically
changes the cable used for communication. Changing this value can force
the use of a particular cable and stop the swapping.
The Status Table shown in Figure 2-10 displays a summary of the configuration
and the status of the cable. The status message provides a detailed description of
the alarm as follows is a summary of the table settings:
Cable Disconnects: The number of times the switch had to swap to
another cable due to cable failure. This number is normally zero and
changes to 1 when a cable has failed. This is a critical failure.
Alley TCP Diagnostic Status: The MSS obtains traffic loss information
collected by the alley EDAQs. If the EDAQs fail to provide this
information, the status changes to red. This is not a critical failure.
Cable n TCP Retransmissions: This is a measure of the traffic lost seen by
the alley EDAQs and indicative of future cable failure. An alarm is
triggered if this quantity exceeds a threshold.
In case of issues, the MSS will set an alarm on the RAE Experion alarm page to
notify the Operator. The Operator should check the web pages for details of the
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alarm. The corrective action is documented under the help section of the above
page.
2.7.2. MSS-server cable redundancy
A second cable between the MSS and RAE server may be installed for all
applications (scanners and fix point measurements).
The status and configure page is accessed through the Cable Status button on the
main MSS web page. At this time, the software is not finalized so the interface
shown in Figure 2-11 can be subject to change.
Figure 2-11 MSS Cable redundancy status page showing MSS-Server cable
status in addition to the scanner cable status
To enable the MSS to Server redundant cable setup and checking, you must have
an additional Phoenix Contact switch LM 8TX. Connect the switch to the MSS on
port 5. Two cables run to the RAE server where they should terminate on another
switch (does not have to be Phoenix Contact LM 8TX).
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Before setting up the redundant network, ensure only cable 1 is connected and
that the RAE alarm check box is off. The set up the redundant network, access the
above page and under the Server LAN Cable header, click the Diagnostic Enable
and RAE Alarm Enable checkboxes (see Figure 2-10, table bottom right). Also
specify the range of IP addresses the switch is allowed to acquire. This is passed
to a local (MSS) DHCP server that contacts the new Phoenix switch and set the
address.
After clicking Update Configuration (see Figure 2-10, bottom right), you are
requested to power cycle the switch to ensure it obtains a new IP address. It is
your responsibility to insure that the range of IP addresses here (and this range
can be a single address) does not clash with any other IP addresses, fixed or
DHCP on the RAE-MSS network. Multiple MSS can exist on this network and
that if each of those has a redundant connection to the server, the ranges specify in
the web page should be unique for each MSS CPU.
The only diagnostic item in the status table is:
Cable Disconnects: The number of times the switch had to swap to
another cable due to cable failure. This number is normally zero and
changes to 1 when a cable has failed. This is a critical failure.
The MSS-Server LAN cables have no TCP loss diagnostics and are not
periodically swapped. However, the switches will detect failures, rapidly switch
to the second cable, and report to the error to the MSS. The MSS in turns set an
alarm on the RAE Experion alarm page to notify the Operator. The Operator
should check the web pages for details of the alarm. The corrective action is
documented under the help section of the page.
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3. MSS
This chapter describes the MSS, including installation and setup. The installed
software in MSS is identical on all scanner types, but the physical hardware is not.
The references to off-sheet buttons do not apply to rubber and metals systems, but
are equivalent to retract (rubber) and x-ray power enable (metals).
Some scanners may have no Ethernet switch. When the information in this
chapter refers to connecting a laptop PC to the scanner LAN switch, you will have
to disconnect any currently connected cable and connect the laptop instead or
connect using wireless interface. If available, a simple locally sourced network
switch may be used temporarily for connecting the laptop along with the existing
connection.
3.1. Hardware Overview
The exact model of the MSS supplied with the scanner may change over time.
The minimum requirements of a typical MSS computer are:
at least 1GB of RAM
Solid State Drive (SSD) 64GB in size
duo core CPU running at 1.5GHz or higher
two 100 or higher Mb/s Ethernet cards
one serial port
PCI slot for wireless cards (if applicable)
monitor, keyboard, and mouse (required only for troubleshooting)
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fully Linux operating system compatible
The CPUs are generally shipped without the internal solid-state SATA drive.
There are kits that contain the CPU, drive, installation DVD and mounting
hardware.
The mounting screws for the MSS flash drive must be nylon or other insulating
material because some drive manufactures connect the 24V return to the chassis.
It is also important that the case of the disk drive does not contact the mounting
plate. These checks prevent accidental connection of the head power supply
ground to the frame which can result in measurement errors.
The MSS runs the Linux operating system (Ubuntu 14.04.1 in R20x release and
Ubuntu 10.04.3 in R10x release), which is preloaded to the flash drive by
Honeywell. When the MSS starts, it does not load any software from the QCS
server, nor does it contact the server for IP address information.
Some of the software on the MSS is licensed under the GNU Public License
(GPL), a copy of which is included with the Experion MX license. Copies of
software that have been modified and are subject to the GNU license are
distributed with the scanner software. See the scanner software release section in
Chapter 1. Source code to the remaining GPL licensed code may be obtained at
http://www.ubuntu.com.
It is possible to temporarily replace the MSS with alternative hardware by moving
the hard drive to a new machine. However, the hardware (in particular the
Ethernet and graphics cards) must be supported by the version of Linux installed
in the MSS. Although most standard desktop PCs on the market are supported,
PCs containing hardware designed after the release of the operating system may
require drivers that are not part of the installation.
A switch is not required between the MSS and the QCS server unless there are
multiple scanners interfacing to the same server.The CAT 5e cable connecting the
MSS and the QCS server if there is no switch in between can be either crossover
or straight.
MSS Ethernet cards are configured to run in auto-negotiation mode and the
switch/server port connected to the MSS must also be configured in auto-
negotiate mode. Setting any switches or server ports directly connected to the
MSS to fixed 100Mb/s full-duplex causes network failures, as the auto-
negotiating partner may default to half-duplex resulting in duplex mismatch issue.
The status of the Ethernet speed and duplex settings can be checked using the
MSS web interface.
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3.2. Q4000 MSS hardware
The exact model of the MSS supplied with the scanner may change over time. At
program release, the hardware was Advantech UNO-2182. Currently, it is the
NISE 2100 from NexCom.
3.2.1. Advantech UNO-2182 model
Figure 3-1 Advantech UNO-2182 MSS
The Advantech UNO-2182 model comes without a drive (drives are normally
installed when the scanner is built). It can be installed by removing the six screws
on the back plate. The drive is attached to the plate with four screws.
The screws must be nylon or other insulating material because some drive
manufactures connect the 24V return to chassis and this would ground the
Q4000 lower head power supply to the frame.
The SATA serial cable and the SATA power cable, which are both part of the
Advantech UNO-2182 kit, must be installed.
There are two Ethernet interfaces labeled as LAN1 and LAN2:
LAN1 should be connected to the QCS server.
LAN2 should be connected to the scanner endbell switch.
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The following BIOS settings on the Advantech UNO-2182 are be configured.
1. Take the scanner off-sheet and press scanner stop button.
2. Connect the monitor and keyboard to the MSS CPU in the scanner
endbell.
3. Recycle power to the MSS CPU, using either the main scanner power
or by temporarily removing the +24V fuses connected to the MSS in
the endbell (preferred, since this leaves the sensors on).
4. Immediately after power up, press the Del key multiple times to force
the CPU into the BIOS menu.
5. Navigate to the “Standard CMOS Features’ setting, choose ‘Halt On’
and set the value to ‘No Errors’.
Figure 3-2 Advantech UNO-2182 BIOS Settings – Halt On
6. Navigate to the ‘Advanced Chipset Features’ setting, select Boot
Display and set the value to CRT.
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Figure 3-3 Advantech UNO-2182 BIOS Settings – Boot Display
7. Press F10 to save and exit. The MSS will restart automatically.
3.2.2. NexCom model
Figure 3-4 NexCom MSS
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NexCom NISE 2110A is the current MSS computer shipped with the Q4000
scanner. The disk drive can be installed by removing the large top cover plate and
then the disk mounting plate.
It is important that the case of the disk drive does not contact the mounting plate.
At the time of writing, NexCom was supplying a special mounting bracket with
an insulating plastic layer. Verify the counter-sunk screws do not touch the metal
bracket or use plastic screws.
In the NexCom MSS, the network port labeled “1” is the sensor LAN port
connecting to the end bell switch and the network part labeled “2” is the server
LAN port connecting to the QCS server. Typically Honeywell puts more explicit
labels on top of these OEM labels to avoid confusion.
There are no switches or special BIOS settings for this model.
3.3. CWS 408x scanner, rubber and metals thickness MSS hardware
3.3.1. Fit-PC2i model
Figure 3-5 Fit PC-2i MSS
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The Fit-PC2i model comes without a drive, which is normally installed when the
scanner is built. It can be installed by removing the four screws on the back plate
(the drive is attached to the plate with four screws).
There are two Ethernet interfaces, labeled as Eth1 and Eth2:
Eth1 on the MSS should be connected to the QCS server.
Eth2 should be connected to the scanner endbell switch.
There are no switches or other settings on this model under consideration. Fit-
PC2i requires 12V DC power.
3.4. Q309x MSS hardware
3.4.1. Advantech ARK-1122 model
Figure 3-6 Advantech ARK-1122 MSS
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At the time of program release, Q309x scanners are shipped with Advatech ARK-
1122 computer as the MSS. This computer has integrated flash hard disk which
cannot be removed.
The LAN ports on either side of this model and does not have any OEM labeling.
Honeywell will be putting explicit labels to identify the sensor and server LAN
ports. The LAN port on the side where antennas are mounted is the server LAN
port which should be connected to the Experion Mx server. The other side where
power supply connection is also has the sensor LAN port which is not typically
connected to anything. This port is bridged with the wireless sensor LAN
interface and can be used for connecting diagnostics devices.
There are no switches or other settings on this MSS model. Advantech ARK-1122
requires 12V DC power connection. The wireless card on these models can be
accessed by removing the four screws on the bottom plate.
Figure 3-7 Q309x MSS Wireless Card
3.5. Initial factory software installation
Initial factory installation and restoration follow essentially the same procedure
and is applicable to all scanner series.
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Each system is shipped with a restoration DVD or USB flash drive containing a
compressed 4.2GB image of the 64GB MSS solid-state drive. Both media are
self-booting.
These media were created using the Clonezilla tool (www.clonezilla.org). The
media contain a Linux operating system that starts and restores the drives.
Recovery is easier from the USB flash drive because no external USB DVD drive
is required. However, the DVD may be transferred to a self-booting USB flash
drive (of at least 5GB capacity) using free tools available on the internet:
UNetbootin or Tuxboot (see Chapter 4).
To install:
1. Attach a monitor and keyboard to the MSS (a mouse is optional).
2. Insert the USB flash drive or attach the DVD drive and reboot the
MSS CPU by recycling either the main scanner power supply or by
using the fuses connected to the MSS in the endbell (the latter method
is preferred, since this leaves the sensors on).
The Clonezilla splash screen appears. See Figure 3-8 If the MSS was
booted from a USB, the start-up screen may look like Figure 3-8. In
versions prior to R200.1, a Honeywell logo splash screen appears as in
Figure 3-9. In all cases, select the default install option or the install
will start automatically when the timeout triggeres.
Figure 3-8 Standard Clonezilla boot up screen (R20x) (early version)
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Figure 3-9 Clonzilla start-up screen - USB install (R20x Release)
Figure 3-10 Modified Honeywell Clonezilla start-up screen (R10x)
If the screen appears blank, verify in the BIOS that the PC is set up to
boot from the DVD or USB drive as the first boot device. Also, verify
whether the SSD drive is detected by the BIOS.
Some USB flash drives get detected as USB hard disk drives. In these
cases, set the Hard Disk Boot Priority in Advanced BIOS Features
to give the USB drive a greater priority than the SATA hard disk drive.
3. Wait until the special, temporary Linux operating system boots.
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4. If the boot is successful, Clonezilla asks twice to ensure the
delete action it is about to perform.
Figure 3-11 Clonezilla Prompt to Copy MSS Image
Enter y both times to start imaging the drive. The entire
operation should take about 10 minutes (longer when using the
DVD install media) and removes all previous content from the
drive.
5. Remove the USB flash drive and reboot the MSS.
After booting with Linux installed, the screen may remain blank with a
small cursor at the top-left. This is normal. A login screen can be called
up by pressing the key combination [CTRL]-[ALT]-F2, through [CTRL]-
[ALT]-F8. This action generates a prompt displaying the message:
Ubuntu 10.14.1 LTS mss ttyx
mss login:
At this point MSS is up and running with full functionality. The MSS does not
boot into GUI mode by default.
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3.6. Setting the MSS type, IP address and time
After the initial image is created, the MSS has a default address on the Ethernet
port connected to the QCS server network of 192.168.10.101. If this is not the
correct address, it can be changed from the MSS Web address.
1. If the QCS server can temporarily be set up at the
192.168.10.* address, use the server to access the MSS Web
page as described in Subsection 3.7.1. Otherwise, connect a
PC to the scanner network or to the second MSS Ethernet
interface and browse to the fixed address of
http://192.168.0.1.
2. The present MSS IP addresses are always displayed on the
main MSS page. Use the Configure MSS (Network Settings
or Ethernet Settings in older releases) option on the left side to
set the MSS IP address and server IP address. Configure MSS
page allows to configure MSS Type also while in previous
releases, MSS Type must be set by selecting this option from
the left menu. See Section 2.8 Network Configuration for
details.
New IP addresses only take effect after a reboot.
3. From the main MSS Web page (see Chapter 6), use the Set
MSS Time option on the left hand side.
The MSS does not automatically correct for daylight savings time. It is
expected that the MSS clock will drift a few minutes per month
relative to the QCS server.
The absolute value of the MSS clock is not used to correlate scanner
data to scanner position; however, it is convenient if the time stamps
on the scanner logs correspond to the QCS server alarm page times.
Resetting the MSS time reboots all EDAQs on the scanner. This is to
avoid potential interlock failures when the local EDAQ clocks jump
forward or backward. The scanner should be off-sheet during any
clock settings.
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3.7. MSS software upgrade
The MSS and EDAQ files are released in tandem. At this time, they are released
by Honeywell Engineering more frequently than RAE releases. The release notes
explicitly state what RAE releases the EDAQ and MSS software are compatible
with. The two upgrade files, one for the MSS and one for the EDAQ, can be
downloaded from a site address provided by Engineering with the notification.
Refer to section 1.6 Software Releases for details about software upgrade image
packaging, naming and numbering conventions. .
3.7.1. Procedures
To upgrade the MSS software:
1. Press the Scanner Stop button on the endbell door to ensure that the
scanner is stopped.
It is important to stop the scanner, before proceeding, to
avoid unexpected head movement. For best safety practice,
lock out the scanner drive.
2. Copy the file mss-files.Rabc.n.SVNpqrs.tar.z to QCS server folder
C:\Program Files\Honeywell\Experion MX\MSS\SenLan\Images (this
is the recommended location for all versions, including previous
versions for roll back).
3. Access the Web interface using one of the following three methods:
Method 1: On the QCS server, navigate to the MSS Setup
Diagnostics tab (3a-1) and click MSS Monitor (3a-2). Select the
required MSS from the drop-down list. Click MSS Web Page (3a-
3). See Figure 3-12.
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Figure 3-12 MSS Diagnostic Page
For systems with multiple scanners, select the correct MSS first.
Method 2: On the QCS server, open Internet Explorer and
navigate to the MSS IP address. The IP address
http://192.168.10.101 is the factory default for the first scanner,
but this is site specific.
Method 3: Connect a laptop to the scanner LAN (one of the
scanner switches in the endbell or in the sensor head), open
Internet Explorer and navigate to the local MSS address which is
always http://192.168.0.1. This is not site specific and is the same
for all scanners on a machine.
After completing any one of the three methods, the page shown in
Figure 3-13 appears.
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Figure 3-13 MSS and EDAQ Info Page: Active Hosts
4. Click Update MSS on the left side of the page.
The Update MSS Image Page appears (see Figure 3-14). The Update
MSS button is grouped under MSS Functions in R10x releases.
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Figure 3-14 MSS and EDAQ Info Page: Update MSS Image
5. In the MSS and EDAQ Info Page, click Upload New Image to MSS.
6. Click Choose File (Browse… in previous versions) to identify the file
to upload, and navigate to the folder C:\Program
Files\Honeywell\Experion MX\MSS\SenLan\Images. Select the file
mss-files.Rabc.n.SVNpqrs.tar.z.
7. Click Upload and Burn. The upload will take only a few seconds.
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8. When uploaded, the page shown in Figure 3-15 appears. Ensure that
the correct (latest uploaded) version is selected, review the release
notes and click Update MSS.
Figure 3-15 Update MSS Image
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9. After approximately 25 seconds, the page shown in Figure 3-16
appears. Verify that the operation completed successfully by checking
the Revision Information After Update: textbox.
Figure 3-16 Revision Information After Update
10. Click Restart MSS to reboot the MSS. On the next page, choose
Hard Reset. The restart takes anywhere from 25–40 seconds. Release
the Scanner Stop button on the endbell door.
11. The MSS software upgrade is now complete. To verify that the new
code has been loaded and the MSS has restarted, click Home on the
left hand navigation bar.
The page shown in Figure 3-17 appears. The MSS is listed in the
Active Hosts list. This indicates that the MSS is running and
communicating.
In addition, the MSS source control revision number is shown. The
number coincides with the pqrs value in the file name that was
downloaded.
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Figure 3-17 MSS and EDAQ Info Page: Active Hosts list
Also on the page shown in Figure 3-17 is the present MSS revision number and
the revision date (as outlined in red in the Figure) near the top of the page.
3.8. Replace the MSS with a spare
This section describes the procedure for configuring the MSS after replacing it
with a spare MSS or with another SSD.
At a minimum, the MSS kits contain:
CPU
Solid State Drive (SSD) 32GB in size
base installation DVD
Hardware required:
USB-DVD drive
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A USB DVD player is required to program the MSS. Alternately, the
DVD can be used to create a self-booting USB flash drive (see Chapter
4), a one-time operation.
DVI or VGA monitor depending on the MSS hardware.
USB keyboard
+ 24V power supply (Q4000), or + 12V power supply (408x. Q309x)
Steps:
1. For the Q4000 MSS: remove the rear panel from the MSS and
connect the solid-state drive (two cables, one for power, one for SATA
serial data).
Use the plastic screws provided to mount the disk drive on to the rear
panel. This is important to avoid scanner grounding issues.
For the 408x, rubber and metals MSS: remove the four screws at the
back of the unit, removing the small cover plate. Slide in the new drive
until seated.
The first version of the Q309x scanner MSS (Advantech ARK 1122)
has integrated flash hard drive. Later versions may have removable
hard drive as in other scanner types.
2. Connect monitor, keyboard, DVD drive, and power to the MSS.
3. If the DVD does not boot up, enter the BIOS (using the DEL key) and
change the disk boot order, and, if required, the hard drive boot
priority.
4. Allow Clonezilla restoration software to boot up.
5. You are asked twice whether to continue the restoration. There are no
options. Copying from the DVD takes approximately 10 minutes.
6. Disconnect the DVD drive and test whether the MSS boots from the
internal SSD.
Verify that the IP address is correct, and upgrade the MSS to the revision running
on the previous MSS:
1. Press the Scanner Stop button on the endbell door to ensure that the
scanner is stopped. Disconnect Ethernet cables and un-mount MSS
from the scanner endbell.
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2. Connect a laptop to a scanner network switch. After obtaining a DHCP
network address, open Internet Explorer and navigate to the MSS web
page at http://192.168.0.1/.
3. The MSS-RAE measurement LAN (server LAN) address may be
changed to suit the site-specific needs. The server LAN address can be
configured using MSS Web interface (see Section 2.6 Network
Configuration).
4. Note the MAC address of the MSS displayed on the main page under
RAE LAN (eth0). This needs to be entered in MSS Setup page under
the MSS Setup Diagnostic tab.
5. Upgrade the MSS (see Section 3.7).
6. Install the MSS back on to the scanner end bell and release the
Scanner Stop button.
3.9. MSS troubleshooting
3.9.1. No MSS-RAE communication
If the MSS Summary Page (MSS Setup Diagnostic tab) does not have a green
light next to the appropriate MSS, or the MSS monitor page does not show
process DR events, then the MSS is not communicating with the Experion MX
system.
1. Verify the MSS has DC power (green LEDs at power connector on all
models). The Advantech UNO-2182 version also has a white power-
reset button (PWR) at the back of the unit that may be pressed to
restart the CPU as shown in Figure 3-18.
Figure 3-18 Rear View of the Q4000-80 Advantech MSS
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The NexCom CPU has a similar LED on the rear next to the power
button as shown in Figure 3-19.
Figure 3-19 Rear View of the Q4000-80 NexCom MSS
The 408x MSS has a green LED indicating whether power is applied.
Figure 3-20 FitPC2i MSS Power Switch and Lights
In Q309x Advantech ARK model, power LED is integrated to the power switch.
This LED lights amber when MSS is shutdown and turns green when MSS is up
and running.
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Figure 3-21 Q309x Advantech ARK Model MSS Power Switch and LED
2. Connect to the MSS Web page (see Subsection 3.7.1) and verify that
the page loads and shows the present IP addresses and MAC
addresses. Verify these against the Experion MX MSS IP setup page,
being careful to note that the Experion MX page uses dots
(unconventionally) to separate the hexadecimals in the MAC address
numbers.
The Experion MX MSS IP setup requires dot (.) characters to be used in between
MAC address fields in place of conventional column (:) characters. MSS-RAE
communication will not be initiated unless MAC address fields are delimited by
dots.
3. Connect to the MSS Web page. There should be a line labeled mss in
the Active Hosts table display. Verify when hovering the mouse over
the Process column that all listed processes show a green icon.
4. If the Web page is not accessible from the server, verify the network
connection: On the QCS server, use Start Run and enter ping
192.168.10.101 (adjust for proper local MSS address), and observe
status of the link. If there is no response the same test can be
performed from a laptop connected to the scanner network (use the
fixed address 192.168.0.1 for the ping test).
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5. If Step 4 fails, connect a keyboard, DVI or VGA monitor, and mouse
to the MSS and reboot. The page should show the BIOS status, then
briefly the Ubuntu boot page, and within 30 seconds, an empty dark
console (press [CTRL] - [ALT] - [F4] to obtain the login prompt,
which should say mss login:. A default username is evolution and
password is the same.)
6. If Step 5 shows the BIOS and initial Linux boot but still fails to result
in a working system, consider booting to the alternate partition (see
Section 3.7), or replacing the SSD disk and restoring the image as
described in Section 3.10.
7. If the MSS appears to be running, the web pages display, and all
processes (in particular, the emss process) are active, check the
MSSLink program is running on the QCS server using Windows Task
Manager.
8. Check that the host file on the QCS server contains the correct IP
address of the Ethernet interface connected to the scanner, with the
MSSLink alias (usually the entry would be in the form 192.168.10.1
MSSLink).
9. Check that the MAC address in the QCS server MSS IP setup window
is all lower case.
10. Free tools such as Wireshark can be used to monitor the network
traffic. They should be installed on the QCS server, otherwise the
traffic between the server and the MSS will not be captured.
There should be periodic UDP messages from the MSS to the QCS
server containing the MAC address of the MSS. This would indicate
that there is an issue with QCS server not responding. In that case, the
MSS (and EDAQs) write extensive log files that can be accessed
through the Web server (see Chapter 6).
Whenever possible, restart the MSS using the main MSS web page reboot
button, not by cycling power on the scanner. This reduces the chance of disk
corruptions and allows the system to perform periodic integrity checks.
3.9.2. Disk drive errors
The MSS uses a flash memory-based disk drive that has no moving parts and is
immune to vibrations, shock and power interrupts. In addition, the operating
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system uses a journaling file system that should, in most cases, recover open files
in case of sudden power loss. However, it can still lead to disk corruptions.
Normally, the operating system will detect these and attempt to fix the issues at
boot time. This might result in a delayed start, usually no more than 1-2 minutes
after power is applied. In severe cases, the operating system will mount the
partitions Read-Only to protect it from further damage. There have also been
cases (with one particular disk model vendor) where the disk became
unresponsive after weeks of running. The MSS continues to function but no log
files information is written and the web pages may become unresponsive.
The main MSS web page scripts will detect this fault and display the message as
seen in Figure 3-22:
Figure 3-22 Error message displayed when disk partitions change from
Read-Write to Read-Only
If the message in Figure 3-22 appears right after a reboot, restart the MSS from
the web page, allowing the system to go through a regular shutdown and restart.
If the message appears after the MSS has been running, the problem is a faulty
flash drive. A restart may fix the issue, but it is strongly recommended that a new
flash drive is ordered.
3.10. Alternate partition boot
Each MSS hard drive contains two identical images of the operating system and
applications. If the MSS boots but makes no connections to RAE, or if you
suspect that a recent upgrade caused issues, you can boot into the other partition.
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There are two ways to access the other partition. If the Apache Web server is still
running on the MSS, the main MSS Web page provides an option for setting the
next boot default to the other partition (see Figure 3-23).
Figure 3-23 Set Boot Partition
If the Web server cannot be contacted, the only option is to attach a monitor,
keyboard, and mouse, and to interrupt the MSS boot process by using the up or
down arrow keys. The display will briefly look like the display shown in Figure
3-24 (although the exact revision numbers of the Linux kernel may change).
Move the cursor keys to the second kernel image containing the text (on
/dev/sda7) as shown in Figure 3-24. The Linux version will be 3.0.0-26 in R20x
release versions.
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Figure 3-24 MSS Boot Loader Display
On the display shown in Figure 3-24, all the references above Memory test refer
to boots into the same partition. Boot options to the second partition are indicated
with partition name, in this instance /dev/sda7. The memory test option may also
be run as a diagnostic.
Select the last line on the screen shown in Figure 3-24, and the MSS boots into
the previously unused partition. This will not automatically be the default for
subsequent boots. To set the new partition as the default, bring up the MSS Web
page and click Set Boot Partition to bring up the Web page, as shown in Figure
3-23, and use this to set the new partition as the default.
Update the MSS to the latest revision, or to the revision used before the troubles
began.
The other partition likely has the factory default IP address for the MSS
(192.168.10.101) set so that the MSS Web page is accessed from within the
scanner network (connect a laptop to the endbell switch). Bring up the fixed MSS
IP address page (http://192.168.0.1), and the IP set address set using the Set
MSS IP function on the Web page.
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3.11. MSS wireless capabilities
Only FitPC2i and Advantech ARK 1122 MSS are shipped with wireless
hardware. Advantech ARK 1122 is used in Q309x scanners and the wireless card
is dedicated to be used as scanner LAN interface only. FitPC2i has built-in
wireless card. An add-on PCI wireless card may be installed in NexCom models.
Contact Honeywell for supported wireless card models. Wireless in these models
can be bridged with either the server LAN or the sensor LAN for diagnostics
purposes. See section 2.6 Network Configuration for details.
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4. Back up and Clone the MSS
If a recent installation DVD (or the ISO file for that DVD) is available, there is
little reason to create an MSS backup. Except for the assigned IP address and the
log files that accumulate there is nothing scanner- or system-specific on the MSS
hard drive. It is therefore recommended that an MSS be restored by taking a base
install image prepared by Honeywell Engineering and installing the latest MSS
release on top of that. Base install image release is R106.4 as of the release of this
manual. Similarly, if a spare disk is required, make it from the base install plus the
latest update files.
Currently, three DVD part numbers exist:
Honeywell Part 6543210114 is version 3 and the latest.This DVD
contains R200.1 as the base image. This DVD can be used in scanners
that will be running R20x release.
Part 6543210088 is version 2 and contains R106.4 as the base image.
This DVD should be used only in scanners running R10x releases
only.
Part 6543210058 is version 1 and is usable only on older MSSes with
32GB disk. Use of this part is discontinued and any MSS with 32GB
hard disk should be upgraded to use the latest flash disk.
Restore a broken MSS by plugging in a USB DVD player. A monitor and
keyboard are required. The MSS BIOS setting may have to be adjusted to boot
from the DVD drive. The live DVD boots to Linux, and asks you whether you
want to over-write the hard disk drive. Answer y to both questions. For details,
see Section 3.5.
In addition, the ISO file may be turned into a bootable USB flash drive using
programs such as UNetbootin http://unetbootin.sourceforge.net/ or Tuxboot
http://www.tuxboot.org. This eliminates the use of a USB DVD player. This
procedure is described in Section 4.1. This is a one-time operation – this USB
drive can now be used to create new MSS within minutes.
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This chapter applies to all MxProLine scanner series and CWS sensors.
4.1. Create a self-booting MSS installation USB flash drive
On a Microsoft Windows PC, use a program (for example, Roxio, 7-Zip) to create
a ISO disk image from the Honeywell MSS installation DVD. The resulting file
has a file extension of .iso or .gi, and is approximately 4.2GB.
Alternatively, obtain the .iso file directly from Honeywell Engineering. The
following instructions assume the use of UNetbootin, but TuxBoot has a very
similar interface.
1. Download the latest UNetbootin. This description is based on
Windows version 5.49 (http://unetbootin.sourceforge.net/unetbootin-
windows-latest.exe).
2. Connect the USB flash drive (4GB or greater) that is to be made into a
bootable drive to a computer, and start UNetbootin (see Figure 4-1).
Figure 4-1 UNetbootin Main Page
3. Point the Diskimage to the .iso file, and select the USB drive.
4. Click OK to start the process, which can take 10 minutes or more.
Restart the computer at the end of the process to test starting from the
new USB drive.
Experience has shown there is some variability in the types and default formatting
of USB flash drives. Most boot as flash devices, but some boot as disk drives and
often require a change to the BIOS settings (hard disk boot priority) to become the
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default boot device. Finally, try using TuxBoot rather than UnetBootin if the USB
drive fails to boot.
A few types and brands fail to start at all, so if there are problems try a different brand
and size before assuming there is a problem with the ISO image.
4.2. Back up the MSS hard drive
This procedure is not recommended. Consider instead creating a bootable USB
flash drive from the installation media .iso file described in Section 4.1. Create
new MSS disks by using the installation media, boot the MSS and upgrading it to
the required software release.
If an image of the MSS is still required, it can be done using any third-party
software that supports the Linux ext3 and ext4 file systems; check the
documentation. The following documentation describes the process using the
open-source Clonezilla program, which may be used to back-up any Windows- or
Linux-based drive. It has the unique capabilities of making a self-booting
restoration image on a USB flash drive, or on a DVD.
The required software packages Clonezilla and UNetbootin can be downloaded
for no cost from the respective Websites.
Hardware required (in addition to the MSS):
two USB flash drives
DVI capable monitor (or VGA/DVI cable)
USB keyboard
USB hub or a monitor with USB ports (MSS has only two USB ports,
and this procedure requires three USB devices to be connected at one
point)
Backup image size of a typical MSS factory installation is about 3GB. One of the
USB drives needs to be big enough to hold three times the MSS image size.
Ensure that there is no data on these drives as it may be lost by the actions
performed in the procedure.
Follow these steps:
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1. Create a Clonezilla USB boot drive (see Subsection 4.2.1). This is a
one-time operation and can be re-used for creating additional backups.
2. Boot the MSS using the Clonezilla USB boot drive, and create a
backup image of the MSS hard disk on another USB drive (see
Subsection 4.2.2).
3. Create an ISO recovery file from the MSS backup image. A recovery
ISO file can be created on the same USB drive (see Subsection 4.2.3).
4. Create the MSS restore USB drive using the recovery ISO file and
UNetbootin (see Subsection 4.2.4).
To create an MSS backup follow Steps 1 and 2. Steps 3 and 4 enable the creation
of a self-booting restoration image. This is not strictly required, an MSS disk may
be re-imaged from the backup files by re-running Clonezilla. The self-booting
image created in Steps 3 and 4 has the advantage of being entirely self-contained,
and requires no additional technical skill from the operator.
4.2.1. Create a Clonezilla USB flash drive
1. Download Clonezilla ISO image.
This description is written based on the maverick version dated
28/03/2011 which can be downloaded from
http://sourceforge.net/projects/clonezilla/files/clonezilla_live_alternati
ve/OldFiles/20110328-maverick/clonezilla-live-20110328-
maverick.iso/download.
2. Download the latest UNetbootin.
This description is based on Windows version 5.49
(http://unetbootin.sourceforge.net/unetbootin-windows-latest.exe).
3. Connect the USB drive that is to be made into a bootable drive to a
computer, and start UNetbootin (see Figure 4-1).
4. Point the Diskimage to the Clonezilla ISO file downloaded in Step 1,
and select the USB drive.
5. Click OK to start the process. Restart the computer at the end of the
process to test starting from the new Clonezilla USB drive.
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4.2.2. Create a backup image of the MSS hard disk
To create a backup image of the MSS hard disk:
1. Connect the monitor, keyboard, and Clonezilla USB boot drive to
MSS, and restart MSS.
2. In order to ensure the boot sequence is set correctly, press DEL
(multiple times), when the restart screen appears, to enter into the
BIOS settings.
3. Enter Advanced BIOS Features, and ensure that the first boot device
is USB-ZIP, and the second boot device is Hard Disk.
Some USB drives (even flash drives) are detected as a hard drive by
the BIOS. In these cases, the USB drive must be configured with a
higher boot priority than the internal hard drive.
To do this, select Hard Disk Boot Priority and see whether the
Clonezilla USB boot drive appears in that list. The internal hard drive
typically appears as a Kingston device.
If there is drive listed below that, press PAGE-UP to bring it above the
internal hard drive.
Press F10 to save the settings and reboot.
MSS now starts using Clonezilla USB drive and shows boot options.
4. Select Clonezilla-live (Default settings...) and press ENTER. It takes
up to a minute before the screen changes to show the boot is in
progress.
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5. Clonezilla (see Figure 4-2) prompts for a number of options, most of
which have default answers as shown in Steps 6–10 (use the arrow
keys to choose to cancel at any prompt).
Figure 4-2 Clonezilla
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6. Select language: en_US.UTF-8 English.
7. Select policy for handling keymaps: Don’t touch keymap.
8. Start Clonezilla.
9. On the next screen, select: device-image.
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10. Select local_dev (such as the USB drive to backup to).
Figure 4-3 Mount Clonezilla Image Directory
11. A message will appear at the bottom of the screen prompting you to
connect the USB device. Connect the USB drive on which the backup
image is to be created and wait until a couple of (cryptic) lines are
displayed indicating the USB device is detected by the system (shown
in Figure 4-3 as [ 107.586525] sd 3:0:0:0:0 [sdb] Assuming
drive cache: write through, indicating the target device has
obtained drive letters sdb).
12. Press ENTER to continue.
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13. At the next prompt, scroll down to select the USB drive as the target
(copy to-) drive, typically mounted as sdb1 or sdc1, but never sdaX,
which is the source drive.
Clonezilla displays the first level of directories in the target USB drive.
14. Select a directory where the image needs to be created, if needed. You
may leave it at the top level as Clonezilla creates a directory by
default.
The example in Figure 4-4 was created using an empty USB flash
drive and there were no sub-folders.
Figure 4-4 Clonezilla (directory)
Clonezilla displays the disk space usage (not shown).
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15. Press ENTER to continue. Answer further prompts and options as
shown in Figure 4-5. Select Beginner.
Figure 4-5 Mode Wizard
16. Select savedisk.
17. If required, edit the name of the destination image folder.
18. Select the source disk. There should be only one disk option in the
MSS, sda.
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Clonezilla asks for confirmation before proceeding to make the image.
The backup process takes approximately 10 minutes to complete.
19. When finished, check for any error messages and press ENTER to
continue.
You now have a set of backup files that can be used to restore the MSS, and the
steps in Subsection 4.2.3 need to be completed only if you want to create a self-
booting restoration image.
4.2.3. Create a self-booting restoration image
1. Select Start over in Step 20 of Subsection 4.2.2 to continue to the next
step of creating recovery ISO file, or reboot the Clonezilla USB flash
drive.
2. Boot MSS using Clonezilla USB boot drive as described in Subsection
4.2.2.
3. Select all options described in Subsection 4.2.2, but in Step 16, instead
of choosing savedisk, choose recovery-iso-zip.
4. From the list of presented folders, select the backup folder created in
Section 4.2.2
5. On the next screen, for the device to be restored, accept the default.
6. Accept defaults for the next two screens that suggest keyboard and
language.
7. On the next screen, select Create ISO file when asked for the type of
file to create.
8. Ignore the warning about exceeding the size of a regular CD image.
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9. The program now creates the self-restoring ISO image in your USB
folder. The image will be about 2.5GB so the flash drive should have
at least that much free space.
4.2.4. Copy image to DVD or USB flash drive
The ISO image file created may be used directly to create a bootable DVD, any
number of programs may be used to burn it.
Alternatively, the ISO file may be used to create a self-booting USB flash drive
by following the procedure described in Subsection 4.2.1
4.2.5. Restore MSS from USB flash drive
A BIOS change might be required to force the MSS to boot from the newly
created USB flash drive (or the DVD). The restoration is the same as described in
Section 3.3.
4.3. Clone the MSS to a virtual machine
The MSS installation image, or the recovery ISO file, can be transferred to a
virtual machine (VM):
1. Use the usual VMware procedure to create a new machine, defining a
SCSI or SATA (not IDE) disk of at least 64.5GB.
2. Direct the VM to boot off the DVD or its corresponding ISO file and,
as during a restoration, Clonezilla copies the MSS image to the VM
disk.
3. Restart.
This simple procedure works as the Linux image contains all known hardware
drivers and will rediscover the new (virtual) hardware at boot time.
The challenging part is mapping the virtual Ethernet devices onto the appropriate
(physical) hardware so that the IP addresses the MSS assigns (192.168.0.1 to
interface 2 and 192.168.10.101 to interface 1) connect to the appropriate real
network. This requires VMware network configuration tool, which is not supplied
with VMware Player. A VM version of the MSS is therefore of limited use in the
field.
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5. EDAQ
The EDAQ board is responsible for converting all analog and digital signals to
and from sensors to Ethernet.
It replaces the functionality of the National Instruments™ cards seen in previous
Honeywell scanner systems.
The board is based on an ARM CPU running the Linux™ operating system and a
Field-Programmable Gate Array (FPGA) that controls real-time data acquisition.
The EDAQ contains software licensed under third party licenses including the
Gnu Public License (GPL). A copy of that software and its source code can be
obtained from Experion Mx Scanner Software release media or by contacting
Honeywell.
The EDAQ board contains a large number of I/O systems, including:
analog inputs (16 inputs of 12 bits @ 4kHz and 8 inputs of 10 bits @
1Hz)
analog outputs (2 @ 12 bits)
digital inputs (16 @ 24V logic)
digital output (16 @ 24V logic)
frequency input (60Hz to 500kHz)
Three serial ports
USB
Ethernet
Wireless Ethernet (using a qualified USB dongle)
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Except for a few dedicated signals such as the green light (radiation safety), all
sensor signals connect through the EDAQ to the new Experion MX MSS by
Ethernet.
The EDAQ contains sensor specific code for all sensors at all times. All EDAQs,
including the EDAQ performing frame motion control (in the endbell) and the
head alley EDAQs are identical and can be interchanged. EDAQs of the same
revision may be exchanged between also between metals or rubber sensors or
scanner.
As shown in Figure 5-1, all the high speed data acquisition components connect to
the FPGA. The ARM CPU controls the USB, serial, slow analog inputs, and
Ethernet.
Figure 5-1 Schematic Overview
Almost everything in this chapter is generic to the EDAQ and applies to all
applications. Where the text refers to EDAQs in the scanner head, these would be
the EDAQs in endbell for the 408x scanner.
EDAQ Physical layout
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5.1. Physical layout
Figure 5-2 and Figure 5-3 show the EDAQ PCBA. On the left are the digital and
analog I/O, which connect directly to a sensor. Below these two large connectors
is a 16 pin expansion connector that is only used when the EDAQ is attached to
the FC expansion board.
Figure 5-2 EDAQ Board (top view)
To the right are Ethernet port, some diagnostic LEDs, serial connections, and
temperature inputs. There are no test points for use in the field.
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Figure 5-3 LEDs and I/O Connectors (EDAQ board, upper right corner)
A serial debug port is available (115200KBS, no flow control, 8N1) that may be
connected to any PC running a serial terminal program. For diagnostic purposes,
service personal may be asked to connect a serial cable between this debug port
and the RS232 of any neighboring EDAQ.
5.1.1. Hardware status information
There are four diagnostic LEDs on the EDAQ. See Figure 5-3.
The 3.3V LED: When lit, indicates that all power supplies on the board
are functional. The signal is derived from the 3.3V power supply,
which in turn is derived from the 15V power supply, which is derived
from the + 24V input.
The CPU OK LED: This LED is under control of the central ARM
CPU. It is lit when the main sensor application (edaqapp) is running on
the CPU.
The FPGA OK 1 (not currently in use).
EDAQ EDAQ reset
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The FPGA OK 2: This LED will blink if the FPGA is loaded and
running code.
In addition, the Ethernet connector contains two LEDs, with amber indicating
good link to the switch, and green indicating activity on the network.
5.2. EDAQ reset
A soft reset of the EDAQ may be performed through the Web interface running
on the scanner Measurement Sub System (MSS). This interface may be accessed
from a real-time application environment (RAE) station as indicated in Subsection
3.5.1.
A hardware reset can be performed by pressing the white button next to the debug
port. This resets both the CPU and FPGA and is equivalent to a power on/off.
5.2.1. EDAQ boot sequence
The EDAQ boot takes about 25 seconds, depending on whether it finds a valid
position location resistor on the digital I/O harness.
During reboot, the EDAQ performs these steps:
1. Load the Linux operation system.
2. Read the Position & Function identification resistors.
3. Determine the IP address and call up the network interface.
4. If (no identification found) request address from DHCP server.
5. Start the time synchronization client process.
6. Start the Web server.
7. Load the FPGA with the appropriate VHDL code for data acquisition.
8. Start the generic EDAQ application (edaqapp). This will load sensor
specific functions if required.
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5.3. EDAQ sensor identification and IP addressing
All EDAQs are identical. EDAQs can be freely interchanged between sensors and
the scanner endbell.
Each EDAQ contains all the code for all supported sensors and loads the
appropriate software depending on the identification ID code read at boot time.
The EDAQ software includes firmware for the FPGA chip that handles the data
acquisition. Most sensors run the same firmware but there are presently about four
different files loaded into the FPGA depending on the application.
Two resistors are used to uniquely identify the EDAQ functions.
In the Q4000 series scanner, for sensor-connected EDAQs, there is a sensor
model resistor embedded in the cable harness connecting the sensor to the EDAQ.
This resistor determines the function code. Function codes are unique for each
sensor model that needs to be differentiated by the EDAQ. For example, all
Source 9 094201XX Basis Weight Measurement Sensors presently have the same
function code, regardless of radioactive isotope. The table of resistor values, their
tolerances and associated functions is available from the main MSS Web page.
In addition, the head power distribution board connects a resistor value to each
port (sensor module platform) that determines the position of the EDAQ in the
head. The EDAQ can therefore self-identify both its position and function. See
Section 7.3 for the number convention of the six-pack head.
In the 408x scanner the sensor model resistor is part of the sensor complement
dependent harness between the EDAQ and the end-term board. The position
identifying resistors are fixed and part of the endbell-terminal PCB.
For all scanner models the FC-EDAQ reads both resistors directly from the
terminal block TB2, part of the FC expansion board.
For the metals C-frame and rubber sensors, the resistors are part of the harness
connecting the EDAQs to the signal terminal blocks.
Every EDAQ has a unique IP address on the scanner network. If the EDAQ can
identify its position, it will set its IP address to 192.168.0.XYZ (where XYZ is the
position number in the head. The FC-EDAQ always sets itself to IP number
192.168.0.2. The MSS is always 192.168.0.1 on the scanner network.
If an EDAQ fails to determine a position, it requests an address from the local
DHCP server (which is presently running on the MSS). Similarly any laptop will
get an IP address once plugged into any of the scanner Ethernet switches.
EDAQ Upgrade EDAQ software
P/N 6510020381 Rev 03 4/1/15 5-7
If there is no DHCP server available (for example, the MSS is powered down)
and there was no other method of identification, the EDAQ eventually assigns
itself the IP address 192.168.0.99, which can take up to five minutes. In that case,
no sensor applications are started up, but the web server can be contacted to
obtain diagnostics or to set the IP address by hand.
Although the EDAQ should be able to correctly assign its position, there may be a
need to hard code this value (see Chapter 7).
5.4. Upgrade EDAQ software
This section applies to all scanner models. To upgrade the EDAQ software, a file
named edaq-files.Rabc.n.SVNpqrs.tar.z must be loaded to the MSS. The MSS
extracts a number of files to be transferred to the EDAQ flash memory.
In the filename:
abc The major scanner software release number.
n The maintenance update number as referenced in Experion MX release documentation.
pqrs Correspond to the technology source control system numbers.
See Section 1.6 in chapter 1 for more detailed description of release numbering.
Upgrading an EDAQ is a two part process. In the first part, the image is
transferred to the scanner MSS. In the second part, the EDAQ copies individual
files from the MSS and burn them to its flash partition.
To upgrade EDAQ software:
1. Press the Scanner Stop button on the endbell door to ensure that the
scanner is stopped.
Lock out the scanner before proceeding to avoid unexpected head
movement.
2. Copy the file edaq-files.Rabc.n.SVNpqrs.tar.z to QCS server folder
C:\Program Files\Honeywell\Experion MX\MSS\SenLan\Images. This
is the recommended location for all versions (including previous
versions for roll back).
3. Access the MSS Web page (see Section 1.5) and click Update.
EDAQs.
Experion MX MSS & EDAQ Data Acquisition EDAQ
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The MSS web interface uses Javasripts to display and hide user interface elements
as different options are chosen.
Ensure that active scripting is enabled in the security settings of the browser for the
proper display of MSS web interface.
Figure 5-4 appears. In new releases, Update EDAQ and Update MSS
are grouped together at the top of the left menu.
Figure 5-4 EDAQ Update Display
4. To copy the new EDAQ files to the MSS, select the Upload New
Image from local PC to MSS for burning (use Browse button) option.
5. To identify the file to upload, click Browse… and navigate to the
folder C:\Program Files\Honeywell\Experion
MX\MSS\SenLan\Images\edaq. Select the appropriate file, for
example, edaq-files.Rabc.n.SVNpqrs.tar.z.
EDAQ Upgrade EDAQ software
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6. Click Upload EDAQ Image. Figure 5-5 appears.
Figure 5-5 EDAQ Second Update Display
7. Select the EDAQs to be upgraded (usually Reburn Root File System
and Reburn Kernel).
The required options below the EDAQ list are automatically populated
(these include Reburn Root File system sometimes Reburn Kernel).
The Web page provides details and recommended defaults for these
options.
The Copy Motion Setup File applies only to the FC-EDAQ. For RAE version
R602.0 and above, copying this file to the new image is not necessary since it is
entirely populated from the RAE RTDR. For RAE versions R600.0 and R601.0,
the Q4000 UPI/HMI panel settings are recorded here and the checkbox should
be selected. See step 8 for the Reburn Kernel option.
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8. Some upgrades include a new Linux kernel, the core of the operating
system. The release information explicitly states this and in this case,
the Reburn kernel option is automatically checked.
9. Some upgrades require a previous revision level. For example,
upgrades for version higher than R101.0 required first an upgrade to
R101.0. This is because upgrades may include one-time changes (such
as a Linux kernel change), not supplied again with the next revision.
This will be explicitly stated in the release notes.
10. Click Burn Image to EDAQ. When the progress messages are done
(after approximately 60 seconds), the list of EDAQs is redisplayed.
A warning message, Permanently Added… (see Figure 5-6) may appear for
some or all of the EDAQs. This message is related to the secure shell (SSH)
communication to the EDAQ and can be ignored.
Figure 5-6 EDAQ Third Update Display
11. Reset the EDAQs by clicking Hard Reset at the end of the EDAQ list.
EDAQs may also be reset by selecting the Reset EDAQ’s option on
EDAQ Upgrade EDAQ software
P/N 6510020381 Rev 03 4/1/15 5-11
the leftmost side of the page (see Figure 5-7). Use Hard Reset to
reboot the EDAQs into the newly flashed partition, completing the
process.
Figure 5-7 EDAQ Reset Display
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12. To verify that the EDAQs successfully rebooted, go to the home page.
The EDAQs are present in the list of Active Hosts, and the Process
Status has a green indicator signaling success (see Figure 5-8).
Figure 5-8 MSS Main Page After Update
The EDAQ software upgrade is now complete.
1. To verify that all EDAQs are now running the expected version, click
Detailed EDAQ Info (under EDAQ Functions on the left panel of
Web page).
EDAQ Upgrade EDAQ software
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After approximately 60 seconds, a table is created on the screen showing the file system revision
number in the second-to-last column (see Figure 5-9
2. Figure 5-9).
Figure 5-9 Typical Detailed EDAQ Display
Experion MX MSS & EDAQ Data Acquisition EDAQ
4/1/15 P/N 6510020381 Rev 03 5-14
In the example shown in
Figure 5-9, only three of the four EDAQs were upgraded to the rev
R100.8.
3. On the Operation Station, click Scanner Control.
4. Click Restart MSS to clear sensor safety fault and do a Send Kill from
the MSS diagnostic tab, MSS Monitor Vi. This will also re-download
the RAE scanner motion parameters to the FC.
5.5. Replace EDAQ with a spare
A spare EDAQ ordered from Honeywell Engineering contains initial
programming, but it may not be the same revision version of the other EDAQs
running on the scanner.
The version could be newer, but it is possible that it is not compatible with
previous version. For example, from time to time, the data format used to
exchange messages between EDAQs may be changed.
To avoid any issues, the spare EDAQ should be upgraded or downgraded to the
major revision level of rest of the system.
To change the version of the spare EDAQ:
EDAQ Upgrade the spare EDAQ
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1. Use the MSS display Detailed EDAQ Info option on the left hand side
to obtain a list of revisions on all EDAQs. An example would be R100.4.
2. Connect the EDAQ to the scanner network. Connect the sensor harness to
make sure the EDAQ identifies correctly. If a sensor harness is not
available, the EDAQ will use DHCP (see Section 5.3).
3. Use the upgrade procedure described in Section 5.6. The upgrade file is
probably already on the MSS, so in step 4 choose Use existing EDAQ
image already on MSS.
4. If the desired version is not listed in the resulting drop-down menu, check
the RAE files system under c:\Program Files\Honeywell\Experion
MX\mss\SenLan for the EDAQ installation file. Contact Honeywell
Engineering if the files (size about 50 MB) are not found.
5. After programming and rebooting, repeat Step 1 to ensure all EDAQs are
running the same revision.
6. If the EDAQ is used for ferro-resonant caliper sensors, make sure the W1
jumper (freq) is in. There are no other configurable items on the EDAQ.
See Section 5.6 for upgrading an EDAQ without replacing an existing one.
5.6. Upgrade the spare EDAQ
If the site has any spare EDAQs they can be upgraded when they are placed in the
head. In the EDAQ Update display (see Figure 5-4), choose Update EDAQ
From Existing Image already on MSS because the required image was
previously uploaded in this step and will remain on the MSS forever.
Alternatively, the EDAQ can be prepared prior to installation. The safest
approach is to use a spare MSS:
1. Connect the MSS, EDAQ, and a regular PC to the second Ethernet
interface (the scanner LAN interface) using an available switch. Set up
the PC to obtain an IP address automatically (DHCP).
2. Bring up a browser and navigate to the MSS Web page at the
permanent address http://192.168.0.1.
3. The new EDAQ appears on the Web page with an address in the range
192.168.0.20 to 192.168.0.50. Follow the steps described in Section
5.4.
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4. If no spare MSS is available, the new EDAQ can be connected to +
24V at the scanner endbell and connected to the Ethernet switch in the
endbell. However, you must be sure that this EDAQ has not previously
been hardcoded with an IP address that might clash with existing
EDAQs in the head, or FC, to avoid IP address clash, which will halt
the scanner.
5. A newly-ordered EDAQ will not have a hard-coded identity. Navigate
to the MSS Web display (see Section 5.5) and upgrade using this
upgrade procedure, selecting only this new EDAQ for upgrade. This
can be done with the scanner running in production environment.
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6. Obtain Status Information
This chapter applies to all scanner and sensor models. Where appropriate,
separate screenshots are provided for the various scanner models.
6.1. Experion MX platform
An overall status page is available from an Operation Station under the MSS
Setup Diagnostics tab. Select the MSS Summary page. Figure 6-1 and Figure
6-2 show, on the left, a list of all expected EDAQ boards with three types of status
indicators (from left to right).
Figure 6-1 408x Scanner
Experion MX MSS & EDAQ Data Acquisition Obtain Status Information
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Figure 6-2 Q4000-80 Scanner MSS Summary page
Table 6-1 describes the MSS Summary page status indicators and their meaning.
Table 6-1 Status Indicators and Descriptions
Column Description
MSS Communication with EDAQ EDAQ is communicating (through the EDAL protocol) with the MSS
EDAQ Data Timestamps Data that the MSS is expecting from that EDAQ is being supplied at the expected rate
EDAQ Card Safety Status EDAQ is not reporting any errors such as interlock or motion control issues
Sensors that are part of the RAE database, but are not enabled on the scanner,
appear in the left-most column indicator as red (for example, 07-p caliper upper
in Figure 6-2).
Obtain Status Information MSS and EDAQ web pages
P/N 6510020831 Rev 03 4/1/15 6-3
6.2. MSS and EDAQ web pages
6.2.1. Access to the web page
More detailed information is available on the MSS and the EDAQs, which all run
Web servers and can display server pages containing information on the state of
the system. As a general rule, consult the MSS Web pages first. They are
accessible in several different ways:
from the server or Thin Client Op Station: navigate to the MSS
Diagnostic tab, click MSS Monitor, select the appropriate MSS and
click MSS Web page.
Open a browser on any computer connected to the Experion MX
server level network and enter the URL: http://192.168.10.101 (the
first MSS on the LAN) or the address set up for the MSS in the
Experion MX system.
Open a browser on any computer connected to the scanner endbell
LAN switch and enter the URL: http://192.168.0.1.
Log on to the MSS computer native console.
When neither RAE nor a laptop are available, access the MSS Web interface
through the MSS console at the CPU:
1. Connect a monitor with a DVI interface, a USB keyboard, and a USB
mouse, to the MSS.
2. Press [CTRL]-[ALT]-[F2] to access the login prompt.
3. Login using the following credentials:
Username: evolution
Password: evolution (case sensitive)
4. Enter the command startx at the command prompt to launch the
graphical user interface (GNOME desktop).
5. Launch the Firefox Web browser using the toolbar icon and enter
http://localhost in the address bar to bring up MSS Web interface.
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6.2.2. Main MSS page overview
Figure 6-3 shows the main MSS Web page (PHP MSS Page) for a typical Q4000
paper scanner running R10x release.
Figure 6-3 R10x MSS Page: Q4000 Scanner
Obtain Status Information MSS and EDAQ web pages
P/N 6510020831 Rev 03 4/1/15 6-5
Figure 6-4 shows the R10x MSS Page for a much more sparsely populated 408x
CWS scanner.
Figure 6-4 R10x MSS Page: 408x Scanner
Figure 6-5 shows R20x release MSS home page for Q309x scanner.
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Figure 6-5 R20x MSS Page - Q309x Scanner
The left panel displays a column of options organized under the following:
Software Update (Starting from R200.1 release)
Scanner Functions (Starting from R200.1 release)
MSS Functions
EDAQ Functions
Frame Controller Functions (Only in R10x releases)
The main panel displays two tables. The upper table contains transmission volume
information to and from the MSS. The device labeled eth1 (Scanner LAN)
typically shows it receiving a few MBs. The MAC addresses of the MSS are also
shown–the eth0 (RAE LAN) address is the one required in the RAE setup.
If a wireless bridge is configured with either RAE LAN or Scanner LAN, the
corresponding interface will be displayed as br0.
Obtain Status Information MSS and EDAQ web pages
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The lower table lists:
all EDAQs discovered on the scanner LAN, and their IP addresses
all other networked devices discovered on the network, such as
intelligent switches, laptops, or sensors that connect directly to the
MSS (for example, Formation Measurement)
a brief description related to the model number
a program status column
the associated function code
the position code
whether the communication protocols are running (http, SSH, and
Edal, the proprietary sensor data transmission protocol)
The EDAQ network name is specified by edaq-pXYZ where XYZ is both its
position and the last octet of the IP address. The EDAQs attached to the head
power distribution boards are known as upper and lower alley respectively. The
FC-EDAQ is the frame controller EDAQ.
The Proc/Run status column is green if all processes known to run on the EDAQ
are present. Hovering the cursor over the status indicator brings up a list of
running and stopped processes. All processes listed should be running at all times.
In R10x release, enter the following credentials:
Username: admin
Password: hmxresult
to access advanced diagnostic options that are not necessary for normal operation
and outside the scope of this manual. As of the R200.1 release, this login process
is eliminated and all functionality and options are exposed with the regular MSS
main page.
6.2.3. Detailed EDAQ information
More detailed information on each EDAQ can be obtained by clicking Detailed
EDAQ Info on the left panel.
The resulting table (see Figure 6-6) shows a number of technical details that are
not discussed in this document. Important columns include Process Load (usually
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less than 0.5), local time (matches MSS time clock shown at top) and Offset
From MSS (should be less than 50 microseconds a few minutes after start-up).
The table also shows the software revision number running on the particular
EDAQ. This should be checked after an upgrade to verify the EDAQ is indeed
running the expected revision.
Figure 6-6 Partial Display of Detailed EDAQ Information
Obtain Status Information MSS and EDAQ web pages
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6.2.4. EDAQ, MSS, and FC scanner log files
Log files record activities of the scanner which is a crucial information for any
troubleshooting. MSS, frame controller and all EDAQs in the scanner generate
log messages which are archived in MSS flash drive. Web interface can be used
to display and download the log files.
Starting with R200.1 release, log messages from all scanner components are
combined and archived into a single log file (scanner.log). R10x release systems
produce three log files – mss.log, fc.log and edaq.log – which are log messages
from MSS, frame controller and all EDAQs combined respectively.
The log files are automatically closed and renamed once per day if they exceed
25MB. Generally, the log file size limit is 25 MB (uncompressed). The current
log files have .log extension and older files are named with an index number, with
1 being the second most recent file. For example, scanner.log.1 is the log file
previous to the currently logged scanner.log file.
By default only the two most recent log files are left uncompressed. Compressed
files are given the gz identifier, so the third most recent scanner log file would be
named scanner.log.2.gz.
There is a limit of 25 log files left on the machine at any given time, so the
minimum time that log files for a given event remain on the MSS is 25 days, but
in practice this could be much longer. Most Windows-based Zip programs can
handle these log file formats.
To access log files click on the Scanner Logs button under Scanner Functions in
the left menu. MSS/EDAQ Log Retrievel Page as in Figure 6-7 displays.
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Figure 6-7 R20x Log Retrieval Page
As of the R10x release, click on MSS/EDAQ/FC Logs button under EDAQ
Functions to navigatee to LogRetrivel Page. (see Figure 6-8).
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Figure 6-8 R10x Log Retrieval Page
Download the log file by right-clicking and selecting Save To Desktop. The files
use the standard Unix/Linux end-of-line (line feed only) convention so they must
be opened in MS WordPad or MS Word. A preferred utility is Notepad++.
At the bottom of the page there is a tool to extract log files by date (see Figure
6-9).
Figure 6-9 Log File Selection By Date
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Select the start and end dates using the calendar selection tools. Click Extract
Log File to Zip File. The Web server will now go through all existing log files on
the MSS and create a new file that includes the range of dates selected. This is
done for the three log file types in the case of R10x releases. A combined zip file
is created and presented to you as a hyperlink. This process is CPU-intensive and
can take some time.
While the log files may be viewed with any number of suitable Windows
applications, a dedicated log file viewer and analysis program (log_analyze) is
available from Honeywell Engineering. A freeware tool, NotePad++, is also
useful.
6.2.5. MSS data logger
The MSS web server contains a powerful data logger module that allows access to
raw EDAQ data. Data may be collected from any number of channels from any
numbers of EDAQ simultaneously, at any rate up to 4 \KHz and for any length of
time. This module is available by choosing the Data Logger option from the main
MSS web page.
The main screen (see Figure 6-10) allows selection of the EDAQ and entry of a
list (separated by commas) of channels.
The criteria below the table determine the end of logging criteria: file size,
number of events or time limits.
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Figure 6-10 MSS Main Page
Once running, the page changes to the one shown in Figure 6-11.
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Figure 6-11 Data logger status page with logger configuration table
This page shows the status of the current data logging. The channel numbering
shows the EDAQ position and function code followed by a list of channels. The
four buttons have the following functions:
Check Logger Status: refreshes the above screen or returns to main
screen once the logging is finished.
Request Logger Stop: send a signal to the data logger to stop running
and close the files
Kill Logger Process: if step (2) above fails, this sends a hard-kill
signal to the process.
Show Run Config File: displays the internal run status file. An
example is show below:
Obtain Status Information MSS and EDAQ web pages
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Figure 6-12 Data logger status table
Repeatedly pressing Check Logger Status refreshes the status table until the data
collection is completed (for example, if the maximum file size has been reached).
As the data are being collected, the new data file shows up in the table at the
bottom of the screen. It is an ASCII text file showing micro-second time stamp,
and in this example, two columns or analog input, and two columns of digital
input data. The file can be downloaded by right-clicking and selecting Save. See
Figure 6-13 for a typical output.
Figure 6-13 Typical log file content
The log files may be permanently deleted from the MSS by selecting them and
pressing Delete Selected File. The log files may also plotted by selecting the file
and clicking Plot Selected File. The plots are generated using client-side
JavaScript. Zooming is done using the left mouse. The smaller graph to the right
always displays the entire plotted data range. Due to CPU limitations, only
approximately 2000 points are plotted.
A total of three plots are displayed for each data item requested. See Figure 6-14.
The first shows a limited set of data at the full acquisition rate.
The second graph (not shown) is a Fast Fourier Transform of this data subset.
The third graph is an overview of the entire set, but with averaging of data to
reduce the number of points displayed.
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Figure 6-14 Sample Data Logger Graph
Since the data collected are guaranteed to be synchronized to about 50µs, it is
possible to study correlations between signals from different EDAQs in the
scanner.
For example, you could request to log the nuclear source EDAQ digital output
line (channel 0) and the nuclear receiver basis weight signal (analog input channel
0) at the same time. The data file would then contain the exact shape of receiver
signal amplitude as the shutter was opening.
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7. EDAQ Position and Function CodeOverrides
EDAQ reads a position number and a sensor type number through resistors
connected to the EDAQ through J1. These two numbers uniquely identify the use
of the EDAQ in a system. The position number is also used as the IP address.
In the Q4000 and Q309x series scanners, the detection of position and function by
the EDAQ is sufficient for the RAE system to set up the I/O channel assignments
and calculate the physical offsets off the sensor.
In the 408x scanner with dual sensors, you must let the system know which
EDAQ is dedicated to the first sensor, and which is dedicated to the second
sensor. This is done through MSS Card Setup under the MSS Setup Diagnostic
tab on the QCS server. In the instance of a single sensor, the system assumes the
EDAQ in position 1 is connected to the sensor.
For metals and rubber systems, RAE has default templates store the expected IP
addresses of the EDAQ cards and no configuration is required in the server.
Ideally, position and function codes are auto-detected by the EDAQ board, and no
specific configuration needs to be implemented. If the EDAQ cannot perform this
detection reliably, it is recommended to hard code (override) the function and/or
position codes. Check the main MSS page to see EDAQ IP addresses and function
names and whether they match expectations.
7.1. Symptoms of an identification failure
EDAQs that fail to identify will show as missing in the MSS Summary page of
the MSS diagnostic tab on RAE. On the main MSS web page, EDAQs that are
missing position information obtain a DHCP address (rather than one
corresponding to a position in the scanner) and show up in red. See Figure 7-1.
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Figure 7-1 MSS page displaying EDAQ with no proper sensor identification
In the Figure 7-1 example, you can click the edaq-p26 hyperlink to see the
relevant diagnostic information from the EDAQ web server (see Figure 7-2). It
shows that the ADC channels for the position and function determinations are
both reading their maximum value (near 4096), which would indicate no resistors
are connected at all (likely a missing harness cable).
Figure 7-2 EDAQ web server raw data of the function and position ADCs
It is also possible to see additional error messages such as ADC’s too noisy –
rejecting data or ADC mean values that are good but significantly different from
what is expected. In the first case, overriding the ID of the EDAQ might be the
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best solution. In the second case, try to re-calibrate the ADC-to-resistance
coefficient (see Section 7.5).
7.2. Override procedures
The MSS Web pages may be accessed as described in Section 6.2.
7.2.1. Check present function and codes
To view the position and function codes for any EDAQs running in a system (on
the sensor LAN), check the MSS Summary page.
Navigate to Scanner Sensor MSS Setup Diagnostics MSS Summary
page, and note the Node (position code) and the Fun (function code) columns
(see Figure 7-3).
Figure 7-3 MSS Summary Page
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7.2.2. Identify a configured override
The following procedure describes how to identify whether an EDAQ has a
position or function code override configured.
1. Launch the MSS Web interface, and wait for the EDAQs to appear in
the Active Hosts list (see Figure 7-4). The EDAQ may take up to a
minute to appear if recently booted.
Figure 7-4 MSS and EDAQ Info Page: Active Hosts
2. Click on Detailed EDAQ Info and wait until the table is populated
(see Figure 7-5).
Figure 7-5 Detailed EDAQ Info
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The two columns on the far right (Pos override and func override) show whether
the EDAQ has a hard coded position and/or function code.
7.2.3. Edit the position and/or function code
1. From the main MSS Web page, click the EDAQ name (edaq-pXXX) to
navigate to the EDAQ-specific page (see Figure 7-6).
Figure 7-6 EDAQ Identification Information
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2. Click Edit ID File from the left menu to display the /etc/override_id
file (see Figure 7-7).
Figure 7-7 Editing File /etc/override_id Display
All lines in this file starting with the character # are comment lines and
can be ignored. Look for lines that start with the keyword
position_code: or function_code:. These lines specify the
hardcoded position and function number for the EDAQ. Note that if
multiple similar lines exist, the last line will take effect.
3. If no configuration changes are to be made, close the Web page. If one
or more EDAQs have overrides, it is good practice to record these
configurations in a logbook for future reference.
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If a change is made to the override file, the following actions need to be taken:
1. Click Update File Content.
2. Click Restart on the left menu, and the EDAQ Functions display will
appear (see Figure 7-8):
Figure 7-8 EDAQ Functions
3. Click Hard Reset to reboot the EDAQ.
4. Click Return to MSS on the left menu, and make sure that the EDAQ
reboots with the configured position and function codes.
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7.3. Determine sensor type override codes
To determine the sensor codes, navigate to the main MSS Web page and select
Display Resistor File under Scanner Function from the menu as shown in
Figure 7-9. As of the R10x release versions, Display Resistor File is grouped
under EDAQ Functions.
Figure 7-9 Functions Menu
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Figure 7-10 shows an excerpt from the file showing several sensor types and their
associated function code.
Figure 7-10 Table for sensor_function Display
The second column, Resistor (Ohm), is the nominal resistor value measured in
Ohms. The third column, Tolerance (Ohm), is the allowed tolerance on that
resistance at manufacturing. The fourth column, Meas. Limits (Ohm), is the
tolerance the software uses to recognize the resistor as corresponding to the
function.
Figure 7-11 shows the table subsection for the 408x CWS scanner endbell
EDAQs.
Figure 7-11 Position Codes & Resistor Values
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7.3.1. Connect an EDAQ to the sensor network
This section describes how to connect an EDAQ (for example, a spare EDAQ) to
the sensor LAN. This should be done if you want to check and possibly configure
an override in an EDAQ, or to upload new EDAQ code.
Because the state of the EDAQ is unknown at this point (it may have a fixed
position code and a fixed IP address), it should not be connected to a running
scanner.
To avoid conflict with another EDAQ already on the sensor LAN, follow one of
the following two procedures.
Procedure 1: Using a spare MSS (preferred)
1. Boot up a spare MSS.
2. Connect 24 V DC power to the EDAQ.
3. Connect the EDAQ to the sensor LAN interface.
4. Bring up the MSS Web interface (see Section 6.2).
Procedure 2: Using the existing scanner system
1. Disconnect the sensor LAN from the MSS sensor LAN port.
2. Connect the EDAQ Ethernet port to the MSS sensor LAN port.
3. Bring up the MSS Web interface (see Section 6.2).
4. When complete, disconnect the EDAQ and reconnect the sensor LAN.
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7.4. Sensor position numbers in the Q4000
The schematic in Figure 7-12 defines the codes based on the sensor position
relative to the paper path.
Figure 7-12 Head Position Numbering Convention
All lower head sensors are in the 1xx range. All upper head sensors are in the 2xx
range. The lower alley EDAQ is 100. The upper alley EDAQ is 200.
The sensors internal to the six-pack head are in the range 101–106 and 201–206
for the lower and upper heads respectively.
External sensor position codes will depend on where the EDAQ connects to the
power distribution board. External sensor connections are labeled J1xx/2xx.
Lower head positions are in the range 123–126. Upper head external positions are
in the 223–226 range.
7.5. Sensor position numbers in Q309x scanner
The Q309x scanner has a dedicated range of position numbers because wireless
functionality has to be enabled in EDAQs. It follows the same scheme as in
Q4000 scanner with lower head sensors in positions 127 and 128 and upper head
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sesnors in positions 227 and 228. The first sensor mounted next to the drive
controller gets the lower position code value (127 or 227).
7.6. Recalibrate the position and function resistance measurement
Depending on the software revision loaded at the factory, the EDAQ memory
contains either a single calibration constant for both the position and function
channel, or two separate constants. In either case, these constants may be
recalculated and reset in the field. The new values will be maintained after a
software upgrade.
7.6.1. Recalibration procedure
Navigate to the main MSS web page as described in Section 6.2. At the top left,
enter the username admin and password hmxresult to obtain additional user
functionality. The Calibrate ID Resistor Gains button appears under EDAQ
Admin Functions on the lower left as shown in Figure 7-13.
Figure 7-13 Calibrate ID Resistor Gains Button
You must select the appropriate EDAQ and measure the value of the position and
function resistor using a precision multi-meter.
1. Remove the head covers and identify the EDAQ to be calibrated. All
necessary precautions to remove the head covers must be followed.
2. Power off the EDAQ by disconnecting the 24V power connector J7.
Disconnect the sensor harness 50-pin connector from the EDAQ
connector J1. Measure the function resistor between pins 1 & 2 and
position resistor between pins 3 & 4 of the 50-pin connector.
3. Reconnect 50-pin connector to EDAQ J1 and reboot EDAQ by
connecting back 24V power to EDAQ J7.
4. Click Calibrate ID Gain (see Figure 7-14). The next page displays the
results and asks for confirmation before writing the gains to the
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EDAQ. The web page will refuse to write noise values or values likely
to be incorrect.
Figure 7-14 EDAQ Resistor ID Gain Calibration Page
The gain values used by the EDAQ are stored in the file /etc/override_id. See
Section 7.2.3 for accessing the file using web interface and scroll to the end of the
file.
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8. Technical MSS and EDAQ Field Procedures
This chapter applies to all MxProLine scanner models.
8.1. EDAQ hardware self-test
Many of the EDAQ hardware components may be self-tested using a Web-based
test interface that is programmed into every EDAQ. A special cable harness that
loops the various outputs to the various inputs on the EDAQ is required. The test
will show whether the EDAQ functions as expected, but if there is a failure mode
there will be an ambiguity on whether it is the driving component, for example,
analog outputs, or the receiving component, for example, analog inputs.
The EDAQ must be powered up with + 24V and connected to any PC (running
either the Windows or Linux operating system) through an Ethernet cable
(straight or crossover). Set the Ethernet card IP address of the PC to a number in
the range 192.168.0.(20–50) with netmask of 255.255.255.0. With the testing
cable plugged in, the EDAQ will configure itself with the correct function and
position codes (250) for the self test. If the configuration fails, the EDAQ will
eventually configure itself with the default address 192.168.0.99.
The self-test page is accessed by bringing up an internet browser and entering the
address http://192.168.0.250. Enter the username admin and the password
hmxresult on the left hand side. A new option, Self Test, appears under Admin
Functions.
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Click Self Test to open the EDAQ Self Test Page (see Figure 8-1). You can
choose to run all or a sub-set of the available tests.
Figure 8-1 EDAQ Self-test Main Page
The program sets digital outputs, analog outputs, and serial communication
interfaces, and reads back the values in the digital inputs, analog inputs, and
complementary serial ports.
The Slow ADC Channels, which normally read the external and internal
temperature sensors, will be tested against fixed input resistances on the tester
harness.
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Figure 8-2 shows a passed test result. If there is a failure, however, this test cannot
point to the exact cause. Because EDAQ is testing its own components, there is an
ambiguity whether the failed component is the input or output. Return the EDAQ
to Honeywell.
Figure 8-2 Sensor Test results for EDAQ
The test program has a set of default test limits that must be satisfied for a channel
to pass. It is possible that a slight gain difference between EDAQs results in a
failed test when the component is functionally working.
Click Edit Test Limits (see Figure 8-1) to edit the parameters. These parameter
changes are overwritten when an EDAQ is upgraded to a different software
revision.
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8.2. Optional windows-based software tools
Some of the tools described in this section are shipped with each MSS and are
accessible through the web page at address:
http://<mss_ip_address>/windows
where <mss_ip_address> is the IP of the MSS as viewed from the RAE server.
Edaq_scope
A Tcl/Tk-based program was created to retrieve raw data from EDAQs and
display it. The program is installed by default on the MSS (Linux version) and
called edaq_scope.tcl. A windows executable that requires no installation is also
available on the mss at http://192.68.10.101/windows (substitute applicable local
MSS IP address for 192.168.10.101). The latest version can be obtained from
Honeywell Engineering.
It is an oscilloscope-like tool that can display 4 kHz raw data from multiple
EDAQs simultaneously, display digital input and output states, and perform basic
data analysis such as fast Fourier transforms.
log_analyze
A Tcl/Tk-based program for Windows and Linux, log_analyze is a convenient
tool for opening and analyzing EDAQ and MSS log files. It allows searching and
filtering of log file text and plotting of numeric data in the files.
Putty
Putty allows you to open a Telnet-like window to the MSS, and then to the
EDAQs. It is used for quick work, or for looking at log files, or anything for
which a GUI application is not required. There are some alternatives, such as Tera
Term. Search Google using SSH application for windows for alternatives. The
executable file putty.exe does not need to be installed on your computer–it is a
single executable file.
WinSCP
WinSCP is a drag-and-drop copy program between Linux and Windows systems.
It uses SSH to make the actual connection. This program is useful for retrieving a
file from the MSS, or to copy over a single file to the MSS for debugging. You
can also use it to set the file description bits, which is necessary to make a
program executable on a Linux machine. Linux refuses to execute programs that
are not specifically set up to be executed.
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NoMachine NXclient
NoMachine NXclient is a full remote-desktop application for Linux and Windows
(only the Linux version is free). The MSS comes with a NoMachine NX server
installed and running. It is similar to RadMin or VNC, and is used when running
GUI applications such as the EDAQ data grabber, Firefox, or Wireshark.
NoMachine uses SSH for its communications. When setting it up, ensure that you
choose GNOME as the desktop manager, not KDE (which is not installed on the
MSS).
A Linux VM
You can use a Linux Virtual Machine (VM) as an alternative to NoMachine NX
Client. A Linux VM runs the same display software (X11) as the MSS, so you can
open up applications from the MSS. Basically, you are using your VM as a thin
client. To get a Linux VM running you do not have to install it. You can get pre-
installed VMWARE or VirtualBox from
http://www.vmware.com/appliances/directory/cat/0?k=ubuntu 10.04 or
http://virtualboxes.org/.
Installing is easy, and both VMware and Virtual box are Ubuntu aware, meaning
they will recognize it and set it up properly. Choose Ubuntu 10.04 or higher.
When connecting from a Linux VM:
1. Open a terminal windows, usually Applications Accessories
Terminal, when using a standard Ubuntu 10.4 installation.
2. Use the command ssh [email protected].
3. Start the required application (for example, Wireshark).
8.3. Check the health of MSS through Linux
Although the MSS Web interface can provide most of the information required
for scanner operations, it is sometimes useful to log into the MSS directly.
There are two users defined on the MSS:
Username Password
User 1 evolution evolution
User 2 root
Measurex
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Note: Passwords are case-sensitive.
User 2 is the the system administration account and should be used with great
care. For simple file transfers and checking of the MSS health it is recommended
to log in as User 1 and use the temporary elevation of privilege command sudo
for operations requiring system privileges.
Assuming you are logged in to the MSS using the username evolution, you can
check the items described in Subsections 8.3.1 through 8.3.3.
8.3.1. Disk usage
Use the command, df –h. A typical output is described in Figure 8-3.
Figure 8-3 Typical Output: Disk Usage
The partitions of interest are labelled / (partition /dev/sda5 in this case) and /var
(partition /dev/sda6 in this case). The / partition should contain approximately 2.5
GB of operation system and program files and should not increase in size over
time. The /var partition stores the scanner log files (under /var/log/scanner). It can
increase in size, but should not exceed 80% of its capacity. If the /var partition
shows more than 80% of its capacity, it’s recommended to remove some of the
log files.
To check which folders or directories contain the largest files, execute the
following command:
du -a -b | sort --key=1 -r -n | more
This lists all the files and sizes (du), sorts them in reverse order (sort) and
displays them page by page (more). Most likely, the large files will be in the
folder /var/log/scanner. To navigate there, use the following command:
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cd /var/log/scanner
Then use the ls -l command to list the files and their sizes. Use the rm command
to remove the offending large file:
rm edaq.log.14.gz
8.3.2. CPU usage
Use the command, top. A typical output is described in Figure 8-4.
Figure 8-4 Typical Output: CPU Usage
Expect the emss process (data binning and alignment process) to occupy 10–20%
of the CPU at any given time. Any percentage much higher signifies a problem.
Quit the program using [CTRL]-C.
8.3.3. Replace a single binary or library on the MSS
The most important binary running on the MSS is the emss process, which
collects data from the EDAQ cards and bins the data using the FC position
information. Upgrades to the MSS are typically done through the Web pages. An
MSS upgrade file contains new copies of all the Honeywell software as well as
some modified system files to ensure that there is no doubt what version is being
run on the scanner; however, it may be useful to copy one or two files for testing
at Engineering’s request.
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8.3.3.1. Method 1: WinSCP
The easiest way to get a file on the MSS from Windows is to use an SSH-based
free GUI client such as WinSCP. It is strongly recommended to install this on a
local PC. Use of the program is fairly intuitive. Log in with the evolution
credentials and drag and drop the files to be copied to the evolution home folder.
8.3.3.2. Method 2: Manually mount a USB flash drive
1. Copy the file on a USB flash drive, insert into the MSS drive, and
manually mount the USB device.
2. Log in to the MSS using SSH as user root. The command is:
mkdir /media/usb
mount -t vfat /dev/sdb1 /media/usb
3. Copy files from /media/usb/ to any user-defined location.
The command, cp /media/usb/myfile /home/evolution, will
copy myfile to the user evolution home folder.
4. Finish with, umount /media/usb before removing the flash drive.
8.3.3.3. Method 3: Through a web page
The MSS Web page has a file upload option under the administrative options. On
the MSS Web page, log in using the following credentials:
Username: admin
Password: hmxresult
Click Upload File to MSS on the lower right. Browse for the file to copy, then
select a destination of one of the three allowed paths:
/usr/local/mss/
/usr/local/apache/
/usr/local/edaq/
Currently, the Web page does not have write privilege to other folders on the disk.
When the file exists on the MSS, move or copy the file to the correct location.
Assume Engineering asked for the field to update the main communication
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library, libedal.so.1.6. Use Putty to establish a terminal to the MSS and log in as
user root. Enter:
cp /user/local/mss/libedal_x86.so.1.6 /usr/local/lib
where in this case the target folder for the library is /usr/local/lib/. Then change to
that folder and check:
cd /usr/local/lib
ls -l (ls and lower case -L)
A possible partial listing:
The new library is clearly there; however, as a rule, Linux makes extensive use of
symbolic links to point a generic program/library name to a specific revision of
that file. In this case, the generic name, libedal_x86.so points to
libedal_x86.so.1.4. Just copying the file is not sufficient, you have to re-assign the
symbolic link as well for the software to use the right version:
root@mss:/usr/local/lib# rm libedal_x86.so
root@mss:/usr/local/lib# ln -s libedal_x86.so.1.6 libedal_x86.so
The command on the second line is lower case L, lower case N.
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The first command removes the old link, not the file it is pointing to. The second
command recreates the link to point to your new library.
As a second example, assume that engineering has supplied a new MSS
executable, emss.1.4.
Copy the file to the correct location (/usr/local/bin in this case). Assume that the
symbolic link for the emss program was already correct and pointing to the old
file, emss.1.4. During the copy, it is likely that the execution bit on the file was
not set. Linux will refuse the execute files that do not have execute permission.
Correct this with the command:
cp /home/evolution/emss.1.4 /usr/local/bin
cd /usr/local/bin
chmod +x emss.1.4
The WinSCP program supports setting execution and other bits:
1. Right click on the file (once it has been copied to Linux), and choose
Properties.
2. Ensure that the X (=execution) check box is selected for the owner.
WinSCP also supports creating new symbolic links, so in principle the entire
operation (copying, setting executing bits, adjusting the link) can be done without
logging into the MSS with your SSH client.
8.4. Manually edit files on the EDAQ
Although most functions can be performed via the Web pages, there might be a
reason to transfer files to and from the EDAQs. There are several ways to do so.
8.4.1. Method 1: WinSCP
Connect a laptop to the scanner network and use WinSCP to connect directly to a
particular EDAQ. For example, to transfer files to and/or from the upper alley
EDAQ, use WinSCP to host 192.168.0.200 and login as username root and
password measurex (all lower case).
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8.4.2. Method 2: WinSCP to MSS
Use WinSCP to transfer the file to some location in the MSS. Connect a SSH
session (Putty) to the MSS as user root or evolution. Then use the command
line version of the SSH copying program:
scp myfile.txt root@edaq-p102
scp myfile.txt [email protected]:/usr/local/lib/
You will be asked for the root password measurex.
8.4.3. Method 3: MSS web interface
On the main MSS Web page, log in with username admin and password
hmxresult to show the administrative functions. There is a File Copy to EDAQ
option. Browse to your file, select the target EDAQs, and remember the
destination path.
To edit files on the EDAQ (for example the EDAQ identity override file), perform
a double SSH connect. Use Putty to connect to the MSS (as username evolution
or root). Once you have a terminal connection, SSH again to the target EDAQ:
ssh root@edaq-p202
Password: measurex
To edit a file, use the built-in edit nano. This simple editor is easy to use. Press
[CTRL]-X to save the file and exit the program.
edaq-p33:~# nano /etc/override_id
8.5. Change the EDAQ boot partition
The EDAQ goes through four boot stages:
ROM boot, internal to the ARM processor
AT91_BootStrap (proprietary to Atmel®, the chip maker)
U-boot (operating system loader)
Linux
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The codes for the first and second stages are in the first NAND flash disk
partition. The Linux kernel, stage four, is in the second partition. The two copies
of the Linux file system and Honeywell software occupy partitions three and four.
Partitions three and four are identical at manufacture. The EDAQ will boot up and
use partition three until it is upgraded. The upgrade image will be written to
partition four. A reboot then switches to this partition. A second upgrade will now
write to partition three and this is activated after a second reboot.
The previous EDAQ image therefore always exists on the NAND flash, and it is
possible to force the EDAQ to reboot to it. This might be useful if the last update
broke a working system or somehow the EDAQ NAND flash was corrupted and
the EDAQ no longer boots.
NAND flash corruption is also possible in partitions one and two, but much less
likely because nothing is ever written to that part of the disk memory, and it is
only read once at boot time. Therefore, a corrupted EDAQ will at least boot to the
U-boot stage, and that U-boot will be able to chain-load the Linux kernel.
If the EDAQ is still operating properly, you can revert to the previous image
using the MSS Web page. On the main MSS Web page, login with the following
credentials:
Username: admin
Password: hmxresult
A Revert EDAQ option will appear at the bottom of the page. Use this Web page
to re-program the EDAQ U-boot code to boot the previous partition. It will
automatically discover whether the older version is on partition three if now
running from four, or vice versa.
8.6. Connect to the EDAQ through serial debug port
If the EDAQ is not working, it is worth checking whether it can be manually
convinced to boot to the older partition. To do this you need to power up the
EDAQ and connect a debug serial cable from EDAQ connector J1 to a standard
PC serial connector. The pin assignment is as follows:
Table 8-1 Pin Assignment
EDAQ J1 3-pin Molex Standard DB9 Serial Connector, Female
2 3
Technical MSS and EDAQ Field Procedures Connect to the EDAQ through serial debug port
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3 2
1 5 (GND)
The connection should set to 115200bps, 8N1. Any Windows serial
communication program such as HyperTerm, or Putty (in serial mode) will do.
The serial connection establishes both an output channel for Linux kernel errors,
as well as a logging type console connection for the boot stages.
Power up the EDAQ and press any key a few times to stop the automatic U-boot
boot phase. A typical boot display is shown in Figure 8-5.
Figure 8-5 Typical Boot Display
Some items in Figure 8-5 should be noted. The first line, RomBoot, corresponds to
stage 1 of the boot process. As shown in Figure 8-5, it failed despite hitting the
EDAQ reset button four times. The power was then reset and the boot continued
past the RomBoot stage, going to the Start AT91BootStrap... stage 2. Finally,
U-boot started and a keyboard key was pressed to stop the boot process there.
Print out the value of the boot variables using the printenv command. If the boot
variable bootargs (see Figure 8-6) indicated the boot partition was mtdblock3,
change it to mtdblock2.
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Figure 8-6 Boot Variables
This procedure is shown in Figure 8-6. The listing of the variables was from a
printenv command. The new values were assigned and saved, and finally the
EDAQ booted (this could have been done by power cycling as well, but here the
U-boot command bootd was used).
This completes the operation. With the EDAQ booted into the older and working
partition, it can be re-connected to an MSS and updated to the latest working
version of the file-system.
8.7. Opstation access to the MSS web pages
For the version of RAE to at least version R602, the MSS and EDAQ web pages
are only accessible from either the scanner network or the Experion MX-MSS
network. Opstations are generally connected to the QCS server from a separate
Ethernet card and therefore exist on a separate network. The QCS server is not set
up to forward requests from this network to the Experion MX-MSS network.
Thin-clients are essentially processes on the QCS server and should be able to
access the MSS directly.
Technical MSS and EDAQ Field Procedures Opstation access to the MSS web pages
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Figure 8-7 illustrates a typical network topology for a system with two scanners
and three opstations (the QCS server is the only connection between the two
networks).
Figure 8-7 Typical Network Topology
If access to the scanner is required from the opstations, or any other PC connected
to that part of the LAN, the QCS server must be set up to forward the request.
This can be done using the Microsoft IIS server. The following software is
required:
IIS 7.0 or IIS 7.5 (included in Windows 2008, Windows 2008 R2,
Windows Vista, and Windows 7)
URL Rewrite 2.0
Application Request Routing
In addition, an XML-based IIS re-write file (web.config) is required. If not
already installed on the server, that file is shipped on each MSS and can be
accessed from the RAE server by accessing http://192.168.10.101/windows
(correct the address for the address of the MSS of the local system).
To set up:
1. Copy the file web.config to the standard location
C:/inetpup/wwwroot/web.config.
2. From the Microsoft site, obtain the two packages, UrlReWrite and
Application Request Routing.
http://www.iis.net/download/URLRewrite
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http://www.iis.net/download/ApplicationRequestRouting
3. Follow the automatic installation procedure.
4. Enable Proxy support in ARR.
Launch IIS Manager using Start AdminTools IIS manager.
Click the server node in the tree view.
Double click the application request routing cache icon.
Select the Server Proxy Settings… task in the Actions panel
Ensure that Enable Proxy is checked. This allows any request in the
server that is rewritten to a server that is not the local machine to be
routed to the right place automatically without any further
configuration.
5. Still in IIS manager, click the default web site on the left hand side.
6. Double click URL ReWrite.
7. On the right, click Manage Server Variable, and add the variable
HTTP_ACCEPT_ENCODING.
8. Add all the MSS IP addresses to the system32/drivers/etc/hosts file
with appropriate names such as:
10.10.1.40 mss1
10.10.1.41 mss2
The web pages are accessible using
http://SERVERNAME/mss1/index.php.
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9. Tasks
This chapter contains procedures for maintaining or troubleshooting the EDAQ.
A number of these activities are relevant to the Q4000 series scanner only, not the
CWS 4080 scanner or the CWS metals and rubber sensors.
All of the tasks in this chapter are referred to by the lists of RAE alarms described
in Chapter 10.
A RAE alarm seen on a 4080 scanner system may be listed in Chapter 10. The
listing links back to tasks in this chapter that will help you investigate and resolve
the issue.
Activity numbers that appear in the task description tables are for the use of the
sensor diagnostics display only, and do not reflect model numbers for the tasks.
To determine whether the task applies to your sensor, check Applicable Models.
If a value in the task description table is blank, that means it is not applicable to
that task.
9.1. Verify EDAQ connections
This task refers to verifying the electrical connections between the head power
distribution board, the EDAQ board, and the sensors.
Activity Number: 80801767-81500030-ACT-001
Applicable Models: All
Type of procedure: Inspect Expertise Level: Honeywell Expert
Priority Level: Average Cautions: High Temperature
Availability Required: Scanner Offsheet Reminder Lead Time:
Experion MX MSS & EDAQ Data Acquisition Tasks
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Overdue Grace Period: Frequency (time period):
Duration (time period): 30 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts: Multi-meter
Required Tools:
Power to the EDAQ is most easily verified by checking for the green 3.3 V LED
on the EDAQ next to the Ethernet connector (see Figure 5–3) and the serial debug
port connector. If that is lit, all of the + 24V, + 15V, and + 3.3V are present on the
EDAQ. There could still be a failure of the + 5V, the 1.0V, or 1.2V converters.
1. Check network connectivity by visually inspecting the Ethernet
connector. The green and amber lights should both be lit up and at
least one of them flashing.
2. Check that the FPGA and CPU are running by inspecting the LEDs on
the EDAQ (see Figure 5–3); the LEDs between the reset button and
the flash memory chip.
3. Check the + 24V and ± 12V (used by sensors, not the EDAQ) on the
head power distribution board connector (see Table 9-1).
Pin Number(s) Function
12, 24 + 12V and - 12V
11, 23 Returns for ± 12V
1–5 + 24V
13–17 + 24V returns
6, 18 EDAQ position resistor
Table 9-1 Head Power Distribution Pin Assignments
9.2. Verify EDAQ ID
EDAQ networking errors or even interlock errors can be reported if the EDAQ
does not identify itself properly and load the appropriate sensor code.
Tasks Verify EDAQ process health
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Activity Number: 80801767-81500030-ACT-002
Applicable Models: All
Type of procedure: Inspect Expertise Level: Honeywell Expert
Priority Level: Average Cautions: High Temperature
Availability Required: none Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Duration (time period): 30 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts: PC
Required Tools:
EDAQ identification issues are best checked from the main MSS display, which
can be accessed on the RAE server or any PC connected to the scanner network.
See Subsection 3.5.1, or Subsection 6.2.1, for methods of accessing the main MSS
display.
The main MSS display lists all EDAQs expected in the head along with their
function and position codes. EDAQs that do not identify properly are labeled
generic and have IP addresses outside the expected range (see Section 5.3).
Chapter 7 describes in detail how to diagnose an identity failure and how to
hardcode the EDAQ function to the desired numbers.
9.3. Verify EDAQ process health
Activity Number: 80801767-81500030-ACT-003
Applicable Models: All
Type of procedure: Inspect Expertise Level: Technician
Priority Level: Average Cautions: High Temperature
Availability Required: none Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Experion MX MSS & EDAQ Data Acquisition Tasks
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Duration (time period): 30 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts:
Required Tools:
The MSS Summary page under the MSS Setup Diagnostic tab will display the
list of expected EDAQs, and show the three status lights. If all three lights are
green, the EDAQ is communicating and the data time stamps from the EDAQ are
synchronized with the other clocks on the network.
A second method is to access the MSS Web page (see Subsection 3.5.1, or
Subsection 6.2.1). The main page shows a list of detected devices on the scanner
network. You can hover the mouse pointer over the Process Status column
indicator light. A popup menu displays the processes expected on the EDAQ, and
whether or not they are running. If any of the processes are not running, the first
course of action is to restart the EDAQ using the Reset EDAQs function on the
left hand side of the page (see Section 6.2). If a reboot is not successful in
restarting the processes, replace the EDAQ and download the corresponding
EDAQ log files using the MSS Web pages (see Subsection 6.2.4), for analysis by
Honeywell Engineering or TAC. See Section 5.5 for a description of replacing
EDAQs.
9.4. EDAQ self-test
Using a special test harness and a regular PC, the hardware I/O of the EDAQs
may be tested outside of the scanner environment.
Activity Number: 80801767-81500030-ACT-004
Applicable Models: All
Type of procedure: Inspect Expertise Level: Honeywell Expert
Priority Level: Average Cautions: High Temperature
Availability Required: none Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Duration (time period): 30 min # of People Required: 1
Tasks Increase RTDR limits
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Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts: Windows or Linux based PC (laptop) with Ethernet card
Ethernet cable
Required Tools:
See Section 8.1 for details on performing the EDAQ hardware self-test. If the
alarm was FPGA related, an EDAQ reboot fixes it. If the alarm repeats, replace
the EDAQ and return it to Honeywell Engineering for investigation.
See Section 5.5 for a description of replacing EDAQs.
9.5. Increase RTDR limits
Activity Number: 80801767-81500030-ACT-005
Applicable Models: All
Type of procedure: Inspect Expertise Level: Honeywell Expert
Priority Level: Average Cautions:
Availability Required: none Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Duration (time period): 10 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts: Access to RAE server or Operator Station with admin privileges
Required Tools:
The EDAQ PCB over-temp limit may safely be increased to 60°C (140°F). In the
RAE-RTDR browser, locate the PCB temperature limit. An example of the RTDR
path is:
/Scanner 1/Mss/Ss1 nuclear/Job set/Sx edaq pcb head temp/Limit
Experion MX MSS & EDAQ Data Acquisition Tasks
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9.6. Improve head cooling
Activity Number: 80801767-81500030-ACT-006
Applicable Models: All
Type of procedure: Inspect Expertise Level: Honeywell Expert
Priority Level: Average Cautions:
Availability Required: none Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Duration (time period): 1 hour # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts:
Required Tools:
See your scanner manual for details of water cooling, controlling flow, and
temperature setpoints.
9.7. Verify HMI panel operation
Activity Number: 80801767-81500030-ACT-007
Applicable Models: All
Type of procedure: Inspect Expertise Level: Technical
Priority Level: Average Cautions: none
Availability Required: Scanner Offsheet Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Duration (time period): 30 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Tasks Verify red light
P/N 6510020381 Rev 03 4/1/15 9-7
Required Parts:
Required Tools:
The amber lights indicating that the radiation gauge is ready to operate are
ultimately controlled by the respective sensor source EDAQ. These EDAQs
receive the human/machine interface (HMI) button-press signals through the FC
through Ethernet, and in turn request the amber light to turn on through Ethernet
through the FC. Feedback indicating that the amber light is on is returned through
the FC to the EDAQ.
Details on the HMI unit can be found in your scanner manual.
To check whether the FC is communicating with the panel:
1. There should be one power green LED ON (right hand side corner),
and two communication green LEDs ON (middle, left side) on the
back of the HMI. The two communication LEDs indicate that the poll
command is received and data is answered back to the FC.
2. If you see only one LED, data is received by the panel but the panel is
not enabled, therefore it will not answer. To get the panel to answer,
enable two panels using the MSS Setup Diagnostic tab and select
MSS EFC Miscellaneous Setup (in RAE 6.02 or higher).
3. If you see any of the communication LEDs blinking, packets are lost
and communication is not reliable. The FC will log and report the error
in the FC log file as timeout or retry limit may. The HMI will be
requested by the FC to run a self-test.
4. If you do not see the power LED, there is an unplugged cable or a bad
HMI board.
9.8. Verify red light
Activity Number: 80801767-81500030-ACT-008
Applicable Models: All
Type of procedure: Inspect Expertise Level: Technician
Priority Level: Average Cautions:
Availability Required: Scanner Offsheet Reminder Lead Time:
Experion MX MSS & EDAQ Data Acquisition Tasks
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Overdue Grace Period: Frequency (time period):
Duration (time period): 30 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts:
Required Tools:
The red lights are turned on at the HMI panel through serial communication with
the FC. The FC relays this information to and from the radiation emitting gauges
source EDAQ board via Ethernet. Details on the HMI unit can be found in your
scanner manual.
To check whether the FC is communicating with the panel:
1. There should be one power green LED ON (right hand side corner),
and two communication green LEDs ON (middle, left side). The two
communication LEDs indicate that the poll command is received and
data is answered back to the FC.
2. If you see only one LED, data is received by the panel but the panel is
not enabled, therefore it will not answer. To get the panel to answer,
enable two panels using the MSS Setup Diagnostic tab (in RAE 6.02
or higher).
3. If you see any of the communication LEDs blinking, packets are lost
and communication is not reliable. The FC will log and report the
error: timeout or retry limit may occur and the HMI will be requested
to run a self-test by the FC.
4. If you do not see the power LED, there is an unplugged cable or a bad
UPI board.
5. If visual inspection of the HMI panel does not indicate problems,
check whether the MSS page reports both the FC-EDAQ and the
nuclear and/or X-ray source EDAQ (see Subsection 6.2.2).
6. There could be a hardware failure in the red light path. See Honeywell
drawing p/n 6580801566 Sheet AS14 for details on the red and green
light wiring.
Tasks Inspect head gap
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9.9. Inspect head gap
Activity Number: 80801767-81500030-ACT-009
Applicable Models: All
Type of procedure: Inspect Expertise Level: Operator
Priority Level: Average Cautions: High Temperature
Availability Required: Scanner Offsheet Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Duration (time period): 10 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts:
Required Tools:
1. Check whether the upper and lower sheetguides appear aligned. There
should be no visible displacement between them in the cross direction
(X) or machine direction (Y).
2. Check whether there are any items in the gap that might be obstructing
the magnetic signal indicating head split. The head split magnet is part
of the alley, the centre part of the sheetguide in the machine direction.
3. If required, remove the scanner beam cover right above the head and
check whether the clutch actuator is inserted (see your scanner manual
for details).
9.10. Inspect HMI panel
Activity Number: 80801767-81500030-ACT-010
Applicable Models: All
Type of procedure: Inspect Expertise Level: Honeywell Expert
Priority Level: Average Cautions: none
Availability Required: none Reminder Lead Time:
Experion MX MSS & EDAQ Data Acquisition Tasks
4/1/15 P/N 6510020381 Rev 03 9-10
Overdue Grace Period: Frequency (time period):
Duration (time period): 5 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts:
Required Tools:
When diagnosing Heads Are Split alarm, check whether the head split key is in
the ON position rather than in the OFF position on either of the two HMI user
panels at the ends of the scanner. The head split key I/O signal does not appear in
the I/O pages, but any state change is logged by the FC in the FC log files (see
Subsection 6.2.4).
9.11. Check time synchronization processes
Activity Number: 80801767-81500030-ACT-011
Applicable Models: All
Type of procedure: Inspect Expertise Level: Honeywell Expert
Priority Level: Average Cautions: none
Availability Required: none Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Duration (time period): 5 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts:
Required Tools:
Loss of time synchronization between the MSS and EDAQ points to either of the
master (MSS) or slave (EDAQs) processes not running. The easiest way to check
Tasks Check ethernet cable
P/N 6510020381 Rev 03 4/1/15 9-11
this is to bring up the main MSS web page and to hover the mouse of over the
Process Status column. See Figure 9-1.
Figure 9-1 Process Status Indicators
All processes listed should have a check mark. In particular, on the EDAQ the
process to check is called ptpd.arm. On the MSS system, look for the ptpd.x86
process.
Reboot the respective devices that are missing. Note that that MSS or EDAQ or
FC log files written to the MSS will have further information or warning
messages if time synchronization fails, and these files can be viewed or
downloaded from the main MSS web page (see Subsection 6.2.4). Finally, time
synchronization will fail if the correct Ethernet switches are not installed in the
scanner, because they will not pass the VLAN tagged time synchronization
messages.
Contact Honeywell Engineering if this time synchronization error happens.
9.12. Check ethernet cable
Activity Number: 80801767-81500030-ACT-012
Applicable Models: All
Type of procedure: Inspect Expertise Level: Technician
Priority Level: Average Cautions: none
Availability Required: none Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Duration (time period): 10 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Experion MX MSS & EDAQ Data Acquisition Tasks
4/1/15 P/N 6510020381 Rev 03 9-12
Part Number Quantity Lead Time
Required Parts:
Required Tools:
This task refers to two type of Ethernet alarms.
All MSS CPUs, with or without configured Ethernet redundancy, monitor the
total rate of re-transmitted network packets. This diagnostic does not distinguish
whether the re-transmission occurs on the RAE network or on the scanner
network, but it is much more likely to indicate problems on the moving power
track Ethernet cable than the stationary cables to the server.
Two quantities are calculated, whose alarms limits are set in the RTDR:
./Scanner X/Mss/Sensor manager/Job set/Mss tcp retrans ratio/limit
./Scanner X/Mss/Sensor manager/Job set/Mss tcp loss ratio/limit
1. In a scanner without power track Ethernet redundancy configured (see
Chapter 2), try to switch to the unused cable. This switch is done at the
endbell Ethernet switch. In scanners without proper redundancy
configuration, only one Ethernet cable should be connected at a time,
or the network will fail.
2. Check whether redundancy is configured using the MSS web page.
Click Cable State on the right side of the display.
If you have configured redundancy, the Ethernet Redundancy Alarm
indicates a failure or imminent failure the Ethernet cables in the power
track or the Ethernet net cable to the RAE server. In this case, the
system points to the specific cable that is source of the problem.
3. You are then directed to the MSS web pages for detailed information
on cause of the alarm.
The alarm may refer to a complete disconnect on one of the two power
track cables or that a diagnostic threshold for TCP packet
retransmissions has been exceeded.
4. After accessing the main MSS web page (see Subsection 3.5.1 or
Subsection 6.2.1) click Cable Status. Further help is available on the
web page.
Tasks Check MSS CPU
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9.13. Check MSS CPU
Activity Number: 80801767-81500030-ACT-013
Applicable Models: All
Type of procedure: Inspect Expertise Level: Technician
Priority Level: Average Cautions: none
Availability Required: none Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Duration (time period): 10 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts:
Required Tools:
The MSS alarms if the internal temperature of the CPU cores exceeds a maximum
limit. This limit is set in the RAE RTDR at the location:
./Scanner X/Mss/Sensor manager/Job set/Mss cpu core temp/limit
Where X is the scanner number (which is 1 for a single scanner system).
There are two potential causes:
The first cause is that a software error is causing the CPU cores to run at 100%
usage all the time. Except at startup time, an average load of less than 25% is
expected.
1. The problem can be fixed by restart of the MSS. Initiate a restart from
the MSS display Restart MSS by clicking Hard Reset.
2. After the restart, collect the MSS log files from the MSS web page by
clicking MSS/EDAQ/FC Logs button.
The MSS log files contain periodic values of the CPU temperatures
and CPU usage.
3. Contact Honeywell Engineering with the log file details for analysis.
Experion MX MSS & EDAQ Data Acquisition Tasks
4/1/15 P/N 6510020381 Rev 03 9-14
The second cause is that the MSS is in an unusually hot environment with little or
no air flow.
1. Check whether endbell cooling (if installed) is functioning.
2. The MSS may be installed remote from the scanner , as long as no
switch is inserted between the MSS and the endbell scanner switch.
9.14. Check temperature measurement
Activity Number: 80801767-81500030-ACT-014
Applicable Models: All
Type of procedure: Inspect Expertise Level: Honeywell Expert
Priority Level: Average Cautions: none
Availability Required: none Reminder Lead Time:
Overdue Grace Period: Frequency (time period):
Duration (time period): 10 min # of People Required: 1
Prerequisite Procedures:
Post Procedures:
Part Number Quantity Lead Time
Required Parts:
Required Tools:
There are three temperatures reported by the system that are accumulated as
averages (per head) from sensor EDAQs. Each EDAQ has an on-board
temperature sensor and is connected to a platform and sheet guide temperature
sensor (EDAQ PCB connectors J5 and J6 respectively). The alley EDAQ code
collects these data and forwards the average of the readings to the MSS and onto
the RAE RTDR.
The alley code performs various checks to ensure the data are valid. Data from
EDAQs that appear to have a short circuit thermistor or an open circuit are
ignored and not reported. The software also looks for outliers – inconsistent data.
Small variations between the reported temperatures are expected due to the
temperature gradients in the head and conversion accuracies, but if an EDAQ
temperature data is too far from the median of the total data set, an alarm is
created.
Tasks Check temperature measurement
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1. The EDAQ log files (See Chapter 6) contain periodic printouts of all
the individual EDAQ temperatures.
2. Download it from the MSS web page and determine which EDAQ is
the outlier. Replace the thermistor.
3. If the problem cannot be resolved, the alarm can be suppressed by
unplugging the sheet guide or platform thermistor from the EDAQ –
the software then ignores the data without alarming.
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10. Experion Alarm Based Troubleshooting
This chapter provides details of the Experion MX alarms that are EDAQ-related
rather than sensor-related, and refers you to an appropriate task to investigate and
resolve the issue.
Only a subset of these alarms is generated on the 4080 CWS scanner. For
example, the Experion MX alarms that refer to the HMI panel or radiation lights
are relevant to the Q4000 scanner series only, and the alarm described in Section
10.11 is relevant to the 408x scanner only and does not occur in the Q4000-80.
10.1. EDAQ I/O Not Ready
Symptom Possible Cause(s) Solution (Tasks)
MSS failed to receive EDAQ data
Source or receiver EDAQ powered down
Verify EDAQ connections
EDAQ incorrectly configured Verify EDAQ ID
EDAQ process not running Verify EDAQ process health
10.2. EDAQ I/O Timestamps
Symptom Possible Cause(s) Solution (Tasks)
MSS failed to receive EDAQ data at the expected rate
Source or receiver EDAQ powered down
Verify EDAQ connections
EDAQ incorrectly configured Verify EDAQ ID
EDAQ process not running Verify EDAQ process health
Experion MX MSS & EDAQ Data Acquisition Experion Alarm Based Troubleshooting
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10.3. EDAQ PCB Head Temp High
Symptom Possible Cause(s) Solution (Tasks)
On-board EDAQ temperature measurement exceeded limit set in RTDR
Internal head temperature too high Increase RTDR limits
Improve head cooling
Failed EDAQ temperature measurement
EDAQ self-test
10.4. Amber Light Not Lit
Symptom Possible Cause(s) Solution (Tasks)
Nuclear radiation sensor was enabled, but the feedback from the amber light not received by the nuclear source EDAQ
HMI panel issue Verify HMI panel operation
FC not running Verify EDAQ process health
Experion Alarm Based Troubleshooting Red Light Not Lit
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10.5. Red Light Not Lit
Symptom Possible Cause(s) Solution (Tasks)
Shutter open command was given but the red light feedback signals at the endbell or scanner head failed to respond
HMI panel issue Verify HMI panel operation
Red light failure on scanner head Verify red light
The FC cannot be accessed Verify EDAQ process health
10.6. Lost LAN Connection
Symptom Possible Cause(s) Solution (Tasks)
The Sensor cannot be enabled or shutters will not open
Partnet EDAQ (for example, Nuclear Receiver to a Nuclear source) failed or not powered
Verify EDAQ functionality
EDAQ self-test
Partner EDAQ not on network Verify EDAQ process health
Partner EDAQ does not have proper identification
Verify EDAQ ID
Experion MX MSS & EDAQ Data Acquisition Experion Alarm Based Troubleshooting
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10.7. Lost Connection to Alley EDAQ
Symptom Possible Cause(s) Solution (Tasks)
Sensor with interlocking requirements was unable to contact the Alley EDAQ for information
Alley EDAQ failed Verify EDAQ functionality
EDAQ self-test
Alley EDAQ network disconnected Verify EDAQ process health
10.8. Heads are Split
Symptom Possible Cause(s) Solution (Tasks)
Head split interlock reed switch is open when required closed for requested operation
Heads are split Inspect head gap
Head split key switch is on Inspect HMI panel
Alley EDAQ failed digital input Verify EDAQ functionality
EDAQ self-test
10.9. EDAQ Time Synchronization Error
Symptom Possible Cause(s) Solution (Tasks)
Time synch test failed. The EDAQ's local time is too far from the master clock in the MSS
MSS master clock stopped running Check time synchronization
processes
EDAQ clock synch process stopped Check time synchronization
processes
10.10. EDAQ FPGA Error
Symptom Possible Cause(s) Solution (Tasks)
FPGA chip on the EDAQ failed to return new or good data
EDAQ board failure EDAQ self-test
Experion Alarm Based Troubleshooting EDAQ GPIO Watchdog
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10.11. EDAQ GPIO Watchdog
Symptom Possible Cause(s) Solution (Tasks)
Endbell EDAQ sensor safety watchdog expired. Watchdog was not refreshed by the MSS jobset in the required time
MSS stalled or disconnected Verify MSS status and LAN between the MSS and EDAQs
10.12. MSS emss SW Version
Symptom Possible Cause(s) Solution (Tasks)
MSS system software revision is too low to support the RAE version
RAE was updated but the scanner software was not
Upgrade scanner MSS and EDAQ code to latest supported release
10.13. MSS Redundant Ethernet
Symptom Possible Cause(s) Solution (Tasks)
MSS is indicating a problem with the redundant Ethernet in the scanner or to the RAE server
Ethernet Cable disconnected or scanner power track is degrading
Check ethernet cable
10.14. MSS CPU Core Temperature High
Symptom Possible Cause(s) Solution (Tasks)
MSS internal CPU temperature exceeds recommended maximum
Software error is causing 100% load of all CPUs at all time
CPU in hot environment with no airflow around CPU enclosure
Check MSS CPU
Experion MX MSS & EDAQ Data Acquisition Experion Alarm Based Troubleshooting
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10.15. MSS Reboot Required
Symptom Possible Cause(s) Solution (Tasks)
MSS Reboot alarm Internal MSS issue detected, such as a faulty disk partition
A restart from the MSS main web page allows the system to perform hard disk checks and correct errors.
10.16. MSS TCP Retransmission Rate Too High
Symptom Possible Cause(s) Solution (Tasks)
Intermittent network failures on scanner or RAE network
Failing Ethernet cable
A restart from the MSS main web page allows the system to perform hard disk checks and correct errors.
10.17. MSS TCP Loss Ratio Too High
Symptom Possible Cause(s) Solution (Tasks)
Intermittent network failures on scanner or RAE network
Failing Ethernet cable
A restart from the MSS main web page allows the system to perform hard disk checks and correct errors.
Experion Alarm Based Troubleshooting Temperature Measurement Deviations
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10.18. Temperature Measurement Deviations
Symptom Possible Cause(s) Solution (Tasks)
Inconsistent readback and/or control of the sheet guides or platform temperatures. Poor head temperature control.
EDAQs all contribute to sheet guide and platform and PCB board temperatures. One EDAQ is returning data inconsistent with the others. Possibly a failing temperature sensor on a sensor EDAQ
Check temperature measurement
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11. EDAQ Error Messages
The EDAQ boards generate their own set of error messages that are visible to the
Experion MX system and the scanner Web pages. On the Operator Station these
are displayed on the MSS Summary page under the MSS Setup Diagnostic tab,
or the I/O point monitor display.
The main MSS Web page has a button labeled Whats Wrong Messages. When
pressed, it displays all the latest messages from all EDAQs.
Check any Whats Wrong message generated against these lists for trouble
shooting purposes. For the metals C-frame and rubber caliper, references to the
HMI panels (Human Interface Panel) and would be the same as the key switch
and enable buttons found on these systems.
Table 11-1 EDAQ Q4000 Specific Error Messages
Erro
r Co
de
Error String Description
Sensor is not enabled. The sensor was operated from the Experion MX displays before enabling from the HMI panel.
Check the HMI panel enable button and key switch, if applicable.
2 Sensor got disabled while in operation.
The sensor became disabled from HMI panel while in operation. Check HMI panel enable button and key switch if applicable.
Check the serial cable connection between frame controller EDAQ and the HMI panel.
Experion MX MSS & EDAQ Data Acquisition EDAQ Error Messages
4/1/15 P/N 6510020381 Rev 03 11-2
Erro
r Co
de
Error String Description
3 Lost network connection with the Frame Controller (FC).
One or both sensor EDAQs lost network connection with the FC.
Check that the FC EDAQ is up and the frame controller application is running.
Check Ethernet cable connection to the sensor EDAQs and to the FC.
4 Lost network connection with MSS.
One or both sensor EDAQs lost network connection with MSS.
Check MSS computer is up and the MSS application is running.
Check Ethernet cable connection to the sensor EDAQs and to the MSS.
5 Lost network connection with partner EDAQ.
Sensor EDAQ pair lost network connection between them.
Check that both sensor EDAQs are up and the EDAQ application is running in both.
Check the Ethernet cable connection to the sensor EDAQs.
6 Lost network connection with upper alley EDAQ.
Source side EDAQ lost network connection to the upper alley EDAQ.
Check the upper alley EDAQ is up and that the EDAQ application is running.
Check the Ethernet cable connection to the source side EDAQ and to the upper alley EDAQ.
7 Lost network connection with lower alley EDAQ.
Source side EDAQ lost network connection to the lower alley EDAQ.
Check that the lower alley EDAQ is up and that the EDAQ application is running.
Check the Ethernet cable connection to the source side EDAQ and to the lower alley EDAQ.
8 Partner EDAQ is in an incompatible state.
The operating state of the sensor EDAQ pairs do not match. This error is caused typically by a software issue.
Report the incident to technical support and power cycle both EDAQs to recover.
9 Upper and lower parts of the head is not aligned or split.
The upper and lower parts of the head are not aligned or the head-split switch is activated.
Check the head alignment and the wiring from upper alley EDAQ to the head-split switch.
EDAQ Error Messages MSS & EDAQ
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Erro
r Co
de
Error String Description
10 Receiver is not in place or not inserted all the way inside.
Receiver assembly is not fitted correctly or the receiver-in-place switch is not activated.
Check the receiver assembly and the wiring from the receiver EDAQ to the receiver-in-place switch.
11 Amber light did not turn on in expected time.
The amber light for the sensor in the HMI panel did not turn on.
Check the amber light lights up for at least half a second when enable push button is pressed.
Check the serial cable connection between the FC EDAQ and HMI panel.
12 Amber light turned off while in operation.
The amber light for the sensor in the HMI panel was on for some time and then turned off.
Check the amber light lights up for at least half a second when enable push button is pressed.
Check the serial cable connection between the FC EDAQ and HMI panel.
13 Scanner red light did not turn on in expected time.
The main scanner red light in the HMI panel or the red lights on the frame head did not turn on.
Check the panel and head red light LEDs and the serial cable connection between the FC EDAQ and HMI panels.
14 Scanner red light turned off while in operation.
The main scanner red light in the HMI panel or the red lights on the frame head were on for some time and then turned off.
Check the panel and head red light LEDs and the serial cable connection between the FC EDAQ and HMI panel.
15 Shutter red light did not turn on in expected time.
The shutter red light for the sensor in the HMI panel did not turn on.
Check the panel red light LEDs and the serial cable between the FC EDAQ and HMI panel.
16 Shutter red light turned off while in operation.
The shutter red light for the sensor in the HMI panel was on for some time and then turned off.
Check the panel red light LEDs and the serial cable between the FC EDAQ and HMI panel.
17 Interlock board failed to turn on power in expected time.
The interlock board controlling power to the source module was unable to turn the power on.
Check the connections from the source EDAQ and the sensor to the interlock board.
Experion MX MSS & EDAQ Data Acquisition EDAQ Error Messages
4/1/15 P/N 6510020381 Rev 03 11-4
Erro
r Co
de
Error String Description
18 Interlock board turned on power without request.
The interlock board controller power to the source module turned on unexpectedly without the request from EDAQ.
Check the connections from the source EDAQ and sensor to the interlock board.
19 Receiver measurement is below absolute minimum.
Receiver measurement is not functioning.
Check the connections from the receiver EDAQ to the sensor and the sensor receiver assembly.
20 Receiver measurement is above absolute maximum.
Receiver measurement is not functioning.
Check the connections from the receiver EDAQ to the sensor and the sensor receiver assembly.
21 Receiver measurement is above HiClosedSafeLimit.
Receiver measurement while the shutter is closed is higher than the expected maximum.Ensure the shutter is being closed correctly.
Check the connections from the receiver EDAQ to the sensor and the sensor receiver assembly.
22 Receiver measurement is below LoOpenSafeLimit.
Receiver measurement while the shutter is open is lower than the expected minimum.
Check the air supply and ensure the shutter is opening correctly.
Check the connections from the receiver EDAQ to the sensor and the sensor receiver assembly.
23 HMI panel key switch is in off position.
The HMI panel Enable button was pressed while the key switch is in the OFF position.
Turn the key switch to the ON position and then Enable again to enable the sensor.
24 Remote mode digital output got turned off.
The remote mode digital output state was turned off and the sensor is now controlled by the button panel on the sensor.
Check the remote mode output state on the RAE MSS Card IO Point Monitor.
Check the serial cable connection between the EDAQ and the sensor.
25 Z Normal analog input is less than Z Max volts.
The ESS wheel assembly is in a position to cause maximum deflection and may cause the sheet to break.
Check the wheel assembly unit.
Check the serial cable connection between the EDAQ and the sensor.
EDAQ Error Messages MSS & EDAQ
P/N 6510020381 Rev 03 4/1/15 11-5
Erro
r Co
de
Error String Description
26 Insert limit switch was activated.
The ESS wheel assembly is inserted unexpectedly and may cause the sheet to break.
Check the wheel assembly unit.
Check the serial cable connection between EDAQ and the sensor.
27 Sensor EDAQ lost communication with the sensor.
The sensor EDAQ lost communication with the sensor module.
Check that the sensor assembly is powered and running the appropriate firmware version.
Check the connection between the EDAQ and the sensor assembly.
28 Laser enabled feedback from the sensor failed.
The laser-enabled feedback from the sensor has failed.
Check the connection between the EDAQ and the sensor assembly.
Check that the receiver assembly is properly mounted and aligned with the source.
29 Color sensor bezel is not retracted; sensor will cause problems while over the sheet.
The color sensor bezel has not retracted and may cause the sheet to break.
Check the wiring between EDAQ and the sensor.
Check the operation of the bezel.
30 Sensor EDAQ received bad status from the sensor.
The sensor assembly is experiencing a problem as described the error code in the WhatsWrong string.
Search the sensor manual for the error description and mitigation.
31 Error accessing data from EDAQ FPGA.
The EDAQ FPGA RAM image is corrupted. When this error is reported, EDAQ reboots without user intervention after five seconds and the error clears itself.
Replace the EDAQ if the sensor does not come back operational or if this error is reported in log files more than once.
32 EDAQ outputs disabled as it lost connection with MSS.
This error is reported only by EDAQs in a CWS scanner.
Ensure that MSS application is running and check the network connection to the EDAQ and the MSS.
33 Time difference between local clock and master clock exceeds configured limit.
Time synchronization between EDAQ and MSS is not working. The time difference is now more than 1 second.
Experion MX MSS & EDAQ Data Acquisition EDAQ Error Messages
4/1/15 P/N 6510020381 Rev 03 11-6
Erro
r Co
de
Error String Description
34 Reset was not done. In laser caliper calibration module, step count was not zeroed-out before writing a new value.
35 Dome movement inhibited.
The limit switches did not trigger as expected while moving the laser caliper sensor dome.
36 Fan frequency feedback not detected.
The EDAQ frequency input for the alley fan speed is measuring out of range.
37 Alley cannot read airwipe temperature.
The alley EDAQ is measuring airwipe temperature out of range.
Check connections from EDAQ to airwipe temperature sensor.
38 Shutter enable switch is in off state.
The X-ray shutter failed to open in the 4036 C-Frame metals scanner, since the shutter enable switch on the cabinet is in an OFF state.
39 Sensor specific driver could not be loaded.
The 4036 C-Frame X-ray source EDAQ could not load the driver for CRSP processing.
40 Run time error detected with sensor specific error.
The 4036 C-Frame X-ray source detected a runtime error with the CRSP driver.
Report the error to technical assistance with log files.
41 Shutter is closed by green light is not ON.
The Source EDAQ commanded to close shutter but the green light failed to light up.
Report the incident to technical assistance immediately. It is possible that something is preventing the shutter to physically close. Access to the sensor should be restricted.
If the shutter is closed, check the green light and associated circuitry.
42 Shutter is open but green is not OFF.
The green light remained ON even after the source EDAQ commanded the shutter to open.
In the Q309x scanner, check the shutter bypass jumpers on the head power distribution board.
43 Pressure failure detected.
The air pressure measurement in the Q309x source EDAQ is out of range.
Check the compressor wiring and pneumatic lines to the head power distribution board.
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12. EDAQ Failure Diagnostic Process
This chapter describes the process used to determine whether an observed EDAQ
fault is a hardware failure or a software failure.
12.1. Completed board failures
When the scanner or sensor device stops measuring, check the MSS Summary
Page (under MSS Setup and Diagnostics) to see if the MSS is no longer
communicating with a particular EDAQ. If it is not, then the MSS
Communication With EDAQ column has a red indicator.
If the red indicator on the MSS Summary page appeared while scanning or while
the system had been operating fine previously, check the edaq log files to see
when this edaq made its last entry and whether there are any diagnostic message
present in the files around that time (see Chapter 6). Attempt to restart the EDAQ,
by removing its +24V power supply cable, rather than re-powering the entire
scanner.
Check the main MSS web page (see Chapter 6). This page detects all devices that
have an IP address and working interface card, regardless of whether any sensor
code is running.
If the EDAQ list contains a new EDAQ with a generic function type,
the EDAQ booted but failed to identify as the proper sensor (see
Chapter 7).
If the EDAQ is not detected at all, it is either unplugged or has failed
to boot. Verify the network connectors and power in the EDAQ.
Verify the 3.3V LED indicator on the board is green (see Chapter 5).
If the LED is not lit, but +24 V appears to be present on the input
connector J7, replace the EDAQ.
Experion MX MSS & EDAQ Data Acquisition EDAQ Failure Diagnostic Process
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Otherwise, if the Power appears ok:
If the Ethernet status LED (part of the Ethernet connector on the EDAQ) briefly
blinks at start up but then show no continuous activity, there are two possible
causes:
The EDAQ may have a corrupted NAND flash memory or a physical
failure of the PCB. Neither issue can be fixed in the field. Replace the
EDAQ and return the original to Honeywell for detailed diagnosis.
The communication issue may be upstream of the EDAQ (cables,
switches, or other). Remove the EDAQ from the scanner. See Chapter
8 on how to connect the EDAQ offline to a regular PC and perform
self-checks.
12.2. I/O sub-component failures
This condition refers to the situation when the MSS summary page and MSS web
pages indicate that the EDAQ is operating and communicating fine but the sensor
or scanner fails to respond appropriately. An example could be a cold sheet guide
heater when the heater target temperature was set high, or a shutter that fails to
open on a basis weight shutter, or if an IR signal suddenly saturates.
These symptoms could indicate that the I/O sections of the board have a fault: a
digital output circuit failure or a bad ADC converter. In these cases, it is best to
remove & replace the EDAQ (see Chapter 5). An EDAQ self-test can be
performed away from the scanner; using just a standard PC, a self-test harness and
a +24V power supply. See Chapter 8.
12.2.1. Caliper frequency readings unstable
A common problem is unstable contacting caliper readings. Unlike previous
scanner systems, the caliper generated frequency signal is directly digitized on the
EDAQ and is not first converted to a voltage. For stable caliper operating, the
jumper W1 must be inserted on the EDAQ.
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13. Storage, Transportation, End of Life
This chapter summarizes the Honeywell policy with regards to the storage and
disposal of components of the MSS/EDAQ Data Acquisition systems.
13.1. Storage and transportation environment
In order to maintain integrity of scanner components, storage and transportation
of all equipment must be within the parameters shown in Table 13-1.
Table 13-1 Storage and Transportation Parameters
Duration of Storage Acceptable Temperature Range Acceptable Humidity Range
Short term (less than one week) -20°C–45°C (-4°F–113°F) 20%–90% non-condensing
Long term -10°C–40°C (14°F–104°F) 20%–90% non-condensing
13.2. Disposal
Honeywell supports the environmentally conscious disposal of its products when
they reach end of life or when components are replaced.
All equipment should be reused, recycled, or disposed of in accordance with local
environmental requirements or guidelines.
This product may be returned to the Honeywell manufacturing location, and it
will be disposed using environmental friendly methods. Contact the factory for
further details and instructions.
Experion MX MSS & EDAQ Data Acquisition Storage, Transportation, End of Life
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Except where identified in this chapter, the scanner does not contain hazardous or
restricted materials.
Guidelines for disposal of equipment by Honeywell or the customer for sensor-
specific materials are as described in Subsection 13.2.1.
13.2.1. Solid materials
remove all non-metallic parts (except plastic) from the sensor and
dispose of through the local refuse system
recycle plastic parts
wires and cables should be removed and recycled; copper may have
value as scrap
electrical and electronic components should be recycled or handled as
special waste to prevent them from being put in a landfill, because
there is potential for lead and other metals leaching into the ground
and water
metals should be recycled, and in many cases have value as scrap.
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14. Glossary
ARM A RISC processor designed by Arm Holding Ltd. It is the main CPU in the EDAQ
EDAL Honeywell proprietary software layer responsible for distributing the acquired data to clients
EDAQ Ethernet data acquisition board, digitizes all the sensor signals
Flash Memory Permanent storage on EDAQ. Functions like a local disk drive but is solid state. Similar to the SSD drive in the Measurement Sub System (MSS).
Field Programmable Gate Array (FPGA)
Programmable chip that runs code as if it were hardware design. Used for real-time control of the EDAQ data acquisition electronics
DHCP Protocol that assigns a dynamic (temporary) IP address to a device. Such a server is provided on the scanner LAN
Local Area Network (LAN)
Refers to either the internal scanner network (EDAQs, MSS) or the network between the MSS and QCS server
Measurement Sub System (MSS)
CPU located at the electronics end responsible for binning sensor data and transmitting to the RAE system
Real-time Application Environment (RAE)
The system software used by the QCS to manage data exchange between applications.
Solid State Device (SSD)
Disk drive manufactured without moving parts from flash memory
User Panel Interface / Human Machine Interface (UPI/HMI)
The control panel at the ends of the scanner
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A. Part Numbers
Table A-1 lists part numbers and descriptions for the Experion MX MSS &
EDAQ data acquisition system.
Table A-1 Part Numbers
Part Number Description
Value Line IPC
6540580201 Pins
6540580304 EDAQ J1 3-pin Molex
6543100025 Advantech UNO-2182
6543100033 CompuLab FitPC2i
6543100034 NexCom MSS PC Intel Atom
6543120016 32 GB solid-state SATA drive
6543210053 Workstation Soft ware Media
6543210058 MSS Base Installation DVD (>32 GB disk)
6543210088 MSS Installation DVD V2 (>64 GB disk)
6553780247 Screws
6572000075 Hard Drive without MSS – Q4000
6572000087 MSS Base Install DVD V2 & Hard Drive
6580500111 Head power distribution board
6580801767 Installation kit
6580801773 EDAQ Self-Test Cable harness
6580801792 EDAQ Debug Serial Cable
6580801828 NexCom MSS, Drive + DVD
6580801880 EDAQ Connector Extender
6581500030 EDAQ PCBA
6581500032 Frame controller expansion board