5314 North Irwindale Ave

Irwindale, California 91706

Tel (626) 960-3300 y Fax (626) 939-3870

705593-C
Rev Date Pages

4-11 – 4-13.
Add Machinery Directive to CE declaration
of conformity.
C December 12, 2003 Modify Edgeseek section on page 4-11
and 4-12.
Correct typo on page 4-13: spelling of
"Interval".
Attach microbric dwgs. 681093 and
B June 11, 2003
681157 at end of manual.
NDC Model 6100TC
Measurement and Control System

User Manual

5314 North Irwindale Avenue Customer Care Dept. Phone (626) 939-3855
Irwindale, CA 91706 Customer Care Dept. Fax (626) 939-3871
Main Phone (626) 960-3300 www.ndcinfrared.com
General Fax (626) 939-3870 © 2003 NDC Infrared Engineering Inc.
Proprietary Notice
The information and design disclosed herein were originated by and are the property of
NDC Infrared Engineering. NDC Infrared Engineering reserves all patent, proprietary design,
manufacturing, reproduction use, and sales rights thereto, and to any article disclosed therein,
except to the extent rights are expressly granted to others. The foregoing does not apply to ven-
dor proprietary parts.

Specifications remain subject to change to allow the introduction of design improvements.

NDC Model 6100TC System Manual

Part Number: 705593-C

Date of Release: November 27, 2002

Last Revised: December 12, 2003

Declaration of Conformity

Declaration of Conformity
CE Marking

We, NDC Infrared Engineering Inc.

5314 North Irwindale Ave.
Irwindale, CA 91706 USA

declare under our sole responsibility that the product

Model Description
6100TC Model 6100TC Gauging System

to which this declaration relates, meets the essential health and safety requirements and is in
conformity with the relevant EC Directives listed below using the relevant section of the following EC
standards and other normative documents;

Product safety Standard: EN61010

EMC Standard: EN 50081-2

EN 50082-2
EN55011 (Class A)
IEC 1000-4-2 IEC 1000-4-8 ENV50141
IEC 1000-4-3 IEC 1000-4-11 ENV50204
IEC 1000-4-4

Directives: LVD 73/23/EEC

EMC 89/336/EEC (As amended by EC directive 92/31/EEC)

The CE marking has been affixed on the device according the EC Directives 89/336/EEC and to 92/31/EEC.

Signature__________________________________________________ Date ____ November 8, 2002

Bo Franklin
Director of Engineering

NDC Infrared Engineering Inc., 5314 North Irwindale Avenue, Irwindale, CA 91706 USA
Telephone: (626) 960-3300, Fax: (626) 939-3870, [email protected]
Contact NDC Infrared Engineering

The NDC Infrared Engineering web site is www.ndcinfrared.com

Americas Support Desk

Tel +1-626-939-3855

Fax +1-626-939-3871

Email [email protected]

Main +1-626-960-3300
Switchboard
Tel

European Helpdesk

Tel +44-(0)1621-841002

Fax +44-(0)1621-856180

Email [email protected]

Main +44-(0)1621-852244
Switchboard
Tel

China Support Desk

Tel +86-(0)20-8666-2790

Fax +86-(0)20-8666-5963
Caution Information

Safety Precautions
To ensure the safety of all persons working with the NDC Infrared Engineering Gauging
System, it is important that each one should be familiar with the following safety instruc-
tions.

1. Radiation Safety

This applies only to systems with Gamma or Beta sensors.

a. Do not in any way try to examine the radioactive source, change it, or touch it with
sharp or pointed instruments. If you must look at the bottom of the source head, use a
mirror so that the source does not face your eyes or body.

b. When the system is not in use, keep the sensor shutter closed.

c. Do not enter the area around the measuring sensor unless the shutter is closed and the
shutter controller has been set to ‘close’ (shutter ‘disabled’ in the closed position).
This is indicated by the Shutter Position indicators showing an illuminated green
CLOSED.

d. In the event of a power failure, the shutters will automatically close and operation by
the computer will be disabled. Due to lack of power, the Shutter Position lndicator
will not be illuminated, so it is important to visually verify that the shutter blade has
closed over the sensor before approaching the measuring head.

e. All safety interlock switches must be operational and must not be bypassed when the
gauge is in use.

f. At no time should any person other than a Classified NDC Infrared Engineering engi-
neer dismantle the measuring sensor or the associated safety interlocks and shutter
assembly.

g. In the event of damage or failure of the shutter or sensor, both NDC Infrared Engi-
neering or the NDC Infrared Engineering representative and the locally appointed
Radiation Safety Advisor or the relevent local authorities must be notified immedi-
ately.

h. Due to the low source activity, no warning signs are legally required, but we suggest
you post a warning to alert personnel that a radioactive device is nearby.

•
•
Model 6100TC: Caution Information • i
•
•
•
 2. Electrical Safety

a. Only trained and authorized Maintenance personnel should open the back of the cabi-
net, or any of the NDC Infrared Engineering units. Before opening any unit, it must be
isolated from Mains Power.

b. For safety reasons all the interlock switches operate at 24V DC.

c. Fuses must only be replaced with a fuse of the same type and rating.

d. Any damaged cables or wiring must be replaced or repaired before the system is reen-
ergised.

e. Be sure the system is grounded, and follow normal operating precautions for any elec-
trical device to prevent shock hazard.

3. Mechanical Safety

a. Scanner and other mechanisms have been designed so that all moving parts are pro-
tected by covers or exert insufficient force to cause damage.

b. At no time when a scanner is in operation should any of the covers be removed or left
open.

c. The torque setting for the motor drive must not be adjusted above the specified level,
otherwise the scanning head may not easily stop when its path is blocked.

d. Systems with Gamma or Beta sensors only:

The sensor safety shutter is a mechanical device designed to block off radiation from
the source. This is excluded from the Machinery (Safety) Regulations because a radio-
active source forms part of the machine. The Radiation Safety procedures and inter-
locks prevent personnel from being close to the shutter when it is in operation.

•
•
ii •
• Model 6100TC: Caution Information
•
•
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
HEADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
ENTERING A VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Main Menu Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Main Menu Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Main Menu Page 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
DATA MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
DESCRIPTION OF DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Scan Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Histogram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Roll Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
DISPLAY SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Trend Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Inline Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Profile Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Histogram Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Header Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Display Zone Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PROCESS MENU PAGE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
PROCESS MENU PAGE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SCANNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
PROXIMITY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
SCANNER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
SCANNER CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
SCANNER SETUP MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Scanner Setup Menu Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Scanner Setup Menu Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Scanner Debug Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
EDGESEEK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
What Happens During Edgeseek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Sheet Break Detection with Edgeseek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
AUTOMATIC PROFILE ALIGNMENT FOR EXTRUDERS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Alignment of the Die Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Scanner Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Convert to Diebolts toggle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Auto Profile Position toggle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

•
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Model 6100TC: Table of Contents • iii
•
•
•
 Manual Alignment of the Profile Position with the Die . . . . . . . . . . . . . . . . . . . . . . 4-17
Automatic Alignment of the Die Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Process Die Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Die Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
RECIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
LOADING A RECIPE TO CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
CREATING A NEW RECIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
EDITING THE CURRENT RECIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
EDITING OTHER RECIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
VIEWING A RECIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
PRINTING A RECIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
DELETING A RECIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
RESTORING ORIGINAL SETUP VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
VIEWING THE RECIPE DIRECTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
REPORTS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
STRIP CHART SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
REPORT SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
DESCRIPTION OF ITEMS IN ROLL REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
AUTO SCREEN PRINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
SPLIT ROLL REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
ROLL DEFECTS REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
What Constitutes a Defect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
How Defects are Reported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Roll Defect List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Roll Defect Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
I/O SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
TACH CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
SERIAL OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
ANALOG OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Channel Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Acknowledging an Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Alarm Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
INPUT B SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Custom Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
CYCLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
SITE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

•
•
iv •
• Model 6100TC: Table of Contents
•
•
 SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Turning Security On or Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Setting Security For Individual Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Changing the Security Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
CONTROL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
DUAL GAP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Left/Right Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Control Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Dual Gap Control Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
CROSS AXIS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Left/Right Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Control Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
CONTROL INHIBITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
CONTROL MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
FAST FOURIER TRANSFORM (FFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
FFT Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
FFT Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
FFT Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
STATISTICAL PROCESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Ppk and Cpk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
SPC Spec Limits on Other Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
ETHERNET OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Software Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Connecting to the T-Gauge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
AUTO RETRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Auto Retract Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Lift Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
GAP EXCLUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
TARGET PROFILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Target Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Error Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
AUTOMATIC TARGET OPTIMIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Setting up Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Viewing ATO Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
PRINTING SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
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 NDC MAINTENANCE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
I/O TESTS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
I/O Tests Menu Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
I/O Tests Menu Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Analog Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Parallel Inputs Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Parallel Outputs Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Analog Input Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
SERIAL INTERFACE ALLOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
Miscellaneous Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
OKIDATA PRINTER CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
NDCBACK-JAVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
SERIAL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
INSTALLING NDCBACK-JAVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
RUNNING NDCBACK-JAVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
CONNECTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
QUITTING NDCBACK-JAVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
VIEWING THE VERSION OF NDCBACK-JAVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
DESCRIPTION OF FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Parameters File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Log File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
BOARD CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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Table of Figures
Figure 1-1 Entering a value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-2 Main Menu Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-3 Main Menu Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure 1-4 Main Menu Page 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 2-1 Scan Profile - Horizontal Scale at Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-2 Scan Profile - Horizontal Scale at Step of 6 . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-3 Scan Profile - Horizontal Scale at Diebolts . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-4 Trend Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-5 Inline Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-6 Histogram Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-7 Roll Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-8 Zones Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-9 Display Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Figure 2-10 Trend Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-11 Inline Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-12 Profile Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 2-13 Histogram Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Figure 2-14 Scale Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Figure 2-15 Header Info Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Figure 2-16 Display Zones screen - Auto Display Zones at Yes . . . . . . . . . . . . . . . . . 2-18
Figure 2-17 Display Zones Screen - Auto Display Zones at No . . . . . . . . . . . . . . . . . 2-19
Figure 2-18 Deleting a display zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Figure 3-1 Process Menu Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Figure 3-2 Alerts Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-3 Process Menu Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 4-1 Scanner Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Figure 4-2 Calibrate Scanner: Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-3 Calibrate Scanner: Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-4 Scanner Setup Menu Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 4-5 Scanner Setup Menu Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-6 Scanner Debug Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-7 Edgeseek Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Figure 4-8 Profile Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Figure 4-9 Scanner display showing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Figure 4-10 Die Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Figure 4-11 Process Die Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Figure 4-12 Die Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Figure 5-1 Recipe Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-2 Current vs. Selected Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-3 Selecting a Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Figure 5-4 Viewing a Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 6-1 Reports Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Figure 6-2 Strip Chart Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Figure 6-3 Report Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Figure 6-4 Sample Roll Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Figure 6-5 Auto Screen Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Figure 6-6 Split Roll Report - Zone 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Figure 6-7 Split Roll Report - Zone 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Figure 6-8 Defect Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

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 Figure 6-9 Report Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Figure 6-10 Roll Defect List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Figure 6-11 Roll Defect Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Figure 7-1 I/O Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Figure 7-2 Tach Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Figure 7-3 Serial Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Figure 7-4 Analog Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Figure 7-5 Channel Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Figure 7-6 Alarm labels flash on Alarm condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Figure 7-7 Alarms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Figure 7-8 Alarm options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Figure 7-9 Input B Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Figure 8-1 Units Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Figure 8-2 Custom Unit Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Figure 8-3 Cycles Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Figure 8-4 Clock Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Figure 8-5 Site Layout Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Figure 8-6 Screen & Printer Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Figure 8-7 Miscellaneous Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Figure 8-8 Security Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Figure 8-9 Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Figure 9-1 Control Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Figure 9-2 Speed Control Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Figure 9-3 Effect of Feedback Control in Avg and Min Modes . . . . . . . . . . . . . . . . . . 9-6
Figure 9-4 Dual Gap Control Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Figure 9-5 Left/Right Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Figure 9-6 Control Zones Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Figure 9-7 Dual Gap Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Figure 9-8 Cross Axis Control Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Figure 9-9 Left/Right Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Figure 9-10 Control Zones Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Figure 10-1 FFT Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Figure 10-2 Last FFT Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Figure 10-3 FFT Composite Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Figure 10-4 SPC Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Figure 10-5 SPC Limits Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Figure 10-6 X-Bar Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Figure 10-7 Range Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Figure 10-8 10BaseT Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Figure 10-9 Network Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Figure 10-10 Auto Retract Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Figure 10-11 Gage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Figure 10-12 Process Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Figure 10-13 Tach Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Figure 10-14 Target Profile Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Figure 10-15 Target Profile Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Figure 10-16 Add Point screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Figure 10-17 Delete Point screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Figure 10-18 Scan Profile Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Figure 10-19 Error Profile Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Figure 10-20 ATO Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Figure 10-21 Process Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

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• Model 6100TC: Table of Figures
•
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Figure 10-22 Trend display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
Figure 11-1 NDC Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Figure 11-2 Version Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Figure 11-3 I/O Tests Menu Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Figure 11-4 I/O Tests Menu Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Figure 11-5 Inputs Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Figure 11-6 Outputs Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Figure 11-7 Analog Inputs Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Figure 11-8 Analog Input Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Figure B-1 NDC Infrared Engineering-supplied null modem cable . . . . . . . . . . . . . . .B-1
Figure B-2 9-to-25 Pin adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Figure B-3 Select System Type screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Figure B-4 Select Connection Type screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Figure B-5 Serial Settings screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Figure B-6 Ethernet Settings screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Figure B-7 Enter filename screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Figure B-8 Select file dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Figure B-9 Current settings screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Figure B-10 Save status dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Figure B-11 Restore status dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Figure B-12 Connection error dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Figure B-13 Version of Ndcback-Java . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Figure B-14 Parameters file saved by Save option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
Figure B-15 Error.log file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
Figure C-1 Mother Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Figure C-2 Scanner Expansion Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Figure C-3 Process Expansion Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3

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Model 6100TC: Table of Figures • ix
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 •
•
x •
• Model 6100TC: Table of Figures
•
•
 CHAPTER

1 Introduction 1
This manual covers operation of NDCInfrared Engineering’s Model 6100TC measurement
and control system.

The system was thoroughly tested and inspected before being shipped, and is ready to install
and use when received. Please read this manual carefully before attempting to use the gauge.

Save the shipping container for future shipment or storage. It is designed especially for your
gauge and is expensive to replace. It will be useful if the sensor or console should ever be
returned to the factory for warranty or non-warranty repairs. In all instances, call the
NDC Infrared Engineering Customer Care Department before returning equipment to the fac-
tory for repair.

Your NDC Infrared Engineering gauge uses a pressure-sensitive touchscreen instead of the
switches and dials found on most instruments.

Each screen shows a display of gauge data or a menu to configure the system. Available dis-
plays include Scan Profile, Trend, Inline, Histogram, Roll Profile and Zones. Every menu and
display includes a header with the most recent gauge reading, the target and the alarm values.
See Section 1.1 - Header. If your gauge includes a tachometer and process control, the header
also shows the linespeed and a label indicating whether the line is under automatic control.

The menus offer a variety of setup and program options that let you configure the system to
your specific needs. Every screen includes a set of prompts or buttons which look like boxes or
arrows and operate like electronic push buttons that control the display and gauge functions.
Some buttons toggle or cycle through two or more choices, such as the interval between
reports. When you touch one of these buttons, the message line in or near the button will
change to show the current selection. Other buttons call up a new display or menu. When you
touch one of these buttons, the screen changes to reflect your instructions.

This manual uses an arrow (→) to indicate a sequence of buttons. For example, the sequence
“Main → More → Control” represents the path from the Main menu to the Control menu.

Once you have made your selections on a given menu, press the Enter button to fix them in
the system memory. If you change your mind or make a mistake, press Abort instead of
Enter.

Most menus include a row of buttons at the bottom marked Display, Exit and Main. The Dis-
play button calls up a menu that allows you to select among the available displays. The Exit
button returns you to the next highest menu level, and the Main button returns you to the Main
menu at the top of menu hierarchy.

When you first power up the gauge, the screen shows a Starting Display with the software
number and other information about the program. If everything is working properly, this dis-
play is replaced in about five seconds by the Display menu. If the Display menu does not
appear after about five seconds, a trained technician can use the Starting Display to help iso-
late the problem.

•
Model 6100TC: Introduction •• 1-1
•
•
•
1 1.1 Header

HI ALARM 73.30
8

72.30
2 TARGET 72.30 1 PRINT
LO ALARM 71.30
MILS 13-NOV-2002
3 PROD: NDC BASIC 5
ROLL: 001 10:30:13
DATA ON FT/MIN: 60.00 FT: 248 NDC SYSTEMS
4 6 7
CONTROL ON POSITION: 53.43 LB: 53.43 MODEL 6100

The header appears on most screens and displays the following:

1. the most recent gauge reading

2. high alarm level

target
low alarm level

3. product ID
roll number

4. status of data mode (on or off). See Section 1.4 - Data mode.
systems with control only: status of automatic control mode (on or off)

5. time and date

6. linespeed
position of the sensor

7. accumulated length (this is visible only if the Accum Length toggle is turned on in
the Header Info menu.)
accumulated weight (this is visible only if the Accum Weight toggle is turned on in
the Header Info menu.)

See Section 2.2.6 - Header Info.

8. the Print button prints the current screen

•
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1-2 •• Model 6100TC: Introduction
•
•
1.2 Entering a Value
1

72.30
TARGET (MILS)

ABORT ENTER

Figure 1-1 Entering a value

This section describes how to change the value for a parameter.

Figure 1-1 shows that the current value for the selected parameter, Target, is 72.30. The cur-
rently selected character, 7, is highlighted. The up and down arrow buttons can be used to
change this character:

y Touch ↑ to move the current character up by one

y Touch ↓ to move the current character down by one

The left and right arrow buttons are used to select another character:

y Touch ← to move the selection one character to the left

y Touch → to move the selection one character to the right

Example

In Figure 1-1, the current target is “72.30”. “7” is the currently selected character. To change
the value to “73.50”:

1. Touch → to move to 2.

2. Touch ↑ once to change “2” to “3”.

continues

•
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Model 6100TC: Introduction • 1-3
•
•
•
1 3. Touch → once to move to 3.
continued from previous page

4. Touch ↑ twice to change “3” to “5”.

5. Touch Enter to save the current value on the screen.

To exit without saving the current value, touch Abort.

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1-4 •• Model 6100TC: Introduction
•
•
1.3 Main Menu
1
The three-page Main menu is at the top of the menu hierarchy and includes buttons that lead to
a variety of setup options.

1.3.1 Main Menu Page 1

MAIN MENU

PROCESS REPORTS GAGE RECIPE

LANGUAGE
DISPLAY SETUP SCANNER
ENGLISH

MORE

SHUTTER CONTROL SCANNER

DISPLAY
CLOSED OPEN OFF ON OFFSHEET

Figure 1-2 Main Menu Page 1

Main Menu Page 1 (Figure 1-2) includes the following buttons:

‰ Process: This button calls up a Process menu that lets you change the current recipe’s
product ID, roll number, target and alarms, sheet width, and specific gravity of your prod-
uct.

See Section 3 - Process.

‰ Reports: The system can produce reports based on individual jobs, shifts, rolls or timed
intervals. This button brings up a menu that lets you select and set up your product reports.

See Section 6 - Reports.

‰ Gage: This button brings up a menu that lets you set up the gauge and set the moving
average for the gauge. A larger moving average tends to show smoother results because
high and low points are averaged into the surrounding data.

See your sensor manual.

‰ Recipe: This button brings up a menu that lets you create and modify product recipes.
See Section 5 - Recipes.

‰ Display Setup: The buttons in this menu lead to sub-menus that let you set up the various
displays. See Section 2.2 - Display Setup.

•
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Model 6100TC: Introduction • 1-5
•
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•
1 ‰ Language: This button allows you to switch between English and any other languages
included with your software.

‰ Scanner: The buttons on this menu let you control the sensor’s movement across the
sheet. See Section 4.2 - Scanner Operation.

‰ More: This button brings up Page 2 of the Main menu. See Section 1.3.2 - Main Menu
Page 2.

‰ Display: This button, which appears on most menus, calls up a menu of available dis-
plays. See Section 2.1 - Description of Displays.

‰ Shutter Closed/Open: If your system includes an automatic shutter, this button opens and
closes the shutter. The current condition (open or closed) is highlighted against a solid
background.

‰ Control Off/On: If your system includes automatic control, this toggle lets you turn the
controller on and off. The sensor must be scanning in order to control.

Note that the Auto/Man toggle on your NDC Infrared Engineering remote control panel
must be set to Auto or the controller will not operate. See Section 9.1 - Remote Control
Panel.

‰ Scanner Offsheet: This button closes the optional automatic shutter and sends the sensor
to the Startup Switch. This command requires confirmation by the user.

•
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1-6 •• Model 6100TC: Introduction
•
•
1.3.2 Main Menu Page 2
1
MAIN MENU - 2

NDC MAINTENANCE UNITS SITE LAYOUT CONTROL

I/O SETUP CYCLES SCANNER SETUP

MORE

DATA
DISPLAY MAIN
OFF ON

Figure 1-3 Main Menu Page 2

Main Menu Page 2 (Figure 1-3) includes the following buttons:

‰ NDC Maintenance: This button brings up a new menu and several buttons that allow a
variety of maintenance, troubleshooting and setup options. See Section 11.3 - NDC Main-
tenance Menu.

‰ Units: This button lets you set English and metric units for a variety of setup parameters.
You can also create a customized unit for your gauge measurements. See Section 8.1 -
Units.

‰ Site Layout: This button brings up a menu that lets you enter the distance between the
sensor and windup, and the minimum length for a roll to be included in reports. See Sec-
tion 8.4 - Site Layout.

‰ Control: This button brings up a menu that lets you set up the system’s automatic control
parameters. See Section 9 - Control.

‰ I/O Setup: This button brings up a menu that lets you set up the analog and serial outputs,
tach settings and alarm outputs. See Section 7 - I/O Setup.

‰ Cycles: This button brings up a menu that lets you set up the basic data collection cycle.
Control and trend cycles are multiples of the basic data cycle. See Section 8.2 - Cycles.

‰ Scanner Setup: This button brings up a menu that lets you set up the various scanner set-
tings and functions. See Section 4.4 - Scanner Setup Menu.

‰ More: This button brings up Page 3 of the Main menu. See Section 1.3.3 - Main Menu
Page 3.

‰ Data Off/On: This toggle tells the system whether to collect data for reports and histo-
grams. The Data toggle is normally left On except during start-up or when you know the

•
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Model 6100TC: Introduction • 1-7
•
•
•
1 product will be scrapped. Note that setting the Data toggle to On alone does not guarantee
that Data mode will turn On. See Section 1.4 - Data mode.

1.3.3 Main Menu Page 3

MAIN MENU - 3

CLOCK SPC FFT FIND EDGES

DISPLAY EXIT MAIN

Figure 1-4 Main Menu Page 3

Main Menu Page 3 (Figure 1-4) includes the following buttons:

‰ Clock: This button brings up a menu that lets you set the clock, calendar, and up to three
shift times. See Section 8.3 - Clock.

‰ SPC: This optional button calls up a menu for setting Statistical Process Control parame-
ters. See Section 10.2 - Statistical Process Control.

‰ FFT: This optional button calls up a menu for setting Fast Fourier Transform parameters.
See Section 10.1 - Fast Fourier Transform (FFT).

‰ Find Edges: This button is visible only if the Edgeseek toggle (in the Edgeseek menu) is
On. When this button is touched, the system immediately starts the Edgeseek function to
find the sheet edges. See Section 4.5 - Edgeseek.

•
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1-8 •• Model 6100TC: Introduction
•
•
1.4 Data mode
1
Data mode is On when ALL of the following conditions are satisfied:

1. The external data switch (input C) is On.

2. The Data toggle in Main Menu Page 2 is On.

3. There is no sheet break. See Section 3.2 - Process Menu Page 2.

4. The linespeed is above the minimum linespeed. See Section 7.1 - Tach Calibration.

5. (Systems with shutters): The shutter is open.

6. (Systems with Auto Retract): The sensor is extended.

7. The motor is on.

8. The sensor is on sheet.

The sensor is considered to be on sheet only if ALL of the following conditions are
true:

y It is stopped between the scan limits, or scanning between the scan limits

y The shutter (if there is one) is open

y There are no alarms such as sheet break or low linespeed

While the sensor is moving, in response to a Go To command or arrow button on the

Scanner page, the sensor is considered to be off sheet and Data mode is Off. When the
sensor stops, if it is on sheet, Data mode will be turned back on, assuming all other cri-
teria are satisfied.

If Data mode is On, the header will display “Data On”. Otherwise “Data Off” will be dis-
played. See Section 1.1 - Header.

While Data mode is Off, the product is considered as scrap, and data will not be accumulated
for the histogram and reports. The reports show the duration that Data is On and Scrap is On as
“Time Data On” and “Scrap.” See Section 6.4 - Description of Items in Roll Report.

•
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Model 6100TC: Introduction • 1-9
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1

•
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1-10 •• Model 6100TC: Introduction
•
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 CHAPTER

2 Displays 2
This chapter describes the standard Scan Profile, Trend, Inline, Histogram, Roll Profile and
Zones displays. Other displays may also be provided, depending on your software options and
application.

The Display button at the bottom of the screen brings up the Display menu and allows you to
select among the available options. Each display includes a Print button to order an immediate
printout of the current display. (The memory is continuously updated so that no data is lost
during a printout.)

Each display also includes a Resolution button that lets you select between three vertical
scales (Lo, Med and Hi.) The scales themselves are defined in the Scale menu (Main → Dis-
play Setup → Scale).

Displays are color coded to visually indicate product quality:

y Green signifies product within the alarm limits

y Yellow signifies product above the Hi Alarm level

y Red signifies product below the Lo Alarm level

•
Model 6100TC: Displays •• 2-1
•
•
•
 2.1 Description of Displays
2.1.1 Scan Profile

2 SCAN PROFILE SCANS PER COMPOSITE: 1

72.50

72.40

72.30

MAX 72.43
AVG 72.24
72.
MIN 72.13
2σ 0.119

72.10
4.0 10.0 16.0 22.0 28.0 34.0 40.0 46.0 52.0
RESOLUTION
DISPLAY MAIN
LO MED HI

Figure 2-1 Scan Profile - Horizontal Scale at Auto

This display shows a cross-web profile, centered around the current recipe’s target or profile
average (set in the Profile menu, see Section 2.2.3 - Profile Setup). The profile is a composite,
based on the number of cycles selected in the Profile menu.

The table on the left shows the following statistics for the profile: maximum, average, mini-
mum, and a multiple of sigma, σ, or coefficient of variation, CV (depending on the Sigma/CV
selection in the Profile menu). The sigma/CV multiplier is entered on the Display Setup menu.

SCAN PROFILE SCANS PER COMPOSITE: 1

72.50

72.40

72.30

MAX 72.42
AVG 72.34
72.
MIN 72.17
2σ 0.148

72.10
0.0 6.0 12.0 18.0 24.0 30.0 36.0 42.0 48.0 54.0
RESOLUTION
DISPLAY MAIN
LO MED HI

Figure 2-2 Scan Profile - Horizontal Scale at Step of 6

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2-2 •• Model 6100TC: Displays
•
•
 SCAN PROFILE SCANS PER COMPOSITE: 1

72.50

72.40 2
72.30

MAX 72.41
AVG 72.24
72.
MIN 72.19
2σ 0.123

72.10
5 9 13 17 21 25 29 33 37 41 45 49 53
RESOLUTION
DISPLAY MAIN
LO MED HI

Figure 2-3 Scan Profile - Horizontal Scale at Diebolts

The Horizontal Scale setting in the Profile menu (Main → Display Setup → Profile) config-
ures the horizontal scale for profile displays (Scan Profile, Roll Profile, Zones). Three choices
are available:

1. Auto. Horizontal scale is automatically scaled (Figure 2-1).

2. Step. Horizontal scale has gridlines at equal-sized intervals (Figure 2-2). The size of the
interval is entered as Scan Display Step in the Profile menu. See Section 2.2.3 - Profile
Setup.

3. Diebolt. Horizontal scale shown in diebolt units (Figure 2-3).

•
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Model 6100TC: Displays • 2-3
•
•
•
 2.1.2 Trend

This display (Figure 2-4) presents a series of thin vertical lines, each representing one trend
cycle. Each trend cycle includes data from 1 to several control cycles and each line is overlaid

2
with a heavier bar. The length of each line indicates the maximum and minimum readings dur-
ing the trend cycle. The heavier bar indicates 1, 2 or 3 sigma, depending on the sigma multi-
plier entered on the Display Setup menu. A short horizontal bar marks the average during each
trend cycle. The graph is centered on the target.

The Trend display is automatically cleared at the end of job.

2 SIGMA TREND CYCLES PER BAR: 1

72.50

72.40

72.30

72.20

72.10 18:15:58 18:18:07 18:20:15 18:22:24

RESOLUTION
DISPLAY MAIN
LO MED HI

Figure 2-4 Trend Display

2.1.3 Inline

This display (Figure 2-5) is a simulated strip chart that shows a continuously updated series of
gauge readings. (See Section 6.2 - Strip Chart Setup for instructions on setting up the printer as
a strip chart recorder.)

•
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2-4 •• Model 6100TC: Displays
•
•
 INLINE GRAPH SECS PER POINT: 1.00

72.50

72.40 2
72.30

72.20

72.10 18:15:58 18:18:07 18:20:15 18:22:24

RESOLUTION
DISPLAY MAIN
LO MED HI

Figure 2-5 Inline Display

2.1.4 Histogram

This display (Figure 2-6) shows the data distribution and statistical summary. The horizontal
scale is automatically adjusted to maintain the peak between 80% and 95% of the grid. The
vertical distribution represents the relative frequencies of each gauge reading.

The Histogram display is automatically cleared at the end of job.

No data will be added to the histogram while Data mode is off. See Section 1.4 - Data mode.

HISTOGRAM

72.50
RUNNING TIME
00:42:16
72.40
SINCE 16:11:28
MAXIMUM 72.65
72.30
AVERAGE 72.26
MINIMUM 71.88
72.20 RANGE 0.77
2 SIGMA 0.157

72.10

RESOLUTION
DISPLAY MAIN
LO MED HI

Figure 2-6 Histogram Display

•
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Model 6100TC: Displays • 2-5
•
•
•
 2.1.5 Roll Profile

This display (Figure 2-7) shows a cross web profile average of all scans for the current roll,
centered around the current recipe’s target or profile average (as determined in the Profile

2
menu, see Section 2.2.3 - Profile Setup).

The table on the left shows the following statistics for the profile: maximum, average, mini-
mum, and a multiple of sigma, σ or coefficient of variation, CV (depending on the Sigma/CV
selection in the Profile menu). The sigma/CV multiplier is entered on the Display Setup menu.

The roll profile data is lagged, so it displays an average of all profiles that have actually
reached the windup roll. Profiles are only included in the roll profile if Data mode was on
throughout the profile. See Section 1.4 - Data mode.

ROLL PROFILE

72.50

72.40

72.30

MAX 72.32
AVG 72.25
72.
MIN 72.19
2σ 0.078

72.10
4.0 10.0 16.0 22.0 28.0 34.0 40.0 46.0 52.0
RESOLUTION
DISPLAY MAIN
LO MED HI

Figure 2-7 Roll Profile

2.1.6 Zones

This display (Figure 2-8) shows the average values of a set of user-defined zones, based on
data from the last composite profile. The zones are set via the Display Zones screen.
See Section 2.2.7 - Display Zone Setup. If the user selects Auto Display Zones and enters the
number of zones, the system will divide the profile into that number of equal-width zones. If
the Edgeseek option is turned on (see Section 4.5 - Edgeseek), the sheet width may vary from
scan to scan. In this case, if Auto Display Zones is selected, the zone widths will automati-
cally be adjusted to maintain the correct number of equal-width zones.

The display zone values can be extracted from the T-Gauge using Open Access item 4087.

A bar is drawn for each zone, marking the location and average of the zone.

•
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2-6 •• Model 6100TC: Displays
•
•
The bar is:

Red if data in the zone is below Low Alarm

Yellow if data in the zone is above High Alarm

Green if data in the zone is within the Alarms 2

If part of the display zone is outside the scan limits, only the section within the scan limits will
be displayed.

ZONES SCANS PER COMPOSITE: 1

72.50

72.12 72.22 72.25

72.40

72.30

72.20
72.31 72.32

72.10
4.0 10.0 16.0 22.0 28.0 34.0 40.0 46.0 52.0
RESOLUTION
DISPLAY MAIN
LO MED HI

Figure 2-8 Zones Display

•
•
Model 6100TC: Displays • 2-7
•
•
•
 2.2 Display Setup
Each display can be customized to match your application. From the Main menu, press Dis-
play Setup to reach a menu of display setup options (Figure 2-9).

2
DISPLAY SETUP

TREND INLINE PROFILE

SIGMA MULTIPLIER
HISTOGRAM SCALE HEADER INFO
1 2 3

DISPLAY ZONES

DISPLAY MAIN

Figure 2-9 Display Setup Menu

‰ Trend: Calls up a new menu that lets you set up the Trend display. See Section 2.2.1 -
Trend Setup.

‰ Inline: Calls up a menu that lets you set the Inline display’s Moving Average and Update
Time. See Section 2.2.2 - Inline Setup.

‰ Profile: Calls up a menu that lets you set up the Profile display. See Section 2.2.3 - Profile
Setup.

‰ Histogram: Calls up a menu that lets you set up the Histogram display. See Section 2.2.4
- Histogram Setup.

‰ Scale: Calls up a menu that lets you set the vertical scale for three screen resolution selec-
tions. See Section 2.2.5 - Scale.

‰ Header Info: Calls up a menu that allows you to turn the display of accumulated
length/weight on or off, as well as set the limits for the length and weight alarms.
See Section 2.2.6 - Header Info.

‰ Sigma Multiplier: Lets you specify the number of sigmas for the Histogram’s statistical
summary, for the Trend display, and for reports. For the Scan Profile and Roll Profile dis-
plays, the Sigma Multiplier sets the mutliplier for the sigma or coefficient of variation,
depending on the Sigma/CV toggle in the Profile menu. Available choices are 1, 2 or 3.

‰ Display Zones: Calls up a menu that lets you set up the display zones for the Zones dis-
play. See Section 2.2.7 - Display Zone Setup.

•
•
2-8 •• Model 6100TC: Displays
•
•
2.2.1 Trend Setup

2
TREND

CYCLES PER TREND AUTO CLEAR TREND

CLEAR TREND NOW
1 NO YES

DISPLAY EXIT MAIN

Figure 2-10 Trend Setup Menu

Note the two types of cycles used by this system. A Basic cycle represents the time between
the start of each scan, or the cycle time entered on the Cycles menu. (See Section 8.2 - Cycles.)
A Control cycle represents the number of basic cycles used to calculate each control action.
The number of basic cycles in each control cycle is set in the Control menu. (See Section 9.2 -
Control Menu.)

Figure 2-10 shows the Trend Setup menu (Main → Display Setup → Trend). If your system
includes a controller, the Control Cycles per Trend button sets the number of control cycles
in each Trend bar. If your system does not include a controller, the Cycles per Trend button
sets the number of basic cycles per Trend bar. The Auto Clear Trend toggle clears the Trend
display after each time interval or roll, and the Clear Trend Now button clears the Trend dis-
play immediately.

The Trend display has room for approximately 70 trend bars. As a result, the maximum period
covered by your Trend display depends on the interval between the start of each scan. If each
cycle (Basic or Control) is 6 minutes, the screen will fill in approximately 420 minutes
(70 bars at 6 minutes each.) If each cycle is 3 minutes, the Trend display will fill up and begin
discarding old data after approximately 210 minutes.

•
•
Model 6100TC: Displays • 2-9
•
•
•
 2.2.2 Inline Setup

2
INLINE

MOVING AVERAGE UPDATE TIME

5.00 1.00

DISPLAY EXIT MAIN

Figure 2-11 Inline Setup Menu

The Inline Setup menu (Main → Display Setup → Inline, Figure 2-11) includes buttons for
setting the Moving Average and Update Time:

‰ The Moving Average represents the number of seconds included in each inline or strip
chart data point. Each time the system receives a new reading, it discards the oldest read-
ing and calculates a new data point. A larger moving average tends to produce a smoother
display because spikes in the data are averaged into the surrounding readings. The moving
average used for gauge readings in the header is set on the Gage menu and is independent
of the Inline moving average.

‰ The Update Time represents the number of seconds between Inline and strip chart
updates. If the Update Time is longer than the moving average, some readings will be dis-
carded without being included in the display calculation. The Inline Update Time and the
Strip Chart Setup menu’s Update Time are always the same. If one button is changed, the
other will change also.

The Inline display has room for approximately 560 data points. If the update time is 1 second,
the screen will fill in approximately 560 seconds or 9.3 minutes. If the update time is increased
to 3 seconds, the screen will fill in approximately 28 minutes. The strip chart recorder also
uses these values.

•
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2-10 •• Model 6100TC: Displays
•
•
2.2.3 Profile Setup

2
PROFILE

CYCLES PER SCAN DISPLAY LO SCAN DISPLAY HI RESET DISPLAY

COMPOSITE
4.00 56.00 LIMITS
1

LIVE PROFILES OPEN ACCESS ZONES CONVERT TO

CLEAR COMPOSITE DIEBOLTS
NO YES 8
NO YES

PROFILE REFERENCE HORIZONTAL SCALE SCAN DISPLAY STEP

TARGET AVERAGE STEP 1.00

SIGMA
DISPLAY EXIT MAIN
CV

Figure 2-12 Profile Menu

The Profile menu (Main → Display Setup → Profile, Figure 2-12) includes buttons that
allow you to configure your profile displays:

‰ The Cycles per Composite button lets you set the number of basic cycles included in each
composite profile.

‰ The Scan Display Lo and Scan Display Hi buttons let you zoom in the display to a spec-
ified portion of the sheet. The scan limits are not affected by changing these values.

‰ The Reset Display Limits button cancels the values entered on the Scan Display Lo and
Scan Display Hi buttons and resets the display to match the scan limits.

This button is visible only if the Edgeseek toggle is Off (in the Edgeseek menu).

‰ The Clear Composite button clears the Composite profile at the beginning of the next
scan/cycle.

‰ Setting the Live Profiles toggle to Yes causes the profile display to be updated every time
a new point is collected. If the toggle is set to No, the profile display will be redrawn at the
end of every scan/cycle.

‰ The Open Access Zones button is used to set the number of equal-width sections of the
profile for output via Open Access. This number can be any value between 2 and 360. Use
Open Access command 4082 to output the values.

‰ The Convert to Diebolts toggle is used to line up the displayed profile with the die-bolt
positions on the die. See Section 4.6 - Automatic Profile Alignment for Extruders.

‰ The Profile Reference toggle determines if profile displays are centered on the product’s
target value (as entered on the Process menu) or on the composite measured average.

•
•
Model 6100TC: Displays • 2-11
•
•
•
 ‰ The Horizontal Scale button determines how the horizontal scale for profile displays is
configured. Three different settings are available:

1. Auto. This causes the horizontal scale to be automatically scaled.

2 2. Diebolt. This causes the profile displays to show a segment for each diebolt. Select
this option only if the scanner has been calibrated in diebolts. The scale does not
include diebolt (0). If there are negative diebolts, diebolt (-1) is followed by diebolt
(1).

The table below shows the location of diebolts (1) and (-1) in terms of scanner posi-
tion:

Starts at Ends at
scanner scanner
position position

Diebolt (1) 0.00 0.99

Diebolt (-1) -1.00 -0.001

3. Step. This is the default Horizontal Scale setting. When this is chosen, a Scan Dis-
play Step button will appear to the right of the Horizontal Scale button. Use the Scan
Display Step button to enter a step value. This will determine how often vertical grid-
lines are drawn on the profile displays. For example, if a step value of 3.00 is selected,
vertical lines will be drawn in the profile at every 3 scanner units.

‰ The Die Setup Menu button is visible only if the Convert to Diebolts toggle is set to Yes.
Touch this button to bring up the Die Setup menu. See Section 4.6.9 - Die Setup Menu.

‰ The Sigma/CV toggle sets whether the Scan Profile and Roll Profile displays show a mul-
tiple of sigma or a multiple of CV in the statistics table (in addition to the maximum, aver-
age and minimum for the profile).

CV, the Coefficient of Variance is calculated as:

(sigma x 100) / average

Open Access item 4081 outputs sigma or CV, depending on the Sigma/CV toggle.

•
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2-12 •• Model 6100TC: Displays
•
•
2.2.4 Histogram Setup

2
HISTOGRAM

AUTO CLEAR HIST

CLEAR HIST NOW
NO YES

DISPLAY EXIT MAIN

Figure 2-13 Histogram Setup Menu

The Histogram Setup menu (Main → Display Setup → Histogram, Figure 2-13) includes the
following buttons:

‰ The Auto Clear Hist button tells the system to clear the histogram after each timed inter-
val or roll.

‰ The Clear Hist Now button clears the histogram immediately.

•
•
Model 6100TC: Displays • 2-13
•
•
•
 2.2.5 Scale

2
SCALE

VERT SCALE: LO VERT SCALE: MED VERT SCALE: HI UNITS

RES (#) RES (#) RES (#)
5.00 1.00 2.0 # %

DISPLAY EXIT MAIN

Figure 2-14 Scale Menu

The Scale menu (Main → Display Setup → Scale, Figure 2-14) is used to set the vertical
scale for the three display resolutions.

The vertical scale settings for the low, medium and high resolutions are set by Vert Scale: Lo
Res, Vert Scale: Med Res and Vert Scale: Hi Res. These values are expressed as a numeric
offset from the target/average or a percentage of the target/average, depending on whether the
Units toggle is set to # or %.

Example 1

Target/Average = 72.30

Units = #

The vertical scale range for each resolution is shown in the table below.

Vert. Scale Vert. Scale Min Vert. Scale Max

value (#)

Lo Res 5 72.30 - 5 = 67.30 72.30 + 5 = 77.30

Med Res 1 72.30 - 1 = 71.30 72.30 + 1 = 73.30

Hi Res 0.20 72.30 - 0.20 = 72.10 72.30 + 0.20 = 72.50

continues

•
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2-14 •• Model 6100TC: Displays
•
•
 continued from previous page

Example 2

Target/Average = 72.30

Units = % 2
The vertical scale range for each resolution is shown in the table below.

Vert. Scale Vert. Scale Min Vert. Scale Max

value (%)

Lo Res 10 72.30 - (10% x 72.30) 72.30 + (10% x 72.30)

= 65.07 = 79.53

Med Res 7 72.30 - (7% x 72.30) 72.30 + (7% x 72.30)

= 67.24 = 77.36

Hi Res 5 72.30 - (5% x 72.30) 72.30 + (5% x 72.30)

= 68.68 = 75.92

•
•
Model 6100TC: Displays • 2-15
•
•
•
 2.2.6 Header Info

2
HEADER INFO

ACCUM LENGTH ACCUM WEIGHT

NO YES NO YES

LENGTH LIMIT WEIGHT LIMIT

(FT) (LB)
0 0

DISPLAY EXIT MAIN

Figure 2-15 Header Info Menu

The Header Info menu (Main → Display Setup → Header Info, Figure 2-15) includes the
following buttons:

‰ Accum Length: If this toggle is set to Yes, the header will display the accumulated length
for the current roll. The accumulated length does not include scrap material.

‰ Accum Weight: If this toggle is set to Yes, the header will display the accumulated
weight for the current roll. The accumulated weight does not include scrap material.

Both Accum Length and Accum Weight may be turned on at the same time.

‰ Length Limit: Sets the length limit when checking for Length Alarm. Length Alarm will
be disabled if “0” is entered for Length Limit.

If Length Alarm is not disabled and the accumulated length for the current roll exceeds the
Length Limit:

1. A flashing “Length” message is displayed in the right header.

2. The A, B or C alarm output will turn on if Length is selected for Alarm A, B or C (in
the Alarms menu: Main → More → I/O Setup → Alarms).

To acknowledge the alarm and turn off the output, touch the flashing button in the
header.

•
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2-16 •• Model 6100TC: Displays
•
•
‰ Weight Limit: Sets the weight limit when checking for Weight Alarm. Weight Alarm will
be disabled if “0” is entered for Weight Limit.

If Weight Alarm is not disabled and the accumulated weight for the current roll exceeds
the Weight Limit:

1. A flashing “Weight” message is displayed in the right header. 2

2. The A, B or C alarm output will turn on if Weight is selected for Alarm A, B or C (in
the Alarms menu: Main → More → I/O Setup → Alarms).

To acknowledge the alarm and turn off the output, touch the flashing button in the header.

•
•
Model 6100TC: Displays • 2-17
•
•
•
 2.2.7 Display Zone Setup

The profile can be divided into sections by creating a display zone for each section. This is
done via the Display Zones screen (Main → Display Setup → Display Zones). The display

2
zones are shown on the Zones display. See Section 2.1.6 - Zones.

2.2.7.1 Adding Display Zones

The system can automatically divide the profile into a selectable number of equal-width dis-
play zones, or the zones can be manually entered by the user.

‰ Automatically adding display zones

DISPLAY ZONES
PRINT

# START END
1 4.00 10.50
2 10.50 17.00
3 17.00 23.50
4 23.50 30.00
5 30.00 36.50
6 36.50 43.00
7 43.00 49.50
8 49.50 56.00

AUTO DISPLAY NUMBER OF DISPLAY

ZONES ZONES
NO YES 8

EXIT MAIN

Figure 2-16 Display Zones screen - Auto Display Zones at Yes

1. Move to the Display Zones screen (Main → Display Setup → Display Zones,
Figure 2-16).

2. Set Auto Display Zones to Yes.

3. Touch Number of Display Zones and enter the number of desired zones.

The maximum number of zones allowed is 20.

The profile will automatically be divided into the specified number of equal-width zones. The
starting and ending positions for each zone are displayed in the table on the left.

•
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2-18 •• Model 6100TC: Displays
•
•
‰ Manually adding display zones

DISPLAY ZONES

2
PRINT

# START END

AUTO DISPLAY
ZONES
NO YES

ADD ZONE

EXIT MAIN

Figure 2-17 Display Zones Screen - Auto Display Zones at No

1. Move to the Display Zones screen (Main → Display Setup → Display Zones,
Figure 2-17).

2. Set Auto Display Zones to No.

3. Touch Add Zone.

4. Touch Zone Start and enter the starting zone position.

5. Touch Zone End and enter the ending zone position.

6. Touch Add This Zone.

7. Repeat steps 3 to 6 to add another zone.

Up to 20 display zones are allowed.

•
•
Model 6100TC: Displays • 2-19
•
•
•
 2.2.7.2 Deleting Display Zones

DELETE ZONE

2 #
1
START
4.00
END
10.50
PRINT

2 10.50 17.00
3 17.00 23.50
4 23.50 30.00
5 30.00 36.50
6 36.50 43.00
7 43.00 49.50
8 49.50 56.00

EXIT DELETE

Figure 2-18 Deleting a display zone

1. Move to the Display Zones screen (Main → Display Setup → Display Zones).

2. Touch Delete Zone.

3. Using the arrow buttons, move the highlight bar and select a display zone (Figure 2-18).

4. Touch Delete.

5. If desired, repeat steps 3 to 4 to delete another zone.

2.2.7.3 Viewing Display Zones

The display zones are shown on the Zones display (Main → Display → Zones).
See Section 2.1.6 - Zones.

•
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2-20 •• Model 6100TC: Displays
•
•
 CHAPTER

3 Process 3
The two-page Process menu lets you change the target, alarm levels, product ID and other val-
ues associated with the current recipe. (If you change the product ID and then “save” your
changes via the Save Current Recipe button in the Recipe menu, the system will create a new
recipe with your changes and leave the original recipe unchanged in the recipe directory.)

3.1 Process Menu Page 1

PROCESS

PRODUCT GAGE FACTOR GAGE CONSTANT SPECIFIC GRAVITY

NDC BASIC 1.000 0.00 1.000

TARGET HI ALARM LO ALARM

(MILS) (MILS) (MILS) ALERTS
72.30 1.00 -1.00

MORE

DISPLAY MAIN

Figure 3-1 Process Menu Page 1

Process Menu Page 1 (Main → Process, Figure 3-1) includes the following buttons:

‰ Product: This button lets you enter a new Product ID. This will be used for the name of
the recipe.

‰ Gage Factor: In most cases, an NDC Infrared Engineering Service Technician calibrates
the gauge so that the NDC Basic recipe measures a typical product correctly with the Gage
Factor set to 1. As a result, most other products will also measure correctly.

If a given recipe does not measure correctly, you can adjust its Gage Factor to correct the
problem. (See your sensor manual). Once the Gage Factor is entered into a recipe, it is
automatically used whenever that recipe is loaded. If no compensation is required, leave
the Gage Factor at 1.

Keep a log when finding the Gage Factor for each recipe. If a simple record is kept of this
adjustment, it becomes clear whether the gauge is consistently high or low for a particular
product. If the measurement fluctuates around the known sample values, the gauge is
probably measuring correctly and the difference is due to normal gauge variations.

•
Model 6100TC: Process •• 3-1
•
•
•
 ‰ Gage Constant: The Gage Constant represents a value which can be added to or sub-
tracted from each gauge reading.

The Gage Constant is applied to the gauge reading before the Gage Factor as follows:

final gauge reading = (raw gauge reading + Gage Constant) x Gage Factor

‰ Specific Gravity: The Specific Gravity needs only be set if your product is measured in
terms of thickness (e.g., mils, micron, millimeters), and you need roll reports to provide an
accurate roll weight.

3 For non-gamma sensors, the system uses the Specific Gravity to calculate roll weights. If
the gauge is calibrated correctly, you need to only set the Specific Gravity to a value that
results in accurate roll weights.

For gamma sensors, the system operates differently. The Specific Gravity affects the
gauge reading, but not the roll weights. Set the Gage Factor to a value that results in accu-
rate roll weights. Then set the Specific Gravity to a value that yields accurate gauge read-
ings.

‰ Target: Enter the target for the current recipe. If you are controlling to a minimum value,
rather than the average, the target should be slightly above the actual minimum allowable
thickness to allow for production variables such as temperature, batch consistency, etc.
that are not controllable with speed adjustments. The actual setting depends on the dead-
band (see Section 9 - Control) and how well you can control these production variables.

‰ Hi Alarm: Sets the High Alarm limit. The value entered here represents a deviation from
the target rather than measured thickness or mass (expressed as a numeric offset or per-
centage, depending on whether the Units toggle is set to # or % in the Scale menu).

If a gauge reading is above the High Alarm limit and the sensor is on sheet:

y A “Hi Alarm” message will flash in the header.

y The A, B or C alarm output will turn on if Hi or Hi/Lo is selected for Alarm A, B

or C (in the Alarms menu: Main → More → I/O Setup → Alarms).

To acknowledge the alarm and turn off the output, touch the flashing button in the header.

The system can be set up to automatically clear the alarm and turn off the output when the
product comes back within spec without requiring the operator to acknowledge the alarm.
See Auto Alarm Reset in Section 8.7 - Miscellaneous.

‰ Lo Alarm: Sets the Low Alarm limit. This is a negative value that represents a deviation
from the target rather than measured thickness or mass (expressed as a numeric offset or
percentage, depending on whether the Units toggle is set to # or % in the Scale menu).

If a gauge reading is less than the Low Alarm limit and the sensor is on sheet:

y A “Lo Alarm” message will flash in the header.

y The A, B or C alarm output will turn on if Lo or Hi/Lo is selected for Alarm A, B

or C (in the Alarms menu: Main → More → I/O Setup → Alarms).

To acknowledge the alarm and turn off the output, touch the flashing button in the header.

•
•
3-2 •• Model 6100TC: Process
•
•
 The system can be set up to automatically clear the alarm and turn off the output when the
product comes back within spec without requiring the operator to acknowledge the alarm.
See Auto Alarm Reset in Section 8.7 - Miscellaneous.

‰ Alerts: Brings up the Alerts menu. See Section 3.1.1 - Alerts.

‰ More: Brings up page 2 of the Process menu. See Section 3.2 - Process Menu Page 2.

•
•
Model 6100TC: Process • 3-3
•
•
•
 3.1.1 Alerts

ALERTS

HI ALERT LO ALERT

99.99 0.00

DISPLAY EXIT MAIN

Figure 3-2 Alerts Menu

The Alerts menu (Main → Process → Alerts, Figure 3-2) includes the following buttons:

‰ Hi Alert: Sets the High Alert limit. This provides a separate alarm level in addition to
High Alarm.

The High Alert value can be less or greater than the High Alarm value. High Alert is
expressed as a numeric offset from the target.

If a gauge reading is above the High Alert limit and the sensor is on sheet:

y A “Hi Alert” message will flash in the header.

y The A, B or C alarm output will turn on if Alerts is selected for Alarm A, B or C

(in the Alarms menu: Main → More → I/O Setup → Alarms).

To acknowledge the alert and turn off the output, touch the flashing button in the
header.

To disable High Alert, enter “9999” for High Alert. (This is the default value.)

‰ Lo Alert: Sets the Low Alert limit. This provides a separate alarm level in addition to
Low Alarm.

Low Alert is a negative value, and can be less or greater than the Low Alarm value. Low
Alert is expressed as a numeric offset from the target.

•
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3-4 •• Model 6100TC: Process
•
•
If a gauge reading is below the Low Alert limit and the sensor is on sheet:

y A “Lo Alert” message will flash in the header.

y The A, B or C alarm output will turn on if Alerts is selected for Alarm A, B or C

(in the Alarms menu: Main → More → I/O Setup → Alarms).

To acknowledge the alert and turn off the output, touch the flashing button in the
header.

To disable Low Alert, enter “0” for Low Alert. (This is the default value.)
3

•
•
Model 6100TC: Process • 3-5
•
•
•
 3.2 Process Menu Page 2

PROCESS - 2

ROLL PRODUCT WIDTH MINIMUM GAGE ROLL INCREMENT

(IN) VALUE

3
003 1
40.00 0.00

MAXIMUM GAGE
VALUE
99.99

DISPLAY EXIT MAIN

Figure 3-3 Process Menu Page 2

Process Menu Page 2 (Main → Process → More, Figure 3-3) includes the following buttons:

‰ Roll: This button lets you set the initial roll ID for the current recipe. The roll ID must
include at least one numeric character, which usually increases by one each time the roll
switch is triggered. See Roll Increment below if you wish the roll ID to increment by a
larger number.

‰ Product Width: Enter the width of your product after trimming. The system uses this
value when it calculates roll weights for reports. The width unit is set in the Units menu
(see Section 8.1 - Units.)

‰ Minimum Gage Value: If the gauge reading goes below this value and the sensor is on
sheet, the system assumes that a sheet break has occurred. This will cause the following to
occur:

y A “Sheet Break” alarm will flash in the header.

y The system will be in No Data mode.

y The sensor will move to the Startup Switch.

y The A, B or C alarm output will turn on if Break/Hi-Val is selected for Alarm A,

B or C (in the Alarms menu: Main → More → I/O Setup → Alarms).

Note: The alarm output will also turn on if the gauge reading is greater than the
Maximum Gage Value.

To acknowledge the alarm and turn off the output, touch the flashing button in the
header. The sensor will remain at the Startup Switch position until the Scan button
is touched. If scanning is resumed and the gauge readings are found to be greater
than the Minimum Gage value, the system will be in Data mode.

•
•
3-6 •• Model 6100TC: Process
•
•
 To disable Sheet Break Alarm, enter “0” for Minimum Gage Value. (This is the default
value.)

Section 4.5.3 - Sheet Break Detection with Edgeseek describes how the system tests for
Sheet Break Alarm when the Edgeseek feature is used.

‰ Roll Increment: Sets the number of rolls the roll number is incremented by after each roll
switch input. Usually set to 1, but some users set this button at some value from 2 to 9 if
rolls are to be sliced further down the line.

‰ Process Die Setup Menu: This button is visible only if the Convert to Diebolts toggle (in
the Profile menu) is set to Yes. Touch this button to bring up the Process Die Setup menu. 3
See Section 4.6.8 - Process Die Setup Menu.

‰ Maximum Gage Value: If the gauge reading is greater than this value and the sensor is on
sheet, a High Value alarm will activate and:

y A “Hi Val Alarm” message will flash in the header.

y The system will be in No Data mode.

y The sensor will move to the Startup Switch.

y The A, B or C alarm output will turn on if Break/Hi-Val is selected for Alarm A,

B or C (in the Alarms menu: Main → More → I/O Setup → Alarms).

Note: The alarm output will also turn on if the gauge reading is less than the
Minimum Gage Value.

To acknowledge the alarm and turn off the output, touch the flashing button in the
header. The sensor will remain at the Startup Switch position until the Scan button
is touched. If scanning is resumed and the gauge readings are found to be less than
the Maximum Gage Value value, the system will be in Data mode.

To disable High Value Alarm, enter “9999” for Maximum Gage Value. (This is the default
value.)

•
•
Model 6100TC: Process • 3-7
•
•
•
3

•
•
3-8 •• Model 6100TC: Process
•
•
 CHAPTER

4 Scanner 4
The scanner must be properly set up and calibrated. The setup procedure sets the scan limits,
scan speeds, and other variables, while calibration ensures that the microcomputer always
knows where the sensor is located and can send it to a designated position on the scanner.
Setup and calibration variables may all be different for different recipes.

4.1 Proximity Switches

The scanner includes a proximity switch at each end. Switch 1 can be at either end of the scan-
ner. To determine which is Switch 1, set the manual control to Reverse and note which way
the sensor moves. At the factory, Switch 1 is designated as the Startup Switch and Switch 2 is
the Away Switch. (This is set by the Startup Switch toggle in Scanner Setup Menu Page 2.
See Section 4.4.2 - Scanner Setup Menu Page 2.)

Whenever the system is turned on, the gauge will “initialize” itself and move the sensor to
whichever switch is designated as the Startup Switch. Note that these designations do not
affect the scan direction when measuring product. (Once the scanner is set up, the Scan From
and Scan To entries in Scanner Setup Menu Page 1 determine the scan and retrace directions.)
The Scanner display (Figure 4-1) includes a small vertical arrow to mark the Startup Switch.

•
Model 6100TC: Scanner •• 4-1
•
•
•
 4.2 Scanner Operation

SCANNER

1 2
0.00 60.00

3
4 5 4
4.00 56.00

20.80 (IN)

DISPLAY SCAN GO TO MAIN

Figure 4-1 Scanner Display

During normal operation, the Scanner display (Main → Scanner) controls the scanner.

Labeled items in Figure 4-1 are described below:

1. A small arrow marks the Startup Switch (see Section 4.1 - Proximity Switches)

2. Away Switch (see Section 4.1 - Proximity Switches)

3. Left Scan Limit

4. Right Scan Limit

5. The number shows the sensor position, which is also marked by a short vertical bar.

The following buttons appear on the Scanner display:

‰ Scan: Starts the sensor scanning back and forth between the scan limits. When touched,
the arrow buttons on the Scanner display will disappear, and the Go To button will be
replaced by the Stop button. Selecting Stop will stop the sensor.

‰ Go To: Sends the sensor to a specified position. When this button is touched, another
menu is displayed for selecting the position. The following choices are available:

y Number Pad - when selected, another screen is displayed for entering the
desired location.

y Startup Switch - sends the sensor to the Startup Switch (by default Switch 1).

continues

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4-2 •• Model 6100TC: Scanner
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 continued from previous page

y Away Switch - sends the sensor to the Away Switch (by default Switch 3).

y Preset Position - sends the sensor to the Preset Position (set in Scanner Setup
Menu Page 1).

‰ Arrow buttons: The larger Left/Right arrows move the sensor at the specified High
Speed (set in Scanner Setup Menu Page 1) while the short arrows move the sensor at a
much slower speed for precise positioning.

We suggest you follow the scanner setup and calibration procedure in this section when the
system is first set up. If there are subsequent problems, Section 4.4.2 - Scanner Setup Menu
Page 2 shows how to re-initialize the scanner.

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Model 6100TC: Scanner • 4-3
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 4.3 Scanner Calibration

CALIBRATE SCANNER

MOVE TO 1ST CALIBRATION

POINT, THEN ENTER POSITION
0.00 60.00

4 4.00

4.05 (IN)
56.00

ABORT GO TO POSITION

Figure 4-2 Calibrate Scanner: Step 1

To calibrate the scanner:

1. Move to the Scanner Setup Menu Page 2 (Main → More → Scanner Setup → More).

2. Press the Calibrate Scanner button. A new display (Figure 4-2) will appear, asking you
to move the sensor to the “1st Calibration Point.”

3. Use the left/right arrows to move the sensor to the first calibrate position. This can be the
sheet edge, center of the first diebolt, one of the proximity switches or any other known
position.

4. Press the Position button and then enter the value for the sensor position from step 3.

5. Follow the screen directions (Figure 4-3) to move the sensor to the “2nd Calibration
Point” and repeat step 4 to enter the second calibrate position. Press the Calibrate button
to fix these positions in the system memory and recall the Scanner Setup Menu Page 2.

6. If desired, press the Scanner Unit button and change the scanner units label. This label
does not affect operation of the system.

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4-4 •• Model 6100TC: Scanner
•
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 CALIBRATE SCANNER

MOVE TO 2ND CALIBRATION

POINT, THEN ENTER POSITION
0.00 60.00

4.00

4.05 (IN)

ABORT GO TO POSITION 4
Figure 4-3 Calibrate Scanner: Step 2

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Model 6100TC: Scanner • 4-5
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 4.4 Scanner Setup Menu
4.4.1 Scanner Setup Menu Page 1

SCANNER SETUP

PRESET POSITION SCAN SPEED HIGH SPEED

(IN/SEC) (IN/SEC) EDGESEEK
2.00
2.00 3.00

SCAN FROM SCAN TO SCAN DIRECTION

4
4.00 56.00 UNI BI

MORE

DISPLAY DEBUG EXIT MAIN

Figure 4-4 Scanner Setup Menu Page 1

Scanner Setup Menu Page 1 (Main → More → Scanner Setup, Figure 4-4) includes the fol-
lowing buttons:

‰ Preset Position: This position is typically off-line and provides a convenient location for
the operator to zero or calibrate the gauge, or to move it out of the way during line mainte-
nance. This is also the location where the sensor can be sent for sample check verification.

‰ Scan Speed: Enter the desired scan speed, up to 12.5 inches (31 cm) per second. The rec-
ommended scan speed is 1 inch (2.5 cm) per second.

‰ High Speed: The system moves the sensor at High Speed when you use the Go To button,
when it moves to the Startup or Away switches, and when you press one of the large
directional arrows. If the Scan Direction button is set for unidirectional scanning, the sys-
tem also retraces at High Speed after each scan.

The recommended high speed is 10 inches (25 cm) per second.

‰ Edgeseek: Brings up the Edgeseek menu. See Section 4.5 - Edgeseek.

‰ Scan From: This is the desired position for the start of each scan. (The beginning and end
of each scan are sometimes referred to as the “Scan Limits.”)

‰ Scan To: This is the desired position for the end of each scan.

‰ Scan Direction: This toggle is visible only if the Edgeseek toggle (in the Edgeseek menu)
is Off. It determines whether the system collects data as the sensor moves in one or both
directions. Select Uni or Bi.

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4-6 •• Model 6100TC: Scanner
•
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‰ More: Brings up page 2 of the Scanner Setup menu. See Section 4.4.2 - Scanner Setup
Menu Page 2.

‰ Debug: Brings up the Scanner Debug page. See Section 4.4.3 - Scanner Debug Page.

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Model 6100TC: Scanner • 4-7
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 4.4.2 Scanner Setup Menu Page 2

SCANNER SETUP - 2

STARTUP VALUE AWAY VALUE SCANNER UNIT STARTUP SWITCH

0.00 60.00 IN 1 2

RE-INITIALIZE SCANNER RESET

CALIBRATE SCANNER (MIN)
SCANNER 480

4
MOVE TOLERANCE SWITCH SPEED ACCELERATION
(IN) FACTOR FACTOR
1.000 1.00 1.00

DISPLAY EXIT MAIN

Figure 4-5 Scanner Setup Menu Page 2

Scanner Setup Menu Page 2 (Main → More → Scanner Setup → More, Figure 4-5)
includes the following buttons:

‰ Startup Value: Shows the position of the Startup Switch. This value is calculated when
the scanner is calibrated, and cannot be manually changed by the user.

‰ Away Value: Shows the position of the Away Switch. This value is calculated when the
scanner is calibrated, and cannot be manually changed by the user.

‰ Scanner Unit: A label indicating the scanner units. This label does not affect operation of
the system.

‰ Startup Switch: Whenever the system is powered on, the sensor moves to the Startup
Switch at either end of the scanner. Use the Startup Switch toggle to determine whether
this represents Switch 1 or Switch 2.

‰ Calibrate Scanner: Used for calibrating the scanner. See Section 4.3 - Scanner Calibra-
tion.

‰ Re-initialize Scanner: Used to initiate a full initialization of the scanner. This command
requires confirmation by the user. Select Yes to proceed with initialization. While initial-
ization is in progress, the Initialize Scanner screen will appear, along with a message in
red stating “Initializing Scanner - Wait.” When initialization is complete, the previous
screen will be restored.

Full initialization involves the sensor traversing the entire length of the scanner to measure
its length. First, the sensor moves in reverse as far as it can go. The Startup Switch then
goes on, the sensor moves slightly off the switch, and zeroes the encoder. The sensor then
moves forward as far as it can go. The Away Switch then turns on, the sensor moves
slightly off that switch, and determines the length of the scanner in encoder pulses and
machine steps. Note that the encoder is read, but not used during full initialization.

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4-8 •• Model 6100TC: Scanner
•
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‰ Scanner Reset (min): Normally, the encoder is reset on startup, and whenever the sensor
moves to either the Startup or Away switch. If desired, the system can be set up to period-
ically move the sensor to the Startup Switch and reset the encoder to a known correct
value. This feature is known as Auto Reset. To activate this feature, enter a non-zero value
for Scanner Reset (min). This parameter sets the number of minutes between resets of the
encoder. The default setting is 480 - this means that the sensor will move to the Startup
Switch and the encoder will be reset every 480 minutes (8 hours).

Allowable values for Scanner Reset (min) are 0 to 1440. Setting this value to 0 will dis-
able the Auto Reset feature.

‰ Move Tolerance: When the sensor is ordered to move to a destination, via the Go To but-
ton on the Scanner display, a “GoTo Failed” alarm is generated when the sensor does not
stop within a certain range from that destination. The Move Tolerance parameter sets

4
how close the sensor must be to its destination before a “GoTo Failed” alarm is generated.
For example, suppose Move Tolerance is 1 inch, and the sensor is ordered to move to
position 16 in. This means that the sensor must stop within 16 ± 1 (15 - 17) in, otherwise a
“GoTo Failed” alarm will be generated.

The default value is 1 inch. The scanner may not operate properly if Move Tolerance is
set to an unreasonable value.

‰ Switch Speed Factor: This adjusts the initialization speed, which is used by the scanner
when initializing, and when approaching the limit switches at retrace speed.

The default value for this parameter is 1.0. This is the recommended value for TFS and
OSA scanners. Setting this value to 2.0 will double the initialization speed. Setting this
value to 0.5 will reduce the initialization speed by half.

‰ Acceleration Factor: The default value for this parameter is 1.0. This is the recommended
acceleration setting for TFS scanners. The recommended setting for OSA scanners is 2.0.
Setting this value to 2.0 will double the acceleration of the scanner. Setting this value to
0.5 will reduce the acceleration by half.

‰ Gamma Standardize: This toggle appears only in selected systems with gamma sensors.
If this toggle is set to Yes, a Standardize Setup button will appear in the Gage menu.
Touching that button will bring up a menu for setting up the standardization parameters.

•
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Model 6100TC: Scanner • 4-9
•
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 4.4.3 Scanner Debug Page

DEBUG

ENCODER 18512
MOTOR ON
NOT MOVING
NOT AT REV LIMIT SW
NOT AT FWD LIMIT SW
SCAN MODE: SCAN
SC PHASE: END WAIT
ON SHEET
LO SCAN: 0.00 HI SCAN: 42.00
PULSE TOLERANCE: 408

4 DISPLAY REFRESH EXIT MAIN

Figure 4-6 Scanner Debug Page

The Scanner Debug page (Figure 4-6) displays information for troubleshooting any scanner
problems:

y Encoder value - this can be used to determine if the encoder is working properly

y Motor On or Off - is power to the motor on or off

y Moving or Not Moving - is the sensor moving

y At or Not At Rev Limit Sw - is the sensor at the Startup Switch

y At or Not At Fwd Limit Sw - is the sensor at the Away Switch

y Scan Mode: xxxx - what the sensor is doing: stopped, scanning, etc.

y Sc Phase: xxxx - if the sensor is scanning, this entry shows what phase of scan-
ning: scan, retrace, begin wait, end wait, etc.

y On or Off Sheet - is the sensor on or off sheet. Data mode is off unless the sensor
is on sheet.

The sensor is considered to be on sheet only if it is stopped between the scan lim-
its, or scanning between the scan limits AND the shutter (if there is one) is open
AND there are no alarms such as sheet break or low linespeed. While the sensor is
moving, in response to a Go To command or arrow button, the sensor is consid-
ered to be off sheet.

y Lo Scan: xxxx, Hi Scan: xxxx - the left and right scan limits

y Pulse Tolerance - the number of pulses corresponding to the Move Tolerance

entry (in Scanner Setup Menu Page 2)

y Nr Edge: xxxx, Far Edge: xxxx - these entries appear only if the Edgeseek tog-
gle (in the Edgeseek menu) is On. They show the sheet edges located by the Edge-
seek function.
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4-10 •• Model 6100TC: Scanner
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4.5 Edgeseek
The Edgeseek function allows the gauge to find the sheet edge on either side of the web. This
allows the system to:

y Measure the product width

y Scan the product without requiring an operator to define the web position

y Abort control immediately if there are large changes in the sheet width

y Maintain accurate data for reports even if the web wanders to the left or right

4.5.1 What Happens During Edgeseek

Edgeseek is activated whenever the Scan button on the Scanner display is touched, and also at
4
regular intervals, if a non-zero value is entered for the Edgeseek Interval. Once activated,
Edgeseek sends the sensor to the Startup Switch. The sensor then moves out toward the sheet
until it sees a value at least equal to the Minimum Gage Value on Page 2 of the Process
menu. The system assumes this is the first sheet edge. The sensor moves an additional distance
defined by the Edge Run On button in the Edgeseek menu, pauses a time equal to one-half the
gauge moving average period, and then scans across the web at normal scan speed. The sensor
stops when the reading drops below the Minimum Gage Value and then backs up slowly to
precisely locate the second sheet edge. The sensor will continue to move back on sheet to a
distance defined by the Edge Run On button, pause for one-half the moving average period
and resume scanning back to the first edge.

4.5.2 Setup

EDGESEEK

DIST FROM STARTUP TRIM EDGESEEK INTERVAL

EDGESEEK
(IN) CONFIGURATION (MIN)
0.000 OFF ON 0
SCAN BEFORE TRIM

SCAN LIGHT EDGES WEB WIDTH OFFSET EDGE RUN ON DEMAND ONLY
(IN) (IN)
OFF ON OFF ON
0.00 1.000

EDGESEEK ON SCAN
RESUME
OFF ON

DISPLAY EXIT MAIN

Figure 4-7 Edgeseek Menu

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rev. C Model 6100TC: Scanner • 4-11
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 1. Move to Page 2 of the Process menu (Main → Process → More) and set the Minimum
Gage Value to approximately ½ the minimum expected gauge value when the line is run-
ning. The actual value should be lower than any single gauge reading when the sensor is
on-sheet, and higher than any reading when the sensor is off-sheet. The Minimum Gage
Value can be different for each recipe.

2. Move to the Edgeseek menu (Main → More → Scanner Setup → Edgeseek,

Figure 4-7) and set up the menu as explained below.

3. Normally, the Dist from Startup should be left at the default value of 0.

However, if there is an object between the Startup Switch and the web, it may erroneously
cause the gauge to detect the location of that object as a sheet edge. To prevent this, set the
Dist from Startup to a value greater than the distance from the Startup Switch to the

4
object. (Note that this is the sensor position shown with Main → Display Setup → Pro-
file → Convert to Diebolts set to No).

4. Set the Edgeseek On/Off toggle to On.

When On, the system uses the Edgeseek function as described in Section 4.5.1 - What
Happens During Edgeseek. If Off, the scanner uses the scan limits entered on the Scanner
Setup menu. This toggle is part of each recipe, so that Edgeseek need not be used for all
recipes.

If the Edgeseek toggle is On, the Edgeseek function will also activate at regular intervals
when a non-zero value is entered for the Edgeseek Interval. For example, if the Edgeseek
Interval is 30 minutes, Edgeseek will activate every 30 minutes. If the Edgeseek Interval
is set to 0, the Edgeseek function will activate on every scan.

Note: When Edgeseek is switched On or Off, the sensor will return to the Startup Switch.
Touch Scan on the Scanner display to resume scanning.

If the Edgeseek toggle is Off, the Demand Only and Edgeseek on Scan Resume toggles
are black, and will not accept touch.

5. Set the Trim Configuration as desired. The Trim Configuration scroll pad allows the
operator to choose between three trim options:

y Off: The product is not trimmed and reports are based on the full scan width.

y Scan Before Trim: If the product is scanned before it reaches the trimmer, this
mode tells the system to calculate profile, histogram, trend, and SPC data on the
basis of net width measurements. The net width is set to be:

Net width = Product Width (entered in Process Menu Page 2),

where the trim is assumed to be equal on both sides of the web

Data from trimmed edges is discarded. Scanner width and sheet width entries
must use the same units. Profiles are shown complete, but with trimmed edges
hatched so that they are visible in color or monochrome printouts. The profile data
box excludes trim.

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4-12 •• Model 6100TC: Scanner rev. C
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 y Scan After Trim: If the product is scanned after trimming, this mode allows sep-
arate calculations of gross and net production. The gross width (before trimming)
is entered as Product Width on Process Menu Page 2.

6. Set the Scan Light Edges toggle to On if you are using a gamma sensor to measure light
materials (i.e., at or less than 25 microns (0.75 mil)). This will enable the system to detect
the sheet edges more reliably. However, it also reduces web width accuracy.

7. Sheet width is measured using the scanner position values taken as the sensor moves
slowly onto the web at the end of each scan. If you find a small consistent error in the
width measurement, press the Web Width Offset button and enter a value to compensate
for the error.

The Web Width Offset is recipe-selectable and expressed in scanner units. It will nor-

4
mally be set to 0.

8. Because of the measurement footprint width and the possibility of sheet wander, it is nec-
essary to define the scan start and end positions to be a calibrated distance in from the
sheet edges. Press the Edge Run On button and enter the distance (in scanner width units)
between the sensor centerline and the web edge at the start and end of each scan. This
establishes the distance between the detected web edge and the start of the scan.

9. Set the Demand Only toggle to On if you want to find edges only when the Find Edges
button is touched. (The Find Edges button appears on Main Menu Page 3. Note that this
button is visible only if the Edgeseek toggle is On in the Edgeseek menu).

If the Demand Only toggle is On, the Edgeseek Interval and Edgeseek on Scan Resume
buttons are black and will not accept touch.

10. Set the Edgeseek on Scan Resume toggle to On to activate the edgeseek function when
the system resumes scanning, e.g., when a Lo Speed alarm is cleared and the linespeed is
above the Minimum Linespeed. If Edgeseek on Scan Resume is Off, the edgeseek func-
tion will not activate when scanning resumes, unless the Edgeseek Interval is a non-zero
value and the interval triggers an edgeseek at that moment.

11. Move to the Scanner display and press Scan to initiate the first edgesearch.

Other buttons that affect Edgeseek include:

‰ Minimum Gage Value: This button appears on Page 2 of the Process menu. It sets the
threshold for detection of the sheet edge. It should be lower than any single gauge reading
when the sensor is on-sheet, and higher than any reading when the sensor is off-sheet. This
value can vary by recipe.

‰ Scan Speed: This button appears on Page 1 of the Scanner Setup menu. Scan speed has no
direct effect on Edgeseek, except that at higher speeds the sensor moves further when
stopping. This means it must travel further when moving back onto the web. In practice,
this means the optimal Edgeseek scan speed is slightly slower than with manual scanning.

•
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rev. C Model 6100TC: Scanner • 4-13
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 4.5.3 Sheet Break Detection with Edgeseek

During normal scanning, the system assumes it is offsheet when the gauge reading drops
below the Minimum Gage Value. In response, the sensor reverses direction and begins to
scan back across the web. If no sheet is detected in eight seconds, the Sheet Break alarm is set
and the sensor returns to its Startup Switch.

If the sensor is stationary and on-sheet, a Sheet Break alarm is triggered whenever the gauge
reading goes below the Minimum Gage Value.

When the sensor is set to scan in Edgeseek, if it moves to a point beyond 90% of the distance
to the far switch without seeing the edge of the web, a Sheet Break alarm is triggered and the
sensor returns to the Startup Switch.

4 If Edgeseek is turned off, a Sheet Break alarm will be triggered if the gauge reading drops
below the Minimum Gage Value while the sensor is scanning between the Manual Scan Lim-
its.

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4-14 •• Model 6100TC: Scanner
•
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4.6 Automatic Profile Alignment for Extruders
4.6.1 Introduction

Gauging systems on extruders have traditionally had problems associated with the line-up
between displayed profiles and die-bolt positions on the die. This feature automatically posi-
tions the scanner profile, and adapts the profile position to dies of different sizes and webs that
wander or shrink. An advantage of this feature is that it will let the gauge display the profile on
a horizontal grid in bolts while the reporting is done using measured width in engineering
units.

To turn this feature on, set the Convert to Diebolts toggle to Yes in the Profile menu (Main
→ Display Setup → Profile).

Two menus allow entry of parameters to set up automatic profile alignment: Process Die
Setup, for entry of parameters that may need to vary from product to product, and Die Setup,
4
for parameters that do not change between products.

The Process Die Setup menu is reached from the Process Die Setup button on page 2 of the
Process menu.

The Die Setup menu is reached from the Die Setup Menu button on the Profile menu.

4.6.2 Alignment of the Die Profile

Basic calibration of the scanner is done in engineering units. The system is then calibrated so
that the profiles are displayed against a horizontal grid marked in bolts. Subsequently, it is
possible to switch between bolt and scanner unit displays.

4.6.3 Scanner Calibration

While the scanner is being calibrated, the Scanner screen is displayed in scanner units. The
scanner may be calibrated in inches, cm, or whatever units are required. The methods for lin-
ing up the profile with the die are described in the following sections.

•
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Model 6100TC: Scanner • 4-15
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 4.6.4 Convert to Diebolts toggle

PROFILE

CYCLES PER SCAN DISPLAY LO SCAN DISPLAY HI RESET DISPLAY

COMPOSITE
0.00 56.00 LIMITS
1

LIVE PROFILES OPEN ACCESS ZONES CONVERT TO

CLEAR COMPOSITE DIEBOLTS
NO YES 8
NO YES

4
PROFILE REFERENCE HORIZONTAL SCALE
DIE SETUP MENU
TARGET AVERAGE DIEBOLT

DISPLAY EXIT MAIN

Figure 4-8 Profile Menu

The Convert to Diebolts toggle appears in the Profile menu (Main → Display Setup →
Profile, Figure 4-8). It selects whether the Profile display and Scanner display are converted
from scanner units to bolts. Whenever it is toggled, the sensor parks and the composite profile
is cleared.

When this toggle is set to Yes, the Scan Display Lo and Scan Display Hi values in the Profile
menu are set to 0 and number of die bolts, respectively. Be sure to set the Horizontal Scale
entry to Diebolt for the clearest display.

When Convert to Diebolts is Yes, the Scanner display has a label displaying BOLTS (see
Figure 4-9). Otherwise, the label shows scanner units. (If the Scanner display was reached
from Calibrate Scanner button (Main → More → Scanner Setup → More), the label
always shows scanner units.)

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4-16 •• Model 6100TC: Scanner
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 SCANNER

0.00 60.00

4.00 56.00

20.80 (BOLTS)

DISPLAY STOP MAIN 4

Figure 4-9 Scanner display showing bolts

4.6.5 Auto Profile Position toggle

The Auto Profile Position toggle appears in the Die Setup menu (Main → Display Setup →
Profile → Die Setup Menu). It allows selection of manual (Off) and automatic (On) align-
ment of the bolt profile with the die. If Off is chosen, the scanner may be set to edge-seek, or
to scan between set limits.

If On is chosen, edgeseek needs to be On, since the system needs to know the positions of the
web edges. See Section 4.5 - Edgeseek.

4.6.6 Manual Alignment of the Profile Position with the Die

DIE SETUP MENU

AUTO PROFILE DIE CENTERLINE BOLT WIDTH AT

POSITION (IN) SCANNER (IN)
OFF ON 60.000 1.0000

LEFT UN-NUMBERED RIGHT UN-NUMBERED

BOLTS BOLTS
0 0

DISPLAY EXIT MAIN

Figure 4-10 Die Setup Menu

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Model 6100TC: Scanner • 4-17
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 All data entry buttons for manual alignment are in the Die Setup menu (Main → Display
Setup → Profile → Die Setup Menu, Figure 4-10).

1. Set Auto Profile Position on the Die Setup menu to Off.

2. To line up the scanned profile with the die, enter the position (in scanner width units) of
the center-line of the die to the Die Centerline button.

3. Enter the distance between adjacent die bolts on the product as it passes the scanner to
Bolt Width at Scanner.

4. If the die has un-numbered, manual-only bolts at the ends, enter the number of Left and
Right Un-numbered Bolts. For dies with no manual end bolts, Left and Right Un-num-
bered Bolts should be left at their default values of 0.

4 5. With the sensor scanning, the Scan Profile should now show the product in the correct
position. The profile position may now be finely adjusted by altering Die Centerline.
Increasing this value has the effect of moving the profile toward the left.

If Auto Profile Position is Off, there is no need to enter any of the values in the Process Die
Setup menu (Main → Process → More → Process Die Setup Menu) unless the system has
profile control.

If desired, security can be set to remove the Process Die Setup button to minimize confusion
by operators. See Section 8.8 - Security.

4.6.7 Automatic Alignment of the Die Profile

If values for Neck In, Left / Right Deckle and Number of Diebolts are correct on the Process
Die Setup menu, the system is able to automatically position the scan profile over the die.

4.6.7.1 Setup of Automatic Alignment feature

Automatic alignment is selected by setting Auto Profile Position to On (in the Die Setup
menu). It is only effective when edgeseek is On. See Section 4.5 - Edgeseek.

Die Centerline and Bolt Width At Scanner (in the Die Setup menu) are now automatically
updated at the end of each scan. These buttons are now disabled.

The values that need to be entered to configure Auto Profile Position are detailed in
Section 4.6.9 - Die Setup Menu.

A possible technique for positioning the profile is to set Auto Profile Position to On for a
scan or two, to establish values for Die Centerline and Bolt Width At Scanner, and then set
Auto Profile Position to Off.

Alternatively, Auto Profile Position may be left On. This is the recommended setup.

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4-18 •• Model 6100TC: Scanner
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4.6.8 Process Die Setup Menu

The Process Die Setup menu is reached by a touch to the Process Die Setup Menu button on
page 2 of the Process menu. This page is available when the Convert To Diebolts toggle in
the Profile menu is set to Yes. It is used to enter parameters that specify how the scanner lines
up with a die. These values vary from product to product.

Any of the buttons on this menu may be removed or disabled under security. See Section 8.8 -
Security.

PROCESS DIE SETUP MENU

LEFT DECKLE
(IN)
RIGHT DECKLE
(IN)
NECK IN
(IN)
NUMBER OF
DIEBOLTS
4
0.00 0.00 2.00 60

FOR USE WITH EDGESEEK

DISPLAY EXIT MAIN

Figure 4-11 Process Die Setup Menu

The Process Die Setup menu (Figure 4-11) includes the following buttons:

‰ Left Deckle: Sets the deckled region on the left side of the die. This corresponds to the left
side of the profile on the Scan Profile and Scanner displays. This value is expressed in
scanner position units (inches or mm).

‰ Right Deckle: Sets the deckled region on the right side of the die. This corresponds to the
right side of the profile on the Scan Profile and Scanner displays. This value is expressed
in scanner position units (inches or mm).

‰ Neck In: This is the amount that the product necks in on each side of the die. It is assumed
that neck in is equal on both sides of the die. Entry is in scanner position units (inches or
mm).

‰ Number of Diebolts: Sets the die size in bolts. This number does not include any un-num-
bered bolts.

•
•
Model 6100TC: Scanner • 4-19
•
•
•
 4.6.9 Die Setup Menu

The Die Setup menu is available when the Convert To Diebolts toggle on the Profile menu is
set to Yes. To bring up this menu, select the Die Setup Menu button in the Profile menu.
None of the buttons in this menu may be disabled under security.

The Die Setup menu contains parameters that determine how the scan profile and scanner
screens line up with a die. No parameter on this page should need to be entered when a product
change is made.

DIE SETUP MENU

4 AUTO PROFILE
POSITION
OFF ON
DIE CENTERLINE
(IN)
60.000
BOLT WIDTH AT
SCANNER (IN)
1.0000

LEFT UN-NUMBERED RIGHT UN-NUMBERED

BOLTS BOLTS
0 0

DISPLAY EXIT MAIN

Figure 4-12 Die Setup Menu

The Die Setup menu (Figure 4-12) includes the following buttons:

‰ Auto Profile Position: This toggle sets whether the profile position is automatically
matched to the die, or manually adjusted.

If this toggle is On:

- The left edge of the profile is positioned at:

Left Deckle + Neck In + Edge Run On - Left Un-numbered Bolts

where Left Deckle and Neck In are set in the Process Die Setup menu

Edge Run On is set in the Edgeseek menu

Left Un-numbered Bolts is set in the Die Setup menu

continues

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4-20 •• Model 6100TC: Scanner
•
•
 continued from previous page

- The right edge of the profile is positioned at:

Right Un-numbered Bolts - Number of Diebolts - Right Deckle - Neck In - Edge Run On

where Right Un-numbered Bolts is set in the Die Setup menu

Number of Diebolts, Right Deckle and Neck In are set in the Process Die Setup
menu

Edge Run On is set in the Edgeseek menu

(All values are expressed in diebolts)

4
For auto profile position to work correctly, the following parameters in the Process Die
Setup menu need to be entered correctly:

y Number of Diebolts

y Left Deckle

y Right Deckle

y Neck In

In addition, edgeseek must be On. See Section 4.5 - Edgeseek.

If Auto Profile Position is On, the Die Centerline and Bolt Width At Scanner values
are automatically calculated by the system, and the respective buttons are disabled.

If Auto Profile Position is Off, the profile position must be manually adjusted by setting
up the Die Centerline and Bolt Width At Scanner parameters. See Section 4.6.6 - Man-
ual Alignment of the Profile Position with the Die.

‰ Die Centerline: This parameter is used to match the profile position to the die. It is
entered in scanner position units as the center-line of the die.

If Auto Profile Position is On, the Die Centerline button is disabled, and a value calcu-
lated by the system is displayed.

‰ Bolt Width At Scanner: This parameter is used to match the profile size to the die. It is
entered in scanner position units as the width of the product from a single bolt as it passes
the scanner.

If Auto Profile Position is On, the Bolt Width At Scanner button is disabled, and a value
calculated by the system is displayed.

Note: This bolt width is accurate for bolts at the center of the sheet that are not subject to
edge neck down.

‰ Left and Right Un-numbered Bolts: These parameters set the number of un-numbered,
manual-only bolts at the ends of the die. They are used only in automatic die- profile line
up, and have no effect when Auto Profile Position is off. For dies with no manual end
bolts, they should be left at 0/0.
•
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Model 6100TC: Scanner • 4-21
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4

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4-22 •• Model 6100TC: Scanner
•
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 CHAPTER

5 Recipes 5
When first shipped, your system included one recipe labeled NDC Basic. This recipe carries
the original linearization and calibration values (generally based on customer-supplied sam-
ples) and can be copied for use as a master template. NDC Basic cannot permanently be
changed without a password and should not be changed except by an NDC Infrared Engineer-
ing Service Technician. In case of a problem, NDC Basic can be copied and used to restore the
original factory-set calibration values.

This section explains how to create, copy, change, view, print and delete individual product
recipes. These operations are performed in the Recipe menu (Figure 5-1).

RECIPE

SELETED RECIPE VIEW SELECTED PRINT SELECTED

CURRENT RECIPE RECIPE

LOAD SELECTED TO SAVE CURRENT DELETE SELECTED

CURRENT RECIPE RECIPE

DISPLAY MAIN

Figure 5-1 Recipe Menu

As you work through the rest of this manual, you will create and change recipes to control
your various products. In most cases, new recipes are copied from templates and need only a
new name, target, gage factor, alarms, and perhaps control gain or scan limits.

When using the Recipe menu, it is important to understand the difference between the “cur-
rent” and “selected” recipes. Refer to Figure 5-2. The “current” recipe is the recipe that is cur-
rently active in the system memory. It is stored in the system’s “current working area” where it
can be modified at any time. (NDC Basic can be modified but the changes will not ordinarily
be saved when a new recipe is loaded to the current working area.) Because the current recipe
can be modified, it may or may not be identical to any recipe in the recipe directory. The cur-
rent recipe supplies the values used to control your product. Any changes to the current recipe
may immediately affect your product unless control is turned off.

Other recipes are stored in the recipe directory. These recipes can be “selected” and then
viewed, printed, deleted or copied (“loaded”) into the current working area. A selected recipe
cannot be modified unless it is loaded into the current working area.

•
Model 6100TC: Recipes •• 5-1
•
•
•
 RECIPE DIRECTORY
CURRENT Save
WORKING AREA NDC Basic
View
Current Recipe A
(Selected) Print

Recipe B Delete
Modify Load
(Copy)
Use for Recipe C
Control
Recipe D

5
Figure 5-2 Current vs. Selected Recipe

When first using your system, press Selected Recipe to call up the recipe directory and check
whether NDC Basic is the only recipe in the memory. If so, load it to the current working area
and use it as a template for creating your first product recipe. If you already have other recipes,
load a template to the current working area and modify as needed. Section 5.1 - Loading a
Recipe to Current and Section 5.2 - Creating a New Recipe explain how to create templates.
Section 5.3 - Editing the Current Recipe and Section 5.4 - Editing Other Recipes explain how
to modify recipes.

5.1 Loading a Recipe to Current

To load an existing recipe:

1. Systems with Control: Be sure the Control toggle on Page 1 of the Main menu is turned
off.

2. Move to the Recipe menu (Main → Recipe), and press Selected Recipe. A directory of
existing recipes (Figure 5-3) will appear.

•
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5-2 •• Model 6100TC: Recipes
•
•
 SELECTED RECIPE: CURRENT

CURRENT

NDC BASIC

LDPE-1

LDPE-2

SPX-1

5
ABORT SELECT

Figure 5-3 Selecting a Recipe

3. Touch the desired recipe and then the Select button on the lower right corner of the screen.
The screen will return to the Recipe menu.

4. Press the Load Selected to Current button. The screen will ask you to confirm your
selection. Press Yes if it is correct or No.

•
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Model 6100TC: Recipes • 5-3
•
•
•
 5.2 Creating a New Recipe
To create a new recipe:

1. Systems with Control: Be sure Control is turned off.

Follow the directions in Section 5.1 - Loading a Recipe to Current to load a template to the
current working area. Do not use NDC Basic as your template unless there are no other
recipes available.

2. Press the Main button and then follow Section 5.3 - Editing the Current Recipe to change
the current recipe as desired. Be sure to change the Product ID on the Process menu. (See
Section 3.1 - Process Menu Page 1).

3. Return to the Recipe menu and press the Save Current Recipe button. The result is a rec-
ipe with a new Product ID and its own values. The template remains unchanged.

5.3 Editing the Current Recipe

5 To modify the current recipe:

1. Change any desired values, except the Product ID.

2. From the Main menu, press Recipe to return to the Recipe menu.

3. Press the Save Current Recipe button to preserve your changes in the system memory.
If you omit this step, your changes will be lost when you load a new recipe to the current
working area.

5.4 Editing Other Recipes

To modify any other recipe in the recipe directory:

1. Follow the instructions in Section 5.1 - Loading a Recipe to Current to select and load the
recipe into the current working area.

2. Press the Main button and then change the recipe as desired.

3. From the Main menu, press Recipe to return to the Recipe menu.

4. Press the Save Current Recipe button to preserve your changes.

5.5 Viewing a Recipe

To view the contents of any recipe:

1. Move to the Recipe menu.

2. Press the Selected Recipe button and then highlight the desired recipe.

3. Press the Select button.

•
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5-4 •• Model 6100TC: Recipes
•
•
 4. Press the View Selected Recipe button. The screen will show several pages of recipe and
setup values. Figure 5-4 shows page 1 of the recipe. An asterisk (*) identifies recipe-load-
able items.

Use the Next Page and Prev Page buttons to view the other pages of the recipe. The label
on the top right shows the current page of the recipe.

RECIPE: NDC PAGE 1

CURVE * LO ALARM: 1.00

MASS MULT: -1.297e-02 * GAGE UNIT: MILS
ZERO COUNT: 813925 * SPECIFIC GRAVITY: 1.000
INFINITE COUNT: 65000 * GAGE FACTOR: 1.000
CURVE TYPE: LINEAR * GAGE CONSTANT: 0.00
PROBE DECIMAL POINT: XX.XX
AGC DRIVE: 2700 VERT SCALE: LO RES: 10.00
ORIG AGC DRIVE: 2700 VERT SCALE: MED RES: 7.00
HI COUNT: 4500 VERT SCALE: HI RES: 0.60

5
WINDOW MULTIPLIER: 5 UNITS: #
AGC GAIN: 50
* HI ALERT: 79.99
LO LEVEL: 2
* LO ALERT: 0.00
HI LEVEL: 0
* UPPER SPEC LIMIT: 72.50
COUNT MODE: WINDOW
* LOWER SPEC LIMIT: 72.10
MINIMUM COUNT: 1000
* X-BAR UCL: 72.40
SPEC 105 DC BOARD: NO
* X-BAR LCL: 72.20
RDS PER SEC: 20.000
* RANGE UCL: 0.10
PROCESS RANGE LCL: 0.00
* TARGET: 72.30 SPC RANGE SCALE: 0.30
* HI ALARM: 1.00 GAGE

NEXT PAGE EXIT

Figure 5-4 Viewing a Recipe

5.6 Printing a Recipe

We strongly suggest you print and file a copy of NDC Basic and each new recipe after it is
saved back to the recipe directory. These printouts may be useful if you have to troubleshoot
the system.

To print a copy of any recipe:

1. Move to the Recipe menu.

2. Press the Selected Recipe button and then highlight the desired recipe.

3. Press the Select button.

4. Press the Print Selected Recipe button.

•
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Model 6100TC: Recipes • 5-5
•
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 5.7 Deleting a Recipe
To delete a recipe from the recipe directory:

1. Move to the Recipe menu.

2. Press the Selected Recipe button and then highlight the desired recipe.

3. Press the Select button.

4. Press the Delete Selected Recipe button and then press Yes to confirm your decision. If
you press No, the screen will return to the Recipe menu. You can delete any recipe except
NDC Basic.

5.8 Restoring Original Setup Values

To restore your factory-set values, contact the NDC Infrared Engineering Customer Care
Department and then follow Section 5.1 - Loading a Recipe to Current to reload NDC Basic to
5 the current working area.

5.9 Viewing the Recipe Directory

To see a list of recipes in the recipe directory, press Selected Recipe. A screen similar to
Figure 5-3 will appear.

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5-6 •• Model 6100TC: Recipes
•
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 CHAPTER

6 Reports 6
6.1 Reports Menu

REPORTS

PRINT SHIFT PRINT BASIC RPT

PRINT JOB REPORT
REPORT (ROLL)

STRIP CHART
STRIP CHART SETUP REPORT SETUP
OFF ON

DISPLAY MAIN

Figure 6-1 Reports Menu

Use the Reports menu (Main → Reports) to format and order reports based on the previous
job, shift, roll or timed interval, and to turn on or off the strip chart recorder. Roll reports
require a customer-supplied roll switch input to Event Input A on the rear gauge panel. Job
reports are triggered by a recipe change. Shift times are set on the Clock menu (Main → More
→ More → Clock).

References below to Basic Reports refer to timed or roll reports, depending on which is
selected on the Report Setup menu. See Section 6.3 - Report Setup.

The Reports menu (Figure 6-1) includes the following buttons:

‰ Print Job Report, Print Shift Report and Print Basic Rpt: Each of these buttons orders
an immediate printout based on data from the most recently completed job, shift, roll or
timed interval.

‰ Strip Chart Off/On: This toggle turns the printer’s strip-chart mode on or off. If another
report is triggered while the strip chart is On, the system will interrupt the strip chart, print
the report, and then resume the strip chart with no loss of data.

‰ Strip Chart Setup: This button calls up a menu that allows you to set the strip chart
parameters. See Section 6.2 - Strip Chart Setup.

‰ Report Setup: This button calls up the Report Setup menu. See Section 6.3 - Report
Setup.
•
Model 6100TC: Reports •• 6-1
•
•
•
 6.2 Strip Chart Setup

STRIP CHART SETUP

UPDATE TIME STRIP CHART SCALE ROLL FORM FEED

1.00 0.20 NO YES

DISPLAY EXIT MAIN

Figure 6-2 Strip Chart Setup Menu

The Strip Chart Setup menu (Main → Reports → Strip Chart Setup, Figure 6-2) is used to

6 set up the strip chart. The strip chart is essentially a printed version of the Inline display. The
Moving Average entry in the Inline Setup menu (Main → Display Setup → Inline) repre-
sents the amount of data averaged for each plotted point. If the Moving Average is 3 seconds,
each plotted point will be the average of the last 3 seconds of data collected.

The strip chart plots a line from the minimum reading to the maximum reading for the Moving
Average period.

Note: If the strip chart is on, and there is a request for a printout of a report or recipe, the
strip chart will summarize whatever is currently on the page, the report or recipe will
be printed, and the strip chart will then continue on a new page, catching up on data
generated during the intervening printout.

The Strip Chart Setup menu includes the following buttons:

‰ Update Time: This button sets the update time for strip chart data points and for the Inline
display. (The Inline Setup menu’s Update Time serves the same function, and the gauge
uses the most recent entry.)

For example, if the Update Time is 5 seconds, a point will be plotted every 5 seconds. Be
sure to select a value for Update Time that is not too small, or else the strip chart will
cover several pages in a short amount of time. A 10 second Update Time will result in
about 1 hour of data per page of output.

‰ Strip Chart Scale: This button sets the distance, in gauge units, from the center to each
edge of the strip chart.

•
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6-2 •• Model 6100TC: Reports
•
•
‰ Roll Form Feed: Use this toggle to tell the system whether the strip chart should begin a
new page at the end of each roll. This toggle appears only if the Basic Report toggle in the
Report Setup menu is set to Roll.

•
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Model 6100TC: Reports • 6-3
•
•
•
 6.3 Report Setup

REPORT SETUP

AUTO PRINT ROLL AUTO PRINT SHIFT AUTO PRINT JOB

OFF ON OFF ON OFF ON

BASIC REPORT HEADER

AUTO SCREEN PRINT
ROLL TIME NDC SYSTEMS

MIN/MAX SPLIT ROLL RPTS

RANGE/SIGMA OFF ON

DISPLAY EXIT MAIN

Figure 6-3 Report Setup Menu

The Report Setup menu (Main → Reports → Report Setup, Figure 6-3) sets a variety of

6 report parameters:

‰ Auto Print Roll/Time, Auto Print Shift and Auto Print Job: These On/Off toggles trig-
ger automatic reports at the end of each roll or timed interval, shift, or job.

‰ Basic Report Roll/Time: This toggle tells the system whether to print reports based on
roll or timed data. If Time is selected, a new Time Interval button appears to let you
select the interval between reports. Available options are 10, 15, and 30 minutes, and 1, 2,
4, 8 or 12 hours.

‰ Header: Use this button to enter a header label for your reports and other printouts. Maxi-
mum number of characters allowed is 11. This label typically identifies the production line
or owner of the system.

‰ Auto Screen Print: Brings up the Auto Screen Print menu. See Section 6.5 - Auto Screen
Print.

‰ Min/Max or Range/Sigma: Sets whether the job and shift reports show the minimum and
maximum, or range and sigma for each roll.

‰ Split Roll Rpts: Turns the Split Roll Reports option On or Off. See Section 6.6 - Split
Roll Reports.

•
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6-4 •• Model 6100TC: Reports
•
•
6.4 Description of Items in Roll Report

21-DEC-2001 REPORT : ROLL 08:50:28

NDC SYSTEMS
PRODUCT: NDC BASIC ROLL : 002
START TIME: 08:27:31
STOP TIME: 08:50:28
RUNNING TIME: 00:22:57
TIME SCANNING: 100%

TIME DATA ON: 100.0%

SCRAP TIME: 0.0%
OTHER: 0.0%
LENGTH (M): 2051.68
SCRAP LENGTH (M): 0.0
HI ALARM (G/M2): 2100
TARGET: 2000
LO ALARM: 1900

MAXIMUM: 2070
AVERAGE: 2045
MINIMUM: 2023
RANGE: 47
2 SIGMA: 14.8
> HI ALARM: 0.00%

6
< LO ALARM: 0.00%
WEIGHT (KG): 2440.6

NDC SYSTEMS : MODEL 6100

Figure 6-4 Sample Roll Report

Figure 6-4 shows a sample roll report. Items shown in the roll report include:

y START TIME - start time of the roll

y STOP TIME - end time of the roll

y RUNNING TIME - difference between start time and stop time

y TIME CTRL ON - percentage of time during the roll that control is on

y TIME SCANNING - percentage of time during the roll that the sensor was scanning

y TIME DATA ON - percentage of time during the roll that data collection was on

Data collection is on if all of these conditions are true:

- scrap is Off

- the sensor is not standardizing

continues

•
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Model 6100TC: Reports • 6-5
•
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•
 continued from previous page

- the scanner is initialized

- the sensor is on sheet

- the shutter is open (if there is a shutter)

- the sensor is extended (if the Auto Retract option is on)

See Section 1.4 - Data mode.

y SCRAP TIME - percentage of time during the roll that scrap is on.

Scrap is considered to be On if any of the following conditions is true:

- the external data input (input C) is Off

- the Data toggle on page 2 of Main menu is Off

- there is a sheet break

- there is a low linespeed alarm

y OTHER - time data on minus scrap time (e.g., the shutter is closed, the sensor is offsheet,

6
or the sensor is standardizing)

y LENGTH - total length of the roll minus scrap length

y SCRAP LENGTH - length of scrap produced during the roll

y HI ALARM - High Alarm for the product being made

y TARGET - target for the product being made

y LO ALARM - Low Alarm for the product being made

The following items use gauge data smoothed by the gauge moving average:

y MAXIMUM - maximum gauge reading during the roll

y AVERAGE - average gauge reading during the roll

y MINIMUM - minimum gauge reading during the roll

y RANGE - maximum minus minimum

2
y 2 SIGMA - sum – sum × sum ⁄ numValues ⁄ ( numValues – 1 )

y > HI ALARM - percentage of gauge readings above High Alarm

y < LO ALARM - percentage of gauge readings below Low Alarm

continues

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6-6 •• Model 6100TC: Reports
•
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 continued from previous page

y WEIGHT

- if the gauge is measuring mass, the roll weight is calculated as:

length x avg thickness x Product Width x conversion factor

where conversion factor is dependent on the length, width and thickness units

Product Width is entered on Process Menu Page 2

- if the gauge is measuring thickness, the roll weight is calculated as:

length x avg thickness x Specific Gravity x Product Width x conversion factor

where conversion factor is dependent on the length, width and thickness units

Product Width is entered on Process Menu Page 2

•
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Model 6100TC: Reports • 6-7
•
•
•
 6.5 Auto Screen Print
The Auto Screen Print feature automatically prints selected displays at the end of a time inter-
val, End-of-Roll or End-of-Job.

AUTO SCREEN PRINT

1 2 3 4
TRIGGER TRIGGER TRIGGER TRIGGER
ROLL JOB OFF OFF

DISPLAY DISPLAY DISPLAY DISPLAY

HIST TREND HIST HIST

DISPLAY EXIT MAIN

6 Figure 6-5 Auto Screen Print Menu

There are four separate triggers, numbered 1 to 4, in the Auto Screen Print menu (Main →
Reports → Report Setup → Auto Screen Print, Figure 6-5).

To enable a trigger:

1. Set Trigger to:

Roll * to print the selected display at end of roll

Time * to print the selected display at end of time interval

Job to print the selected display at end of job

* Either Roll or Time appears in the Trigger menu, depending on whether Basic Report
is set to Roll or Time (in the Report Setup menu).

The trigger can be disabled by setting Trigger to Off.

2. Select the Display to print when the trigger is activated.

When a trigger is activated (e.g., at End-of-Roll), all the displays for that trigger will be
printed. For example, if Trigger 1 and Trigger 2 are set to Roll, and the Trend and Inline dis-
plays are selected for the triggers, those displays will be printed at the end of a roll. While the
displays are being printed, the Print button is replaced by the Abort Print button. Touching
Abort Print will abort printing of the displays.

•
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6-8 •• Model 6100TC: Reports
•
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6.6 Split Roll Reports
Split Roll Reports are useful for applications that slit and wind sheets on to two or more cores.
To map each split region, a display zone is created. The scan data is separated for the different
sections, and multiple Roll Reports are generated, one for each split roll. A maximum of 3 split
roll reports is allowed.

6.6.1 Setup

1. Create up to 3 display zones in the Display Zone Setup screen (Main → Display Setup →
Display Zones). If more than 3 zones are created, split roll reports will be generated for
the 3 leftmost zones.

Follow the procedure in Section 2.2.7 - Display Zone Setup.

Display zones are included in every recipe, so they will change automatically when a new
recipe with different values is loaded.

2. Activate the Split Roll Reports feature:

a. Move to the Report Setup menu (Main → Reports → Report Setup, Figure 6-3).

b. Set the Split Roll Rpts toggle to On.

Split roll reports will be generated when a roll is completed. The format of a split roll
report is exactly the same as a standard roll report, except that the roll number will be fol-
6
lowed by the zone number in parentheses.

If the Split Roll Rpts toggle is Off, one roll report will be generated for the whole roll.

Figure 6-6 and Figure 6-7 show two Split Roll Reports.

Note: Job and Shift reports list the full roll, not the split rolls.

For Open Access, item 4078 is used to extract split roll reports.

•
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Model 6100TC: Reports • 6-9
•
•
•
 13-NOV-02 REPORT : ROLL 08:50:28
NDC SYSTEMS
PRODUCT: NDC BASIC ROLL : 002 (ZONE 1)
START TIME: 08:27:31
STOP TIME: 08:50:28
RUNNING TIME: 00:22:57
TIME SCANNING: 100%

TIME DATA ON: 100.0%

SCRAP TIME: 0.0%
OTHER: 0.0%
LENGTH (M): 2051.68
SCRAP LENGTH (M): 0.0
HI ALARM (G/M2): 2100
TARGET: 2000
LO ALARM: 1900

MAXIMUM: 2070
AVERAGE: 2045
MINIMUM: 2023
RANGE: 47
2 SIGMA: 14.8
> HI ALARM: 0.00%
< LO ALARM: 0.00%
WEIGHT (KG): 2440.6

NDC SYSTEMS : MODEL 6100

6 Figure 6-6 Split Roll Report - Zone 1

13-NOV-02 REPORT : ROLL 08:50:28

NDC SYSTEMS
PRODUCT: NDC BASIC ROLL : 002 (ZONE 2)
START TIME: 08:27:31
STOP TIME: 08:50:28
RUNNING TIME: 00:22:57
TIME SCANNING: 100%

TIME DATA ON: 100.0%

SCRAP TIME: 0.0%
OTHER: 0.0%
LENGTH (M): 2051.68
SCRAP LENGTH (M): 0.0
HI ALARM (G/M2): 2100
TARGET: 2000
LO ALARM: 1900

MAXIMUM: 2135
AVERAGE: 2066
MINIMUM: 2039
RANGE: 96
2 SIGMA: 38.6
> HI ALARM: 0.00%
< LO ALARM: 0.00%
WEIGHT (KG): 2780.0

NDC SYSTEMS : MODEL 6100

Figure 6-7 Split Roll Report - Zone 2

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6-10 •• Model 6100TC: Reports
•
•
6.7 Roll Defects Report
The Roll Defects Report provides the following:

y Roll Defect List

A listing of sections of the sheet where defects were found. The defective sections
are listed by distance from the beginning of the roll, and starting and ending points
across the web.

y Roll Defect Map

A graphical map showing the various defect locations.

6.7.1 What Constitutes a Defect

The system goes through the following sequence when checking for defects:

1. The system waits until the portion of the sheet measured in a scan reaches the roll windup.

2. The smoothed1 scan profile is then examined for defects.

3. A defect is found when a value exceeds the High and Low Alarm levels. The defect is
recorded as starting not on the scan where the value was measured, but on the previous
scan at the very same cross-direction point. 6
4. At the next scan, the value at the cross-direction point (same point as in step 2) is com-
pared to the Alarm limits:

a. If the value is within the Alarms, that point marks the end of the defect.

b. If the value is outside of the Alarms, that point is assumed to be a continuation of the
defect. The same cross-direction point continues to be checked on subsequent scans.
As soon as the sensor sees good data at that location, the defect is recorded as ending
at the same cross-direction point on that scan.

This conservative approach to defect detection recognizes that the sensor sees a portion of the
defect, but cannot identify exactly where it begins and ends. Note that this type of defect
reporting is different from the standard Roll Report, which considers product as within spec as
soon as the gauge readings are back within the Alarm levels, regardless of the sensor position.
This means the Defects Report may indicate slightly more product outside the Alarm levels
than the Roll Report.

1. Smoothing is performed by averaging each gauge reading with adjacent readings. The
amount of smoothing is based on the gauge Moving Average value (in the Gage
menu).

•
•
Model 6100TC: Reports • 6-11
•
•
•
 6.7.2 How Defects are Reported

Reported
Defect

a
c
d

Cross Web Direction

6 To Windup Roll

Windup Roll

Figure 6-8 Defect Reporting

In the Roll Defects Report, the location of a defect is specified by the following points:

y its start location relative to the beginning of the roll

y its end location relative to the beginning of the roll

y the leftmost cross-direction point

y the rightmost cross-direction point

These points are illustrated in Figure 6-8:

a - Start of defect, measured from the beginning of the roll

b - End of defect, measured from the beginning of the roll

c - Left edge of defect

d - Right edge of defect

•
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6-12 •• Model 6100TC: Reports
•
•
 Minor variations in the edges of a defect are tolerated. A defect is considered to be a continua-
tion of an existing defect if each edge wanders no more than ± 2% of the scanned distance2.
The width of such a defect is reported as starting from the minimum left edge of the defect to
its maximum right edge.

A maximum of four defects are recorded for each scan. If more than four defects are found,
they are reported as a single defect spanning all the points outside the alerts.

The maximum number of defects stored for a roll is 100.

6.7.3 Setup

REPORT SETUP

AUTO PRINT ROLL AUTO PRINT SHIFT AUTO PRINT JOB

OFF ON OFF ON OFF ON

BASIC REPORT HEADER

AUTO SCREEN PRINT
ROLL TIME NDC SYSTEMS

MIN/MAX
RANGE/SIGMA
ROLL DEFECT MAP
OFF ON
SPLIT ROLL RPTS
OFF ON 6
DISPLAY EXIT MAIN

Figure 6-9 Report Setup Menu

To activate the Roll Defect feature:

1. Move to the Report Setup menu (Main → Reports → Report Setup, Figure 6-9).

2. Set the Roll Defect Map toggle to On.

When Roll Defect Map is turned on, the Roll Defect List and Roll Defect Map are generated as
part of the Roll Report.

2. The scanned distance is the distance from the left scan point to the right scan point.

•
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Model 6100TC: Reports • 6-13
•
•
•
 6.7.4 Roll Defect List

01/10/02 ROLL DEFECT LIST 16:57:38

NDC SYSTEMS - IRWINDALE, CA - 8300
PRODUCT ID: NDC ROLL #:1

START/END CROSS WEB

NO DATA 0.0 TO 383.6 0.0 TO 25.0
< LO ALARM 383.6 TO 496.8 0.0 TO 25.0
> HI ALARM 542.8 TO 872.9 0.0 TO 1.9
HI & LO 543.4 TO 881.9 0.0 TO 3.5
NO DATA 872.9 TO 921.2 0.0 TO 25.0

Figure 6-10 Roll Defect List

The Roll Defect List (Figure 6-10) shows defects by location and description. The system rec-
ognizes the following types of defects:

6 y Actual Defects

These are locations on the sheet where gauge readings exceed the High and Low Alarm
levels. These defects are noted in the Roll Defect List as:

> HI ALARM
< LO ALARM
HI & LO

y No Data Defects

A No Data Defect will be generated if data collection is turned off, or if the sensor is not
scanning.

•
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6-14 •• Model 6100TC: Reports
•
•
6.7.5 Roll Defect Map

The Roll Defect Map (Figure 6-11) is always one page long, and is scaled to fit the length of
the roll.

11/13/02 ROLL DEFECT MAP 16:57:38

NDC SYSTEMS
PRODUCT ID: NDC ROLL #:1

0.0 25.0
0.0 xx
xx xx
xx
xx
xx

150.0

xx
xx

300.0

450.0
xx
xx
x xx
x
6
x

600.0
xxxx
xxxx
xxxx
xx
xx
xx
750.0

900.0

FT
OUT OF SPEC = xxx NO DATA =

Figure 6-11 Roll Defect Map

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Model 6100TC: Reports • 6-15
•
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6

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6-16 •• Model 6100TC: Reports
•
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 CHAPTER

7 I/O Setup 7
The system offers a variety of analog and serial outputs, three alarm outputs and an optional
event input through the rear panel. The output options are factory-set to the customer’s specifi-
cations. The I/O (Input/Output) Setup menu (Main → More → I/O Setup) lets you set up and
calibrate these inputs and outputs.

I/O SETUP

TACH SERIAL ANALOG ALARMS

INPUT B

GAGE SAMPLES

DISPLAY EXIT MAIN

Figure 7-1 I/O Setup Menu

The I/O Setup menu (Figure 7-1) includes the following buttons:

‰ Tach: Brings up a menu for calibrating the tach and setting the minimum linespeed.
See Section 7.1 - Tach Calibration.

‰ Serial: Brings up a menu for setting up the serial output. See Section 7.2 - Serial Output.

‰ Analog: Brings up a menu for setting up the analog outputs. See Section 7.3 - Analog Out-
puts.

‰ Alarms: Brings up a menu for settings up the alarm outputs. See Section 7.4 - Alarms.

‰ Input B: Selects the option for Input B. See Section 7.5 - Input B Setup.

•
Model 6100TC: I/O Setup •• 7-1
•
•
•
 7.1 Tach Calibration

TACH

PULSES PER FT MINIMUM LINESPEED

LINESPEED
300.00 0.0

DISPLAY EXIT MAIN

Figure 7-2 Tach Menu

To reach the Tach menu (Figure 7-2), press Main → More → I/O Setup → Tach. This menu
includes the following buttons:

‰ Pulses per __: The tachometer’s rotopulser input must be calibrated to the number of
pulses per unit distance or to a known linespeed.

7 The Pulses per __ button is used to calibrate the tach to the pulse rate. The rotopulser sup-
plied with your system outputs 300 pulses per rotation. When it is attached to a wheel or
roller of known circumference, the number of pulses per foot, yard or meter can be easily
calculated. To avoid slippage or overloading the counter, the pulser should take its input
from a non-slip idler or drive roller at least 2 inches (5 cm) in diameter.

Press the Pulses per __ button and enter the calculated value. The tach unit is specified by
the Length Unit entry in the Units menu (Main → More → Units).

•
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7-2 •• Model 6100TC: I/O Setup
•
•
‰ Linespeed: This button is used to calibrate the tach to a known linespeed.

Bring the line up to speed, press the Linespeed button and enter the current linespeed.
This method tends to be less precise than calculating the number of pulses per unit dis-
tance.

‰ Minimum Linespeed: This button determines the minimum linespeed for the system’s
data collection mode. The system does not accumulate data for reports unless the
linespeed is above this minimum. This feature is generally used to prevent data collection
during start-up and after a linestop.

If the linespeed is below the Minimum Linespeed, a Lo Speed Alarm will activate and:

y A “Lo Speed Alarm” message will flash in the header.

y The system will be in No Data mode.

y The sensor will move to the Startup Switch.

When the linespeed comes back above the Minimum Linespeed:

y The flashing “Lo Speed Alarm” message will be turned off.

y The system will return to Data mode.

y The sensor will resume its previous action (i.e., continue scanning).

To disable Lo Speed Alarm, enter “0” for Minimum Linespeed. (This is the default value.)

•
•
Model 6100TC: I/O Setup • 7-3
•
•
•
 7.2 Serial Output

SERIAL

SERIAL OUTPUT BAUD PARITY DATA BITS

OPEN ACCESS 9600 NONE 7 8

OPEN ACCESS MOVING AVERAGE OUTPUT POSITION

UPDATE TIME
5.00 NO YES
1.00

DISPLAY EXIT MAIN

Figure 7-3 Serial Menu

Move to the Serial menu (Main → More → I/O Setup → Serial, Figure 7-3) and set up as
needed for your output device. This menu includes the following buttons:

‰ Serial Output: Sets what is output through the RS-232 port. Options include:

y None - No output

7 y Gage - Outputs the gauge reading.

Additionally, if the Output Position toggle (in the Serial menu) is set to Yes,
the sensor position will be output with each gauge reading. Otherwise, if Out-
put Position is No, only the gauge reading will be output.

The table below shows what is output. All transmissions are in ASCII.

Gage output only Gage and Position output

STX (ASCII 2) STX

Sign (+ or -) Sign (+ or -)

Gauge value Gauge value (four digits and

(i.e., 53.22 is sent 5 first, floating decimal)
with four digits and
floating decimal point) Space

ETX (ASCII 3) @

Sign (+ or -)

Position value (four digits,

decimal, two digits)

ETX

continues
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7-4 •• Model 6100TC: I/O Setup
•
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 continued from previous page

y Strip Chart- Sends a strip chart to a second printer.

If this is selected, no other buttons appear in the Serial menu.

y Open Access- Sets up the gauge for communication with a host computer using
Open Access

‰ Baud: Sets the baud rate. The following choices are available: 2400, 4800, 9600 and
19200.

‰ Parity: Sets the parity (Even, Odd or None). Parity should be None for Open Access.

‰ Data Bits: Sets the number of data bits (7 or 8). Data Bits should be 8 for Open Access.

‰ Open Access Update Time: Sets the Open Access Update Time for Open Access. Please
refer to your T-Gauge Open Access manual.

‰ Moving Average: Sets the amount of data averaged for each data point that is output.
For example, if the Moving Average is 5 seconds, each data point will be the average of
the last 5 seconds of data.

‰ Output Position: If Serial Output is set to Gage and Output Position is Yes, the sensor
position will be output with each gauge reading. Otherwise, if Output Position is No,
only the gauge reading will be output.

•
•
Model 6100TC: I/O Setup • 7-5
•
•
•
 7.3 Analog Outputs

ANALOG

MOVING AVERAGE CHANNEL

5.00 SETTINGS

DISPLAY EXIT MAIN

Figure 7-4 Analog Menu

The gauge offers four 0-10 VDC, 0-2.5 VDC or 4-20 milliamp 12 bit d/a analog outputs.
The analog output options are factory-selected to the customer’s specifications and the Analog
menu lets you configure and calibrate them to your recorder, computer or other devices.

Move to the Analog menu (Main → More → I/O Setup → Analog, Figure 7-4). This menu
includes the following buttons:

7 ‰ Moving Average: Use this button to set the moving average for the analog outputs.
This moving average is independent of those used for the gauge displays and serial output.

‰ Channel Settings: Brings up the Channel Settings menu for configuring the analog out-
puts. See Section 7.3.1 - Channel Settings.

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7-6 •• Model 6100TC: I/O Setup
•
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7.3.1 Channel Settings

CHANNEL SETTINGS - 1

CENTER FULL SCALE DATA GAGE READING

ABSOLUTE 5.00 GAGE1 CYCLE AVG

ANALOG CHANNEL
DISPLAY EXIT MAIN
1 2 3 4

Figure 7-5 Channel Settings Menu

The Channel Settings menu (Figure 7-5) is used to configure the analog channels. This menu
includes the following buttons:

‰ Analog Channel: This button selects an analog channel (1, 2, 3 or 4). The settings in the
Channel Settings menu will apply to the selected channel.

‰ Center/Absolute: Use this toggle to tell the system whether you want the outputs to cen-
ter on the target (Center) or range from zero to the full scale value (Absolute). If the out- 7
put is centered on the target, 100% of the full-scale range is above the target and 100% is
below.

In other words, if your full scale is 3 mils, the target is 4 mils and the analog output is cen-
tered on the target, the analog output will cover a range from 1 to 7 mils. If the analog out-
put is absolute and the full scale remains 3 mils, the analog output will cover a range from
0 to 3 mils no matter where the target is set.

‰ Full Scale: Sets the full-scale reading for the analog output.

Choose a full-scale value that allows for the full range of product in a given recipe.
Remember that any gauge readings above the full-scale value will be output as the maxi-
mum analog value.

‰ Data: Selects Gage or Position. If Gage is selected, the analog output for the selected
channel will be the gauge reading or scan average, depending on whether Gage Reading
or Cycle Avg is selected in the Channel Settings menu. If Position is selected, the analog
output for the selected channel will be the sensor position.

If Position is selected, the Full Scale, Center/Absolute and Gage Reading/Cycle Aver-
age buttons do not appear. Instead, the analog output is scaled between the two scan limit
switches. For example, suppose the scan limit switches are 0.0 and 60.0. This corresponds

•
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Model 6100TC: I/O Setup • 7-7
•
•
•
 to a minimum output voltage of 0 and a maximum output voltage of 10. If Data is set to
Position and the current position is 48.0, the analog output will be 8.0.

‰ Gage Reading/Cycle Avg: Sets whether the analog channel outputs the gauge reading or
the scan average.

If desired, an analog test may be carried out on an analog channel. See Section 11.4.3 - Analog
Output Test.

•
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7-8 •• Model 6100TC: I/O Setup
•
•
7.4 Alarms
7.4.1 Acknowledging an Alarm

If an Alarm condition occurs, a message will flash in the header. If an alarm output has been
set up to activate on that alarm condition, that output will turn on. Touching the flashing mes-
sage in the header acknowledges the alarm condition and turns off the alarm output.

Refer to Figure 7-6.

• When any reading is less than the Low Alarm limit and Data mode is On, a Low
Alarm condition is triggered and the Lo Alarm label in the header will flash.

• When any reading is greater than the High Alarm limit and Data mode is On, a High
Alarm condition is triggered and the Hi Alarm label in the header will flash.

To acknowledge a High or Low Alarm, touch the flashing label in the header. The A, B or C
alarm output will turn on if Hi, Lo or Hi/Lo is selected for Alarms A, B or C (in the Alarms
menu: Main → More → I/O Setup → Alarms).

If the alarm is acknowledged while the gauge is still out of spec, the label in the header will
stop flashing and the alarm output will turn off. However, the label will still appear in its alarm
state (reverse video).

If the alarm is acknowledged after the gauge has gone back to spec, the label in the header will
stop flashing and appear in its non-alarm state (normal video), and the alarm output will turn
off.

Flashes on High Alarm condition

7
Header
HI ALARM 73.30

72.30
Flashes on TARGET 72.30
Low Alarm LO ALARM 71.30
condition PROD: NDC BASIC MILS
ROLL: 001

Figure 7-6 Alarm labels flash on Alarm condition

Note: If the Auto Alarm Reset toggle is On (in the Miscellaneous menu), a High or Low
Alarm does not have to be acknowledged. When the product comes back within spec,
the alarm will automatically be cleared. See Section 8.7 - Miscellaneous.

•
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Model 6100TC: I/O Setup • 7-9
•
•
•
 7.4.2 Alarm Setup

ALARMS

A B C
ALARM ALARM ALARM
HI LO HI/LO

DISPLAY ALARM LOG EXIT MAIN

Figure 7-7 Alarms Menu

To set up the Alarm outputs, go to the Alarms menu (Main → More → I/O Setup → Alarms,
Figure 7-7). Press one of the three Alarm buttons (Alarm A, Alarm B or Alarm C, correspond-
ing to the three alarm outputs on the rear gauge panel.) The screen will show a set of Up/Down
arrows and a list of alarm options. If your system uses a dual-gap control, Alarm B and
Alarm C are reserved for the controller. As a result, only Alarm A appears on the Alarms
menu.
7
ALARM - A

NONE

HI

LO

MORE CHOICES HI/LO

BREAK/HI-VAL

CTRL

DELAYED HI

ABORT ENTER

Figure 7-8 Alarm options

Figure 7-8 shows the various alarm options. There are 2 pages of alarm options. Touch the
More Choices button to switch from one page to the other.

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7-10 •• Model 6100TC: I/O Setup
•
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The alarm options include:

y None - Turns off the alarm output

y Hi - A gauge reading greater than the High Alarm limit will cause the alarm out-
put to turn on. See Hi Alarm in Section 3.1 - Process Menu Page 1.

y Lo - A gauge reading less than the Low Alarm limit will cause the alarm output to
turn on. See Lo Alarm in Section 3.1 - Process Menu Page 1.

y Hi/Lo - A gauge reading outside the High or Low Alarm limit will cause the
alarm output to turn on.

y Break/Hi-Val - The alarm output will turn on when a Sheet Break or High Value
Alarm occurs. See Minimum Gage Value and Maximum Gage Value in
Section 3.2 - Process Menu Page 2 and Section 4.5.3 - Sheet Break Detection
with Edgeseek.

y Ctrl - (Systems with Control only): The alarm output will turn on when a control
inhibit occurs. The control inhibit can be caused by a High or Low Alarm,
sheet break, low linespeed, etc. See Section 9.6 - Control Inhibits.

y Delayed Hi - Delayed Hi Alarm. This applies only to 4100TC systems.

y Delayed Lo - Delayed Lo Alarm. This applies only to 4100TC systems.

y Delayed Hi/Lo - Delayed Hi/Lo Alarm. This applies only to 4100TC systems.

y Alerts - The alarm output will turn on when a gauge reading is outside the alert

7
limits. See Section 3.1.1 - Alerts.

y Lamp Alarm - This applies only to systems with the UVF sensor.

y Length - The alarm output will turn on when the accumulated length for the cur-
rent roll exceeds the Length Limit. See Length Limit in Section 2.2.6 -
Header Info.

y Weight - The alarm output will turn on when the accumulated weight for the cur-
rent roll exceeds the Weight Limit. See Weight Limit in Section 2.2.6 -
Header Info.

y Hardware - The alarm output will turn on when any of the following “hardware-
related” alarms is activated:

• Lift Alarm - For systems with Auto Retract, a Lift Alarm is triggered
whenever there is a failure in the extend/retract mechanism.
See Section 10.4.2 - Lift Alarm.

• Breakaway Alarm - The alarm output will turn on when pressure on

the sensor forces it out of position.

continues

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Model 6100TC: I/O Setup • 7-11
•
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 continued from previous page

• Lag Alarm - This applies only to multiple sensor systems. The alarm
output will turn on if there is insufficient storage for lagged net calcula-
tions. More memory is required.

• GoTo Fail - The alarm output will turn on when the sensor is ordered to
move to a certain destination via the Go To button on the Scanner dis-
play, and the sensor does not stop within a certain range from that desti-
nation. See Move Tolerance in Section 4.4.2 - Scanner Setup Menu
Page 2.

• Stop Failed - The alarm output will turn on when the moving sensor is
ordered to stop, and the command fails.

• Tpp Alarm - This applies only to systems with the Telescopic Probe
Positioner (TPP).

Use the arrow keys to select the desired alarm option, then press Enter to save the selection.

Be sure the alarm devices are connected to the Alarm outputs on the rear panel. Alarm signals
are output via a dry contact switch. The customer must supply power (16-240 VAC) for each
alarm loop. Alarms are fused at 4 amps internal on the optoisolator, part #G40AC5A, inside
the console.

7.4.3 Alarm Log

The Alarm Log button in the Alarms menu brings up the Alarm Log page. The Alarm Log
shows information only about hardware alarms, including the date and time of the alarm, and a
7 brief explanation of the cause of the alarm. If the Auto Print toggle is set to Yes, each time an
entry appears in the Alarm Log, it will be printed as well.

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7-12 •• Model 6100TC: I/O Setup
•
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7.5 Input B Setup

INPUT B

STRIP CHART

GAGE SAMPLES

START SCAN

ABORT ENTER

Figure 7-9 Input B Menu

External Input B on the rear panel will take inputs from three different options, depending on
how the Input B menu (Main → More → I/O Setup → Input B, Figure 7-9) is set up. The
following options are available for Input B:

‰ Strip Chart: If this option is selected, an event mark will be drawn on the left side of the
strip chart each time Input B is activated. See Section 6.2 - Strip Chart Setup.

‰ Gage Samples: If this option is selected, a remote switch input will trigger a Gage Sample 7
report. The Gage Samples screen must be displayed when the input is activated (Main →
Gage → Gage Samples.)

‰ Start Scan: If this option is selected, a remote switch input will start the sensor scanning.

Use the arrow keys to selected the desired option, then press Enter to save the selection.

•
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Model 6100TC: I/O Setup • 7-13
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7

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7-14 •• Model 6100TC: I/O Setup
•
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 CHAPTER

8 Setup 8
8.1 Units
The Units menu (Main → More → Units) lets you select a variety of English and metric units
for different parameters. Most buttons call up a set of Up/Down arrows to scroll through the
available options and an Enter button to fix your selection in the system memory.

UNITS

DECIMAL POINT GAGE UNIT ROLL LABEL

CUSTOM UNIT
XXX.X MILS ROLL

LENGTH UNIT WEIGHT UNIT SHEET WIDTH UNIT

FT LB IN

DISPLAY EXIT MAIN

Figure 8-1 Units Menu

The Units menu (Figure 8-1) includes the following buttons:

‰ Decimal Point: This button lets you set the decimal point for gauge readings, displays,
control and all other values based on gauge readings. Options are xxxx, xxx.x, xx.xx,
x.xxx or .xxxx.

‰ Gage Unit: This entry determines whether gauge measurements are reported in mils,
microns, millimeters, ounces/yard2, grams/meter2, lbs/1000 ft2, kg/m2, percent or custom
units.

The Gage Unit is only a label, and does not cause any units conversion to be done on the
gauge readings. If the data does not match the selected units, a Gage Factor must be
entered to convert it to those units.

‰ Custom Unit: This button calls up a new menu that lets you configure a custom unit.
See Section 8.1.1 - Custom Unit.

‰ Roll Label: This button lets you substitute a new label wherever the word “Roll” appears
in displays and reports. The label can be as many as eight characters long.

•
Model 6100TC: Setup •• 8-1
•
•
•
 ‰ Length Unit: This entry determines whether the tachometer and site layout distances are
registered as yards, feet, meters or inches.

‰ Weight Unit: This entry determines whether weights are reported as pounds or kilograms.

‰ Sheet Width Unit: This entry determines whether the sheet width is entered in inches,
centimeters or millimeters.

8.1.1 Custom Unit

CUSTOM UNIT

CUSTOM UNIT NAME CONV FACTOR TO G/M2 THICKNESS UNIT

LBS/REAM 1.627 WEIGHT UNIT

DISPLAY EXIT MAIN

Figure 8-2 Custom Unit Menu

To create a custom unit:

1. Move to the Custom Unit menu (Main → More → Units → Custom Unit,

8
Figure 8-2).

2. Set the Thickness Unit/Weight Unit toggle as appropriate for your custom unit.

3. Calculate the conversion from microns (if you are measuring thickness) or grams per
square meter (if you are measuring mass).

Touch the Conv Factor to __ button and enter the Conversion Factor.

4. Enter the Custom Unit Name.

•
•
8-2 •• Model 6100TC: Setup
•
•
8.2 Cycles

CYCLES

CYCLE TIME CYCLE TYPE

(SECS)
60 SCANS TIME

DISPLAY EXIT MAIN

Figure 8-3 Cycles Menu

You must set up the system so that its basic data collection cycle is based on a calculated scan
or elapsed time.

1. From the Cycles menu (Main → More → Cycles, Figure 8-3), set the Cycle Type toggle
to Scans or Time.

This sets whether cycles are based on scans or a timed interval.

2. If your cycles are timed, press the Cycle Time button and use the resulting arrows to enter
the desired interval (in seconds).

If your cycles are based on scans, the cycle time is calculated from the scanner calibration
and scanner speed. 8

•
•
Model 6100TC: Setup • 8-3
•
•
•
 8.3 Clock

CLOCK

SET DATE SET TIME SHIFT TIMES

DISPLAY EXIT MAIN

Figure 8-4 Clock Menu

To set the clock and calendar, go to the Clock menu (Main → More → More → Clock,
Figure 8-4).

‰ Set Date: This button calls up a menu for setting the date. Enter the date as
DD/MM/YYYY.

‰ Set Time: This button calls up a menu for setting the time. Enter the time as Hour:Minute.
Midnight must be entered as 00:00.

‰ Shift Times: This button calls up a menu for setting the start and end time for up to three
shifts.

8 Make sure that the end time for one shift does not overlap the start time for the next shift.

•
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8-4 •• Model 6100TC: Setup
•
•
8.4 Site Layout

SITE LAYOUT

MINIMUM ROLL
(FT)
0.000

ROLL LAG DISTANCE

(FT)
0.000

DISPLAY EXIT MAIN

Figure 8-5 Site Layout Menu

The Site Layout menu (Main → More → Site Layout, Figure 8-5) includes the following but-
tons:

‰ Minimum Roll: A short roll of scrap is often produced during start-up or while changing
recipes. This button determines whether data from this roll is included in reports. If the roll
length is less than the value entered here, it is not counted.

‰ Roll Lag Distance: Enter the distance from the sensor to the windup. If the Roll Lag Dis-
tance is greater than 0, gauge readings from a section of the sheet are not included in roll
reports until that section of the sheet has reached the windup. This allows the max, aver-

8
age, min, range, sigma and weight values in the roll report to accurately represent what is
actually in the completed roll.

•
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Model 6100TC: Setup • 8-5
•
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•
 8.5 Screen

SCREEN & PRINTER

SCREEN SAVER CALIBRATE TOUCH

TOUCH TEST
OFF ON SCREEN

PRINTER PRINTER PRINTER BAUD

EPSON B/W COLOR 9600

DISPLAY EXIT MAIN

Figure 8-6 Screen & Printer Menu

To bring up the Screen & Printer menu (Figure 8-6), select Main → More → NDC Mainte-
nance → Screen & Printer. The following buttons in this menu apply to the screen:

‰ Screen Saver: If this toggle is On and the operator does not touch the control screen for 5
minutes, the system substitutes a small bouncing display for the larger display. Any touch
restores the full-size display. This feature may extend the life of your touchscreen.

‰ Calibrate Touch Screen: This button brings up a page for calibrating the touch screen.
You will be prompted to touch two objects on the bottom left and top right corner of the
screen.

8 ‰ Touch Test: This button brings up a page for testing how the touch screen responds to
touch. The page will display several columns of buttons. Each button touched should turn
green. When done with the touch test, press Exit to quit.

‰ Mouse Sensitivity: This button appears only if a mouse is connected to the touch port
(J54). It sets how far the pointer moves for a given mouse movement. Allowable values
are from 0.02 to 25. Larger values magnify pointer movement.

•
•
8-6 •• Model 6100TC: Setup
•
•
8.6 Printer
To set up the printer, bring up the Screen & Printer menu (Main → More → NDC Mainte-
nance → Screen & Printer, Figure 8-6).

There are two Printer buttons in the Screen & Printer menu:

The left Printer button selects the printer emulation. The following choices are available:

y Epson

y HP Paintjet

y HP Laserjet

y HP Deskjet

The right Printer button selects Black and White or Color printouts. HP Laserjet only
prints in black and white.

The Printer Baud button selects the printer baud rate. Choices include 2400, 4800, 9600 and
19200.

•
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Model 6100TC: Setup • 8-7
•
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•
 8.7 Miscellaneous

MISCELLANEOUS

ZERO SUPPRESS GAGE MOVING

MINIMUM AVERAGE NETWORK DEBUG
0.00 SECS IN

AUTO ALARM RESET

OFF ON

DISPLAY EXIT MAIN

Figure 8-7 Miscellaneous Menu

To bring up the Miscellaneous menu (Figure 8-7), select Main → More → NDC Mainte-
nance → Miscellaneous. Buttons in this menu include:

‰ Zero Suppress Minimum: Sets the zero suppress minimum value.

If Zero Suppress Minimum is 0, the gauge reading will not be adjusted. If Zero Suppress
Minimum is a non-zero value, any measurement less than the Zero Suppress Minimum
value will be adjusted as follows:

Adjusted value

8
= Measured value × ( 1 – 0.9 × ( Zero Suppress Min – Measured value ) ⁄ Zero Suppress Min )

This results in a reading that is closer to zero.

Example

Measured value is 3.5 and Zero Suppress Minimum is 5.

Adjusted value
= 3.5 × ( 1 – 0.9 × ( 5 – 3.5 ) ⁄ 5 ) = 2.56

The gauge will display 2.56 when the measurement is 3.5.

‰ Gage Moving Average: Sets whether the (Gage) Moving Average (in the Gage menu) is
expressed in seconds or inches. Seconds is the default, and should always be used except
for special cases.

‰ Network: Brings up a menu for setting up the Ethernet option. See Section 10.3 - Ethernet
Option.

•
•
8-8 •• Model 6100TC: Setup
•
•
‰ Debug: Brings up a page used primarily by NDC Infrared Engineering personnel for
debugging purposes.

‰ Auto Alarm Reset: When this toggle is Off, a High or Low Alarm must be acknowledged
by the operator before it is cleared. This is described in Section 3.1 - Process Menu Page 1,
under Hi Alarm and Lo Alarm.

When this toggle is On, a High or Low Alarm does not have to be acknowledged. When
the product comes back within spec, the alarm will automatically be cleared.

This is a non-recipe item. Auto Alarm Reset is item 1037 in Open Access.

•
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Model 6100TC: Setup • 8-9
•
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 8.8 Security

SECURITY

SECURITY SET SECURITY

SECURITY SETTINGS
OFF ON PASSWORD

DISPLAY EXIT MAIN

Figure 8-8 Security Menu

Your NDC Infrared Engineering gauge includes a password security system that allows super-
visors to limit access to the menu and control buttons.

If you press the Security button (Main → More → NDC Maintenance → Security) and then
enter the password, the screen will show a Security menu (Figure 8-8). This menu includes
buttons that let you turn security on or off, change the password and set individual buttons to
be active, visible but inactive, or blanked out.

8.8.1 Turning Security On or Off

8 The Security toggle in the Security menu turns security on or off.

•
•
8-10 •• Model 6100TC: Setup
•
•
8.8.2 Setting Security For Individual Buttons

SECURITY SETTINGS
PAGE 1 O-OPEN V-VIEW N-NO_SHOW

[0] DATA [0] MINIMUM GAGE VALUE

[0] PROCESS [0] MAXIMUM GAGE VALUE
[0] PRODUCT [0] PRODUCT WIDTH
[0] GAGE FACTOR [0] PROCESS DIE SETUP MENU
[0] GAGE CONSTANT [0] LEFT DECKLE
[0] SPECIFIC GRAVITY [0] RIGHT DECKLE
[0] TARGET [0] NECK IN
[0] HI ALARM [0] NUMBER OF DIEBOLTS
[0] LO ALARM
[0] ROLL
[0] ROLL INCREMENT

CHANGE SETTING NEXT PAGE EXIT MAIN

Figure 8-9 Settings Page

The Security Settings button in the Security menu calls up several pages of system variables
(Figure 8-9). Use the Next Page button to move through the pages. A set of up/down arrows
let you select a specific variable by moving the highlight bar up or down.

A button marked Change Setting lets you set the security level for the selected variable:

y O for open or active - no security is applied for the selected button

y V for view only - the button is displayed, but its value cannot be changed

y N for no-show - the button is not displayed. This can be used to simplify
certain screens for operators.

If Security is turned off (the Security toggle is off), all buttons are open or active. Some man-
8
agers will leave security off to allow operators maximum control over the product while others
will limit access to the recipes or other variables. If a button does not have any effect or you do
not see the buttons described in this manual, press Security Settings and check to make sure
they are not inactivated or blanked-out by the security system.

8.8.3 Changing the Security Password

We suggest that a supervisor enter a new password as soon as possible and then limit access to
the password to prevent unauthorized personnel from changing the password or production
values.

To change the password:

1. Press the Set Security Password button in the Security menu.

2. Follow the screen directions to enter and confirm a new password.

A maximum of 6 characters is allowed.

•
•
Model 6100TC: Setup • 8-11
•
•
•
8

•
•
8-12 •• Model 6100TC: Setup
•
•
 CHAPTER

9 Control 9
The NDC Infrared Engineering gauging system with a speed or dual gap controller uses the
values entered in the Control menu to keep the product within tolerance. The speed control
option is designed for screw, pump or linespeed control. The dual gap controller controls the
left and right gap under a roller or knife.

The appropriate deadband, gain and backlash values are required for best results. Before using
the controller, a remote control panel must be connected to J514 on the rear microcomputer
panel.

After each control action, the system delays subsequent control until the end of the first com-
plete control cycle after the transport lagtime (based on the tach input and the delay distance.)
This delay ensures that each control is based only on material produced since the previous
control.

Pump, line or screw speed can be controlled with either a solid-state triac circuit or a motor-
operated potentiometer. A triac is most often used when the production line uses digital cir-
cuitry, while the motor-operated pot is most often used with analog circuitry, and when the
line already uses a pot to control speed. If you use the pot, which can also be operated manu-
ally, it probably will be less confusing if the small NDC Infrared Engineering remote panel is
installed on your control panel in place of the existing pot.

If your system includes dual-gap control, NDC Infrared Engineering uses a sophisticated algo-
rithm to monitor and control the roller or knife gap for two zones extending in from the outside
edges of your sheet. As it adjusts the gap between rollers or under the knife for one zone, the
microcomputer also takes into account how that change will affect the other zone, and adjusts
it as well. Section 9.4.4 - Dual Gap Control Calculation discusses dual-gap control calcula-
tions in more detail.

•
Model 6100TC: Control •• 9-1
•
•
•
 9.1 Remote Control Panel
The remote control panel includes the following controls and indicators:

‰ Auto and Man lights - These two LEDs indicate the control mode.

‰ Inc(rease) and Dec(rease) lights - These two LEDs indicate the direction the system is
controlling.

‰ Auto/Man - A toggle switch used to put the system under automatic control. The switch is
coupled with the Control On/Off toggle on Page 1 of the Main menu so that if the toggle
switch is set to Man or the button is Off, the system will be in its manual mode.

‰ Zone 1 Up/Down - (Dual-gap control only:) One of these LEDs lights while an automatic
control is in progress.

‰ Zone 2 Up/Down - See above.

‰ Speed Control - A ten-turn locking potentiometer used to control speed. Not included in
triac-equipped or dual-gap systems.

•
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9-2 • Model 6100TC: Control
•
•
•
9.2 Control Menu
Before beginning to control your product, you must set a number of control variables. These
variables are entered in the Control menu (Main → More → Control, Figure 9-1).

CONTROL

SPEED CTRL CONTROL LOG

CYCLES PER SPOT ERROR LIMIT AVG ERROR LIMIT

CONTROL (%) (%)
1 50.0 50.0

DISPLAY EXIT MAIN

Figure 9-1 Control Menu

The Control menu includes the following buttons:

‰ [Control]: The leftmost button on the top row brings up a menu for setting up the control
loop. If the control loop is Speed control, this button is labeled Speed Ctrl and provides
access to the Speed Control menu. See Section 9.3 - Speed Control. If the control loop is
Dual Gap control, this button is labeled Dual Gap and provides access to the Dual Gap
Control menu. See Section 9.4 - Dual Gap Control.

‰ Control Log: Shows a summary of the last 10 control actions. Section 9.6 - Control Inhib-
its and Section 9.7 - Control Messages describe the messages that may appear in the con-
trol log.

9
‰ Cycles per Control: Enter the number of basic cycles used to calculate each control
action. Most operators set this value at 1. Accumulated control data is discarded whenever
a recipe change occurs during a cycle.

‰ Spot Error Limit: If any gauge reading exceeds the target by this limit, the system
assumes there is a problem that requires action by the operator. No control action will be
attempted until the gauge reading is back within the Spot Error Limit.

‰ Avg Error Limit: This sets a maximum error for control. If the control cycle average is
off-target by more than the percentage entered here, the system assumes there is a problem
that requires action by the operator. No control action will be attempted until the average
is back within the error limit. The alarm levels should be set within this limit and the Spot
Error Limit (see above).

•
•
Model 6100TC: Control • 9-3
•
•
•
 9.3 Speed Control

CTRL LOOP 1 - SPEED CTRL

GAIN AUTO GAIN DEADBAND DELAY DISTANCE

(FT)
10.00 OFF ON 0.10
30.000

CONTROL MODE SCREW SPEED LINE SPEED MULT.

AVG MIN LINESPEED OFF ON

PRINT CTRL LOG

NO YES

DISPLAY EXIT MAIN

Figure 9-2 Speed Control Menu

The Speed Ctrl button in the Control menu (Main → More → Control) brings up the Speed
Control menu (Figure 9-2). This menu includes the following buttons:

‰ Gain: This button scales the controller so that each control action is proportional to the
error times the gain.

Depending on the selected control mode, the system uses the following formulas to calcu-
late the duration of any control action:

In Avg mode -

( Avg – Target ) × Gain × 100

Control = ------------------------------------------------------------------
Target

In Min mode -

9 ( Min – Target ) × Gain × 100

Control = -------------------------------------------------------------------
Target

In either case, the gain is entered in 0.1-second increments and represents the duration of
the control response to each 1% error from target. If the gain is too high, the controller will
oscillate around the target. If the gain is too low, control will be unnecessarily slow.

Manually finding the best gain setting for your system is an experimental process. To
manually find the optimal gain:

1. Once everything else is set up and the line is running, return to the Main menu and set
the Control On/Off toggle to On.

2. Set the Auto/Man toggle on the remote control panel to Auto.

•
•
9-4 • Model 6100TC: Control
•
•
•
 3. Move to the Speed Control menu (Main → More → Control → Speed Ctrl) and
then press the Gain button. Use the Left/Right and Up/Down arrows to set the gain to
10 and press the Enter button.

4. Wait for the system to begin controlling your product and note if it controls too far. If
so, set the gain back to 5. If it controls too little, set the Gain higher. Repeat until the
setting is correct.

‰ Auto Gain Off/On: The system has an automatic gain function that can be used during
start-up to find the optimal gain setting. We recommend that you initially use this feature
for several hours to find the best gain for your system and then turn it off.

‰ Deadband: The deadband is a range of product on one or both sides of the target where
the system does not attempt any control. In any process, there is a range of random varia-
tions that are too unpredictable or too high-frequency to be effectively controlled. In addi-
tion, every controller has a minimum control movement which limits the precision of any
control. To reduce wear and tear on your control equipment and to prevent introduction of
errors based on random variations, set the deadband just outside the range of statistical
variations and beyond the minimum control limits.

‰ Delay Distance: This is the distance from the control mechanism (e.g., die or coater) to
the measuring gauge. This parameter allows time for a control action to travel from the
point from where it was applied, to the gauge measuring the effects of that action.

‰ Control Mode (Avg/Min): This toggle determines whether the Target value on the
Process menu represents an average or minimum. If Min mode is selected, the deadband
applies only above the target. Figure 9-3 illustrates the effect of choosing one or the other.

continues

•
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Model 6100TC: Control • 9-5
•
•
•
 continued from previous page

Target
Deadband
1(a)

Lo Alarm Hi Alarm
Control Limit Control Limit
1(b)

Production Units

Avg Mode

Target
2(a)
Deadband

Lo Alarm Hi Alarm
Control Limit Control Limit
2(b)

Min Mode

1(a), 2(a), with Control

1(b), 2(b), without Control

Figure 9-3 Effect of Feedback Control in Avg and Min Modes

‰ Screw Speed/Linespeed: Set this toggle to whichever control option is used by your sys-
tem. The microcomputer uses this entry to set the direction of the control output.

‰ Line Speed Mult.: This toggle appears only when the control loop is Linespeed control.
This is a switch toggle that allows insertion of a line speed multiplier into control calcula-
tions. This is intended to be used as standard for extruder speed (hauloff) control. In this

9 case, the control gain can be tuned at one web thickness / speed, and subsequently, the
control response adapts so that it is well-tuned for all machine conditions.

When the Line Speed Mult. toggle is On, the error is multiplied by (line speed/100). In
this case, the Gain probably needs to be adjusted to account for this change. Set the gain as
follows:

New Gain = Old Gain × 100 ⁄ Current Line Speed

‰ Print Ctrl Log: If this button is turned on, then after each control action for this control
loop, the line of data displayed in the Control Log will also be printed.

If there is more than one control loop (e.g., Dual Gap and Cross Axis), then whenever the
Print Ctrl Log button is turned on, the Print Ctrl Log button(s) for the other control(s)
are automatically turned off.

•
•
9-6 • Model 6100TC: Control
•
•
•
 The Print Ctrl Log selection is not saved when the gauge is turned off. When the gauge is
turned back on, the Print Ctrl Log selections for all control loops are set to No.

‰ Screw Delay (secs): This button appears only when the control loop is Screw Speed con-
trol. This is the number of seconds the screw requires to respond to a change. It may be set
to 0 or any positive real number.

•
•
Model 6100TC: Control • 9-7
•
•
•
 9.4 Dual Gap Control

CTRL LOOP 1 - DUAL GAP

GAIN RT/LT GAIN RATIO DEADBAND DELAY DISTANCE

(FT)
10.00 1.00 0.10
30.000

LEFT/RIGHT SETUP CTRL ZONES

PRINT CTRL LOG

NO YES

DISPLAY EXIT MAIN

Figure 9-4 Dual Gap Control Menu

Dual gap control divides the scanned web into two zones. A separate control output is made to
bring each zone’s average toward the target. The outputs typically close relays that are located
on the Remote Control Panel. Before beginning to control the product, you must set a number
of variables in the Dual Gap Control menu (Figure 9-4). To bring up this menu, select Main
→ More → Control → Dual Gap.

‰ Gain: The control gain ensures that each control action is proportional to the error and
should be set after the rest of the control is set up. Section 9.4.3 - Gain shows how to set
the gain.

‰ Rt/Lt Gain Ratio: This button sets the right gain as a ratio of the left gain.
Section 9.4.3.1 - Right Gain shows how to set the right gain.

‰ Deadband: The deadband is a range of product on either side of the target where the sys-
tem does not attempt any control. In any process, there is a range of random variations that

9
are too unpredictable or too high-frequency to be effectively controlled. In addition, every
controller has a minimum control movement which limits the precision of any control. To
reduce wear and tear on your control equipment and to prevent introduction of errors
based on random variations, set the deadband just outside the range of statistical variations
and beyond the minimum control limits.

‰ Delay Distance: This is the distance from the control mechanism (e.g., die or coater) to
the measuring gauge. This parameter allows time for a control action to travel from the
point from where it was applied, to the gauge measuring the effects of that action.

‰ Left/Right Setup: This button leads to a menu that allows you to enter the controller’s
pivot points and the backlash. See Section 9.4.1 - Left/Right Setup.

•
•
9-8 • Model 6100TC: Control
•
•
•
 ‰ Ctrl Zones: Press the Ctrl Zones button to reach the Control Zones menu.
See Section 9.4.2 - Control Zones.

‰ Print Ctrl Log: If this button is turned on, then after each control action for this control
loop, the line of data displayed in the Control Log will also be printed.

If there is more than one control loop (e.g., Dual Gap and Cross Axis), then whenever the
Print Ctrl Log button is turned on, the Print Ctrl Log button(s) for the other control(s)
are automatically turned off.

The Print Ctrl Log selection is not saved when the gauge is turned off. When the gauge is
turned back on, the Print Ctrl Log selections for all control loops are set to No.

9.4.1 Left/Right Setup

The Left/Right Setup menu (Figure 9-5) allows you to enter the controller’s pivot points and
the backlash.

LEFT/RIGHT SETUP - CTRL LOOP 1

LEFT PIVOT PT RIGHT PIVOT PT

-5.00 65.00

LEFT BACKLASH RIGHT BACKLASH

0.0 0.0

DISPLAY EXIT MAIN

Figure 9-5 Left/Right Setup Menu

‰ Left and Right Pivot Pts: Enter the position values for these points, using the same units
as your scanner calibration. 9
‰ Left and Right Backlash: Enter the backlash for the left and right controller. This is the
time (in seconds) required to change control directions. This value should be included
with the specifications for your equipment.

•
•
Model 6100TC: Control • 9-9
•
•
•
 9.4.2 Control Zones

The Control Zones menu (Figure 9-6) allows you to set the left and right control zone loca-
tions. It also displays a diagram showing the Startup and Away switch positions, the Scan
Limits and the control zone locations.

Left and Right Control Zones

CTRL ZONES - CTRL LOOP 1

Startup 0.00 60.00 Away

Switch RT
Switch
LT
Left Right
4.00 56.00
Scan Scan
Limit Limit
LEFT ZONE START RIGHT ZONE START
10.00 40.00

LEFT ZONE END RIGHT ZONE END

20.00 50.00

DISPLAY EXIT MAIN

Figure 9-6 Control Zones Menu

Use the Left and Right Zone Start/End buttons to enter the start and end positions for your
left and right control zones. These points should be within the scan limits.

9.4.3 Gain

The Gain button in the Dual Gap Control menu sets the gain for the two control zones so that
each control action is proportional to the error. To calculate the duration of any control action,
the system uses the following formula:

9 ( Avg of Control Zones – Target ) × Gain × 100

Control = ----------------------------------------------------------------------------------------------------------
Target

The gain is entered in 0.1-second increments and represents the duration of the control
response to each 1% error from target. If the gain is too high, the controller will oscillate
around the target. If the gain is too low, control will be unnecessarily slow.

Manually finding the best gain setting for your system is an experimental process. To manu-
ally find the optimal gain:

1. Once everything else is set up and the line is running, return to the Main menu and set the
Control On/Off toggle to On.

2. Set the Auto/Man toggle on the remote control panel to Auto.

•
•
9-10 • Model 6100TC: Control
•
•
•
 3. Return to the Dual Gap Control menu (Main → More → Control → Dual Gap) and then
press the Gain button. Use the Left/Right and Up/Down arrows to set the gain to 10 and
press the Enter button.

4. Wait for the system to begin controlling your product and note if it controls too far. If so,
set the gain back to 5. If it controls too little, set the Gain higher. Repeat until the setting is
correct.

9.4.3.1 Right Gain

Because the right control’s response may not precisely match the left control, the system
allows you to tweak the right gain until the two controllers are in synch. The Rt/Lt Gain Ratio
is ordinarily set to 1.0 but can be changed to compensate for different control gains on the left
and right.

To calculate the right gain ratio:

1. Use the procedure above to set the Gain so that the left controller responds correctly.

2. Move to the Dual Gap Control menu and set the Rt/Lt Gain Ratio to ±1.05 depending on
the error. Turn on control (Main menu) and wait for a control action. Evaluate whether the
system is over- or under-compensating. Repeat until the setting is correct.

9.4.4 Dual Gap Control Calculation

This section describes how the system calculates the gap adjustments for Left/Right control.
Tilt control is similar, except that instead of controlling the product to the target, it controls to
the averaged value of the Left and Right Control Zones ([Left Control Zone Avg + Right Con-
trol Zone Avg] / 2).

PL
ZL
YL

9
0 20 30 40 100 110 120 140
Target Profile
ZR YR
20 cm 20 cm PR

100 cm

140 cm

Figure 9-7 Dual Gap Control

•
•
Model 6100TC: Control • 9-11
•
•
•
 Figure 9-7 shows a plot of the left and right zone average points (ZL and ZR) and the left and
right pivot points (PL and PR). For the zone average point, the horizontal coordinate repre-
sents the center position of the zone, and the vertical coordinate represents the average value
for that zone.

A line is drawn connecting the zone average points and the pivot points. It will be used to
determine how much gap adjustment is required at each pivot point.

Known system settings include:

y Width of Coater Roll/Knife = 140 cm

y Width of Web = 100 cm

y Left Control Zone: from 20 cm to 40 cm

y Right Control Zone: from 100 cm to 120 cm

ZL = (Center of Left Control Zone, Average of Left Control Zone relative to Target)
= (30, 0.2)

ZR = (Center of Right Control Zone, Average of Right Control Zone relative to Target)
= (110, 0)

PL = Left Pivot Point = (0, YL)

PR = Right Pivot Point = (140, YR)

To determine the amount of correction required at the Left and Right Pivot Points, we need to
calculate the values for YL and YR.

We do this by finding out the equation of the line passing through the pivot points (PL, PR)
and zone average points (ZL, ZR).

continues

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9-12 • Model 6100TC: Control
•
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•
 continued from previous page

Y–Y X – X1
----------------1- = ------------------
Y2 – Y1 X2 – X1

( X 1, Y 1 ) = Z L = ( 30, 0.2 )

( X 2, Y 2 ) = Z R = ( 110, 0 )

Y – 0.2 X – 30
---------------
- = ------------------
-
0 – 0.2 110 – 30
Y – 0.2 – 30-
- = X
--------------- --------------
– 0.2 80
– 0.2X + 6
Y – 0.2 = ------------------------ = – 0.0025X + 0.075
80

Y = – 0.0025X + 0.275

Substituting the pivot points in the equation:

Y L = – 0.0025(0) + 0.275 = 0.275

Y R = – 0.0025(140) + 0.275 = – 0.075

Thus, when the left zone is 0.2 cm above target and the right zone is on target, the following
control actions should be performed:

y Move the left actuator 0.275 cm downwards

y Move the right actuator 0.075 cm upwards

These calculations are automatically performed by the system before each control action. This
example assumes the left and right gain are the same. If they are not, the system calculates the

9
appropriate correction and then applies the right gain factor.

•
•
Model 6100TC: Control • 9-13
•
•
•
 9.5 Cross Axis Control
Cross Axis control is used to make the thickness of the center of the sheet from a calender
stack the same as the sides.

Cross Axis control corrects profile variations by moving the ends of the roll clockwise or
counter-clockwise about the center of the roll. This causes less pressure at the outer edges of
the roll as compared to the pressure at the center of the roll.

CTRL LOOP 2 - CROSS AXIS

GAIN RT/LT GAIN RATIO DEADBAND DELAY DISTANCE

(FT)
10.00 1.00 0.10
30.000

ROLL DIAMETER
LEFT/RIGHT SETUP CTRL ZONES (IN)
10.00

PRINT CTRL LOG

DEBUG
NO YES

CTRL LOOP
DISPLAY EXIT MAIN
1 2

Figure 9-8 Cross Axis Control Menu

Before beginning to control the product, you must set a number of variables in the Cross Axis
Control menu (Figure 9-8). To bring up this menu, select Main → More → Control → Ctrl
Loop 1 or 2 (depending on which control loop is Cross Axis control).

‰ Gain: The control gain ensures that each control action is proportional to the error and
should be set after the rest of the control is set up. Section 9.5.3 - Gain shows how to set
the gain.

9
‰ Rt/Lt Gain Ratio: This button sets the right gain as a ratio of the left gain.
Section 9.5.3.1 - Right Gain shows how to set the right gain.

‰ Deadband: The deadband is a range of product on either side of the target where the sys-
tem does not attempt any control. In any process, there is a range of random variations that
are too unpredictable or too high-frequency to be effectively controlled. In addition, every
controller has a minimum control movement which limits the precision of any control. To
reduce wear and tear on your control equipment and to prevent introduction of errors
based on random variations, set the deadband just outside the range of statistical variations
and beyond the minimum control limits.

‰ Delay Distance: This is the distance from the control mechanism (e.g., die or coater) to
the measuring gauge. This parameter allows time for a control action to travel from the
point from where it was applied, to the gauge measuring the effects of that action.

•
•
9-14 • Model 6100TC: Control
•
•
•
 ‰ Left/Right Setup: This button leads to a menu that allows you to enter the controller’s
pivot points and the backlash. See Section 9.5.1 - Left/Right Setup.

‰ Ctrl Zones: Press the Ctrl Zones button to reach the Control Zones menu.
See Section 9.5.2 - Control Zones.

‰ Roll Diameter: This button sets the diameter of the rolls on the roll stack (sum of the
radius of the top roll and the radius of the bottom roll). This value is expressed in inches.

‰ Print Ctrl Log: If this button is turned on, then after each control action for this control
loop, the line of data displayed in the Control Log will also be printed.

Whenever the Print Ctrl Log button is turned on for one control loop, the Print Ctrl Log
button(s) for the other control loop(s) are automatically turned off.

The Print Ctrl Log selection is not saved when the gauge is turned off. When the gauge is
turned back on, the Print Ctrl Log selections for all control loops are set to No.

‰ Debug: This button brings up a screen used primarily by NDC Infrared Engineering per-
sonnel for troubleshooting purposes. This screen displays the value of the left and right
analog inputs.

‰ Ctrl Loop: This toggle is used to select a control loop (i.e., 1 selects the first control loop,
2 selects the second control loop). The screen will show the parameters for the currently
selected control loop.

9.5.1 Left/Right Setup

The Left/Right Setup menu (Figure 9-9) allows you to enter the controller’s pivot points, the
backlash and the full scale value for the analog inputs.

LEFT/RIGHT SETUP - CTRL LOOP 2

LEFT PIVOT PT RIGHT PIVOT PT LEFT FULL SCALE RIGHT FULL SCALE
-5.00 65.00 (IN) (IN)
1.0 1.0

LEFT BACKLASH
0.0
RIGHT BACKLASH
0.0
9

DISPLAY EXIT MAIN

Figure 9-9 Left/Right Setup Menu

‰ Left and Right Pivot Pts: Enter the position values for these points, using the same units
as your scanner calibration.

•
•
Model 6100TC: Control • 9-15
•
•
•
 ‰ Left and Right Backlash: Enter the backlash for the left and right controller. This is the
time (in seconds) required to change control directions. This value should be included
with the specifications for your equipment.

‰ Left and Right Full Scale: Enter the position of the ends of the roll in inches when the
left and right analog inputs are at full scale.

9.5.2 Control Zones

The Control Zones menu (Figure 9-10) allows you to set the location of the left control zone
and the width of the center control zone. It also displays a diagram showing the Startup and
Away switch positions, the Scan Limits and the control zone locations.

Left, Center and

Right Control Zones

CTRL ZONES - CTRL LOOP 2

Startup 0.00 60.00 Away

Switch
CN
RT
Switch
LT
Left 56.00
Right
4.00
Scan Scan
Limit Limit
LEFT ZONE START RIGHT ZONE START CENTER ZONE WIDTH CENTER ZONE START
10.00 40.00 6.00 27.00

LEFT ZONE END RIGHT ZONE END CENTER ZONE END

20.00 50.00 33.00

DISPLAY EXIT MAIN

Figure 9-10 Control Zones Menu

‰ Left Zone Start/End: Enter the starting and ending position of the left control zone.

9
These points should be within the scan limits.

‰ Right Zone Start/End: These buttons show the starting and ending position of the right
control zone. These values are automatically calculated by the system, and may not be
changed by the user.

‰ Center Zone Width: Enter the width of the center control zone. The system will automat-
ically calculate the starting and ending position of the center control zone, based on this
value.

‰ Center Zone Start/End: These buttons show the starting and ending position of the cen-
ter control zone. These values are automatically calculated by the system, based on the
value entered for Center Zone Width. They may not be changed by the user.

•
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9-16 • Model 6100TC: Control
•
•
•
9.5.3 Gain

The Gain button in the Cross Axis Control menu sets the gain for the two control zones so that
each control action is proportional to the error. To calculate the duration of any control action,
the system uses the following formula:

( Avg of Control Zones – Target ) × Gain × 100

Control = ----------------------------------------------------------------------------------------------------------
Target

The gain is entered in 0.1-second increments and represents the duration of the control
response to each 1% error from target. If the gain is too high, the controller will oscillate
around the target. If the gain is too low, control will be unnecessarily slow.

Manually finding the best gain setting for your system is an experimental process. To manu-
ally find the optimal gain:

1. Once everything else is set up and the line is running, return to the Main menu and set the
Control On/Off toggle to On.

2. Set the Auto/Man toggle on the remote control panel to Auto.

3. Return to the Cross Axis Control menu (Main → More → Control → Ctrl Loop 1 or 2)
and then press the Gain button. Use the Left/Right and Up/Down arrows to set the gain to
10 and press the Enter button.

4. Wait for the system to begin controlling your product and note if it controls too far. If so,
set the gain back to 5. If it controls too little, set the Gain higher. Repeat until the setting is
correct.

9.5.3.1 Right Gain

Because the right control’s response may not precisely match the left control, the system
allows you to tweak the right gain until the two controllers are in synch. The Rt/Lt Gain Ratio
is ordinarily set to 1.0 but can be changed to compensate for different control gains on the left
and right.

To calculate the right gain ratio:

1. Use the procedure above to set the Gain so that the left controller responds correctly.
9
2. Move to the Cross Axis Control menu and set the Rt/Lt Gain Ratio to ±1.05 depending
on the error. Turn on control (Main menu) and wait for a control action. Evaluate whether
the system is over- or under-compensating. Repeat until the setting is correct.

•
•
Model 6100TC: Control • 9-17
•
•
•
 9.6 Control Inhibits
There are several conditions that prevent the microcomputer from trying to control when the
gauge is in its Automatic mode. Relevant control messages are listed in the header and in the
control log. These messages include:

‰ Control Limits: If the gauge reading or average exceeds the corresponding error limit, the
system assumes there has been a sheet break or other error that requires operator interven-
tion. As a result, alarms are activated but no control occurs until the measurements are
back within the error limits. As with any alarm condition, the alarm box in the upper right
corner of the screen will flash until touched by the operator.

‰ Manual Operation: No automatic control is ordered when the Auto/Man toggle on the
remote panel is in its Manual position or when the Control toggle on the Main menu is
set to Off.

‰ Deadband: No control is ordered if the product is within the deadband.

‰ Sheet Break: No control is ordered if there has been a sheet break alarm in the most recent
cycle.

‰ Minimum Linespeed: No control is ordered if the linespeed drops below the minimum
linespeed entered on the Tach menu.

•
•
9-18 • Model 6100TC: Control
•
•
•
9.7 Control Messages
The upper left corner of the header displays a series of messages that describe each control
action or inhibit. Typical messages include:

‰ Control Off: The control screen toggle or the remote control switch is turned off.

‰ Control On: Control is turned on but no control actions have occurred.

‰ < Deadband: The control average is within the deadband.

‰ Ctrl Delay: After any control action, this message is displayed until the product has
moved from the point of control to the sensor and the microcomputer has accumulated
data for a full set of control scans.

‰ Avg Inhibit: The average exceeded the target by more than the Average Error Limit.

‰ Spot Inhibit: The minimum or maximum exceeded the target by more than the Spot
Error Limit.

•
•
Model 6100TC: Control • 9-19
•
•
•
9

•
•
9-20 • Model 6100TC: Control
•
•
•
 CHAPTER

10 Options 10
10.1 Fast Fourier Transform (FFT)
Fast Fourier Transform (FFT) is a data analysis tool that reveals the frequencies of machine-
direction variations. The sensor must be stationary for effective results. To reach the optional
FFT menu, press Main → More → More → FFT.

10.1.1 FFT Menu

FFT

MIN DISPLAYED PERIOD RANGE

CLEAR FFT NOW PERIOD (SECS) (SECS)
0.00 0.1 - 102

DISPLAY EXIT MAIN

Figure 10-1 FFT Menu

The FFT menu (Figure 10-1) includes the following buttons:

‰ Clear FFT Now: This button clears FFT data and displays. New calculations and displays
will occur after the maximum period (i.e., 102 seconds, 8.5 minutes or 34 minutes,
depending on the Period Range (secs) selection).

‰ Min Displayed Period (secs): This is the minimum period that will be displayed on the
Last FFT and FFT Composite display screens.

‰ Period Range (secs): The operator can select one of three period ranges. In each case, the
first FFT calculations and displays occur after the selected maximum. For example, if the
range “0.5 - 512” is selected, the first FFT is calculated and displayed after 8½ minutes.

Subsequent FFTs are recalculated and displayed each minute.

•
Model 6100TC: Options •• 10-1
•
•
•
 FFT data and displays are cleared each time the Period Range is changed. New data is
then displayed after the new maximum period.

Available choices are:

y 0.1 - 102: Each FFT data point represents two 50-millisecond readings.

y 0.5 - 512: Each FFT data point represents an average of ten

50-millisecond gauge readings.

y 2.0 - 2048: Each FFT data point represents an average of forty 50-millisecond
gauge readings.

10.1.2 FFT Operation

The system begins collecting FFT data when first started up. The message No Data Available
will appear on the Last FFT (Figure 10-2) and FFT Composite (Figure 10-3) displays until
2048 data points have accumulated (i.e., 102 seconds, 8.5 minutes or 34 minutes.) Once suffi-
cient readings have accumulated, the system will put up a new FFT display each minute.

At each roll switch input or recipe change, any FFT calculation already in progress will be
completed. The system will then accumulate 2048 readings before changing the FFT display.
During this period, the most recent Last FFT and FFT Composite calculations remain avail-
able for display. As noted above, a No Data Available message will be displayed after the
Clear FFT Now button is pressed or the Period Range is changed.

The end of a shift or time interval does not affect FFT calculations.

10.1.3 FFT Displays

LAST FFT TIME: 16:24:00

2.008 SEC
2.008 FT
0.091

0.073

0.055

0.036

0.018

10
0.000
SEC: 102.4 0.545 0.273 0.182 0.137 0.109
FT: 102.4 0.545 0.273 0.182 0.137 0.109

DISPLAY MAIN

Figure 10-2 Last FFT Display

•
•
10-2 •• Model 6100TC: Options
•
•
 FFT COMPOSITE TIME: 16:35:24-17:06:41
2.008 SEC
2.008 FT
0.091

0.073

0.055

0.036

0.018

0.000
SEC: 102.4 0.545 0.273 0.182 0.137 0.109
FT: 102.4 0.545 0.273 0.182 0.137 0.109

DISPLAY MAIN

Figure 10-3 FFT Composite Display

There are two FFT bar graph displays. Both are used to detect cyclic variations (ranging from
0.1 seconds to 34 minutes) in product thickness or mass. The Last FFT (Figure 10-2) repre-
sents the most recently calculated FFT, and is useful for early identification of a periodic prob-
lem. The FFT Composite (Figure 10-3) is an average of successive FFTs and provides a record
of periodic defects in the product.

Both displays show frequency spectra where each bar represents the amplitude of variations at
different frequencies or periods. The horizontal axis is a period scale, labeled in seconds, cor-
responding to the period of detected variations. This axis runs from the longest detectable
period to the value selected as the Min Displayed Period.

The horizontal scale is also labeled in length units, which are calculated by multiplying the
period by the line speed. The scaling provides two alternative methods for tracking the cause
of any cyclic variations. For example, the period between variations may suggest a cyclic
extruder surge, while the distance between variations may suggest problems with a roller of a
given circumference.

The vertical axis is labeled in multiples of the background noise level, and is scaled so that the
bar representing the strongest period fills the graph. The vertical scale is limited so that the
noise level represents no more than 1/8 of the total height. If the maximum amplitude is less
than eight times the background noise level, its bar will not fill the graph. This condition
occurs when the process is running well and there are no serious periodic variations. If the

10
maximum amplitude is at least 4 times the background noise level, it will be labeled above the
graph with its exact period in seconds and length.

The Last FFT display includes a Time label that shows the time of the last gauge reading in the
FFT calculation. The FFT Composite display shows the start and stop times for the period cov-
ered by the display.

•
•
Model 6100TC: Options • 10-3
•
•
•
 10.2 Statistical Process Control
10.2.1 Setup

10.2.1.1 SPC Menu

SPC

AUTO CLEAR SPC POPULATION SIZE SPC SIGMA

MULTIPLIER SPC LIMITS
NO YES 20
3.0

CLEAR SPC NOW

DISPLAY EXIT MAIN

Figure 10-4 SPC Menu

The path to the SPC menu (Figure 10-4) is Main → More → More → SPC. This menu
includes the following buttons:

‰ Auto Clear SPC: If this toggle is set to Yes, the SPC displays and data will be cleared
after each timed interval or roll.

‰ Population Size: The Population Size is the number of SPC cycles1 used in the calculation
of Cpk data and X-Bar Control Limits. Upcoming sections of this manual will refer to the
Population Size as p.

Typical values for Population Size are 25 to 50. The maximum allowable value is 100.

‰ SPC Sigma Multiplier: SPC uses its own Sigma Multiplier. Unlike the general Sigma
Multiplier found in the Display Setup menu, which is limited to integers 1, 2 or 3, the SPC
Sigma Multiplier can be set to real values such as 2.5. Normally, the value is set to 3.0.
Upcoming sections of this manual will refer to the SPC Sigma Multiplier as k.

10 ‰ SPC Limits: This button leads to SPC Limits menu. See Section 10.2.1.2 - SPC Limits
Menu.

‰ Clear SPC Now: This button clears the SPC data and displays immediately.

1.An “SPC cycle” is a cycle during which Data mode is always on. The duration of the
cycle is defined in the Cycles menu (Main → More → Cycles).

•
•
10-4 •• Model 6100TC: Options
•
•
10.2.1.2 SPC Limits Menu

SPC LIMITS

UPPER SPEC LIMIT X-BAR UPPER CTRL RANGE UPPER CTRL

LIMIT LIMIT CALCULATED
11.00
11.00 0.10 CTRL LIMITS

X-BAR UCL 72.51

LOWER SPEC LIMIT X-BAR LOWER CTRL RANGE LOWER CTRL X-BAR LCL 72.02
LIMIT LIMIT
9.00
9.00 0.00

SPC RANGE SCALE

0.20

DISPLAY EXIT MAIN

Figure 10-5 SPC Limits Menu

The SPC Limits menu (Figure 10-5) consists of the following buttons:

‰ Upper and Lower Spec Limits: These are the Upper and Lower Specification Limits.

‰ X-Bar Upper and Lower Ctrl Limits: These are the Upper and Lower Control Limits for
the X-Bar display. If desired, these limits may be set to the calculated control limits.

‰ Range Upper and Lower Ctrl Limits: These are the Upper and Lower Control Limits for
the Range display.

‰ Calculated Ctrl Limits: The Calculated Control Limits are displayed at the end of each
SPC cycle, using the last p cycles. The calculations are:

X-Bar UCL = x-bar + (k x sigma)

X-Bar LCL = x-bar - (k x sigma)

‰ SPC Range Scale: This sets the range of the vertical scale for the Range display.

Note that there is no mention of sample size. For our purposes, the sample size is the number
of measurements in one SPC cycle. Also, the factor A2 is not used in x-bar control limit calcu-

10
lations. A2 is used to estimate sigma from a small number of samples, usually fewer than 20.
Since we have a large number of samples (20 per second), sigma is calculated directly, rather
than estimated.

•
•
Model 6100TC: Options • 10-5
•
•
•
 10.2.2 Ppk and Cpk

The Process Capability Index (Ppk) is determined from the following formula:

Ppk = Min [ (USL - x-bar) / (k x sigma), (x-bar - LSL) / (k x sigma) ]

where x-bar and sigma are calculated from all SPC cycles since SPC was last cleared

The Capability Index Cpk uses the same formula, except x-bar and sigma are calculated using
only the last p SPC cycles.

10.2.3 Displays

There are two SPC displays - X-Bar (Figure 10-6) and Range (Figure 10-7).

10.2.3.1 X-Bar Display

X-BAR SPEC CTRL

73.30

Cpk DATA
Ppk DATA
72.80

SCANS
72.30 20

X 72.262
71.80 R 0.322
3.0s 0.248
Cpk 0.654
71.30 17:00:09 17:16:26

DISPLAY MAIN

Figure 10-6 X-Bar Display

Figure 10-6 shows the X-Bar display. The upper and lower spec limits are represented by short
dashed lines. The upper and lower control limits are represented by longer dashed lines.

For each SPC cycle, a short horizontal bar represents the average of the SPC cycle. The verti-
cal bar extending above and below the average represents (k x sigma). This vertical bar is a

10 graphical representation of Ppk and Cpk.

A button on the right side of the screen allows the user to choose between a display of Ppk and
Cpk data.

If Ppk data is chosen, a table of values with x-bar-bar (the average of the averages), r-bar (the
average range), sigma and Ppk will appear. These values are based on all data collected since
SPC was last cleared.

•
•
10-6 •• Model 6100TC: Options
•
•
 If Cpk data is chosen, a table of values with x-bar-bar, r-bar, sigma and Cpk will appear. These
values are based on the last p SPC cycles. No values will appear in this table until p SPC
cycles have been completed.

The resolution depends on the vertical scale values set in the Scale menu (Main → Display
Setup → Scale). This is the same resolution used in the other standard displays (Trend, Inline,
etc.).

The X-Bar display is automatically cleared at the end of job.

10.2.3.2 Range Display

RANGE

0.60

Cpk DATA
Ppk DATA
0.45

SCANS
0.30 20

X 72.262
0.15 R 0.322
3.0s 0.248
Cpk 0.654
17:00:09 17:16:26
0.00

DISPLAY MAIN

Figure 10-7 Range Display

Figure 10-7 shows the Range display. For each SPC cycle, a small square represents the range
for that cycle. Each data point is connected by a line to the previous and next points. The scale
for the display is based on the SPC Range Scale value in the SPC Limits menu. The upper and
lower range control limits are represented by a long dashed line. Since the lower limit is usu-
ally 0, it usually does not appear.

As in the X-Bar display, there is a button that allows the user to chose between Ppk and Cpk
data, and a table that displays the appropriate values.

The Range display is automatically cleared at the end of job.

10.2.4 SPC Spec Limits on Other Displays

10
The upper and lower spec limits appear on the Trend, Inline, Histogram and Scan Profile dis-
plays as short dashed lines.

•
•
Model 6100TC: Options • 10-7
•
•
•
 10.3 Ethernet Option
The Ethernet option provides industry standard TCP/IP network access to the T-Gauge system
over Ethernet. This option is only available on systems that include the Open Access option.

The T-Gauge system functions as a server waiting for connection on TCP port 20000. Com-
munication with the system is conducted using the Open Access protocol.

10.3.1 Hardware Setup

10BaseT, twisted pair cable, is the standard Ethernet connection. It connects to the Ethernet
port (J551) on the rear gauge panel (see Figure 10-8). Additionally, a 10Base2 or 10Base5
coax connection may be established using an optional external hub.

T-Gauge
machine in system
local area network

Ethernet
twisted port (J551)
pair
hub cable

Figure 10-8 10BaseT Connection

10

•
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10-8 •• Model 6100TC: Options
•
•
10.3.2 Software Setup

To set up the Ethernet option, move to the Network menu (Main → More → NDC Mainte-
nance → Miscellaneous → Network, Figure 10-9):

NETWORK

IP ADDRESS IP MASK GATEWAY

192.0.2.8 255.255.255.0 0.0.0.0

DISPLAY EXIT MAIN

Figure 10-9 Network Menu

The Network menu includes the following buttons:

‰ IP Address: This is the unique address assigned by the customer to the T-Gauge system.
This number must be unique among the network nodes in the customer’s local area net-
work.

The IP Address consists of two parts: a network address that identifies the network, and a
host address that identifies the particular host. It is written as four sets of numbers sepa-
rated by periods (e.g., 192.101.92.121). The default IP Address is 192.0.2.8.

‰ IP Mask: This is the bitmask that identifies what portion of the IP Address is the network
address in the customer’s local area network. It must be identical for all nodes on the local
TCP/IP network (e.g., 255.255.255.128). The default IP Mask is 255.255.255.0.

‰ Gateway: This is the IP Address of the machine on the customer’s local area network
(LAN) that serves as the gateway between the LAN and outside networks. The default
gateway is 0.0.0.0. If there is no connection to outside networks, set the gateway to
0.0.0.0. 10
Note: If the IP Address, IP Mask or Gateway setting is changed, the system must be reboo-
ted to allow the changes to take effect.

•
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Model 6100TC: Options • 10-9
•
•
•
 10.3.3 Connecting to the T-Gauge System

The T-Gauge system accepts as many as 9 socket connections on TCP port 20000.

To connect to the T-Gauge system, run the telnet program as follows:

telnet IP_Address 20000

where IP_Address is the IP Address of the T-Gauge system

Example

telnet 192.101.92.121 20000

If the connection is successful, the following Open Access welcome message and prompt will
appear:

Host Interface : Initialization complete

Ok

If there are problems communicating with the system, do the following:

1. Check the IP Address, IP Mask and Gateway settings.

2. Check the Ethernet cabling.

3. Run the ping program to check for a response from the T-Gauge system.
Type the following:

ping IP_Address

where IP_Address is the IP Address of the T-Gauge system

Example

ping 192.101.92.101

Once a connection has been successfully established, Open Access commands can be sent to
the T-Gauge system. Please refer to the T-Gauge Open Access manual for the syntax of the
commands.

10

•
•
10-10 •• Model 6100TC: Options
•
•
10.4 Auto Retract
The Auto Retract option keeps the sensor retracted unless the sensor is scanning or the sensor
is stopped between the user-entered scan limits.

When the Scan button is touched, the sensor is retracted and moved to the start-scan position.
The sensor is then extended, and scans back and forth in the extended position. After extend-
ing, scanning will not begin until the gauge reading has stabilized. The stabilization time is the
gauge moving average plus the settle time. The user should set the settle time (in the Auto
Retract menu: Main → More → Auto Retract) to a long enough time that the gauge reading
is in fact stable before scanning begins.

For non-scanning moves, the sensor is retracted and then moved to its destination. When the
destination is reached, the sensor is extended if it is between the scan limits. If the sensor is not
between the scan limits, it remains retracted.

10.4.1 Auto Retract Menu

AUTO RETRACT

SIMULATE
EXTEND PROBE RETRACT PROBE
NO YES

LOCK EXTENDED LOCK RETRACTED SETTLE TIME

(SECS)
NO YES NO YES
1

DISPLAY DEBUG EXIT MAIN

Figure 10-10 Auto Retract Menu

The sensor can be manually extended, retracted, and locked retracted in the Auto Retract menu
(Main → More → Auto Retract, Figure 10-10). This menu includes the following buttons:

10
‰ Extend Probe: Extends the sensor.

‰ Retract Probe: Retracts the sensor.

‰ Simulate: Set this toggle to No if the sensor includes a retract mechanism.

Select Yes if the sensor does not have a retract mechanism, or if the retract mechanism is
defective. In Simulate mode, the Extend/Retract signals are operational - the system will
send such a signal to extend or retract the sensor, when required. However, the actual
input signals indicating the Extended/Retracted status are ignored, and correct signals are
simulated with a one-second delay.

•
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Model 6100TC: Options • 10-11
•
•
•
 ‰ Lock Extended: The sensor may only be locked in Extended mode if Simulate mode
is selected. If the sensor is extended, setting this toggle to Yes will lock the sensor in
Extended mode. While the sensor is locked in Extended mode, it can be moved to any
position. The sensor will remain locked in Extended mode until the Lock Extended tog-
gle is set to No.

‰ Lock Retracted: If the sensor is retracted, setting this toggle to Yes will lock the sensor in
Retracted mode. While the sensor is locked in Retracted mode, it can be moved to any
position. The sensor will remain locked in Retracted mode until the Lock Retracted tog-
gle is set to No.

‰ Settle Time (secs): A delay to allow the gauge reading to stabilize after the sensor has
extended. This should be set to a long enough time so that the gauge reading is in fact sta-
ble before scanning begins. After extending, scanning will not begin until a time period
equal to the gauge moving average plus the settle time has elapsed.

10.4.2 Lift Alarm

Whenever there is a failure in the extend/retract mechanism, a Lift Alarm is activated and a
Lift Alarm message will flash in the screen header. While the Lift Alarm is active, the sensor
is not allowed to extend nor move if it is extended. If the sensor is retracted while Lift Alarm is
active, it is allowed to move.

The Lift Alarm can be cleared by touching the flashing button in the header. The Alarm Log
(Main → More → I/O Setup → Alarms → Alarm Log) shows information about the Lift
Alarm, including a brief explanation of the cause of the alarm.

10

•
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10-12 •• Model 6100TC: Options
•
•
10.5 Gap Exclusion
The Gap Exclusion feature allows the T-Gauge to exclude relatively small uncoated areas in
the machine direction of the sheet from profiles, reports, trends and histograms.

A maximum of 5 seconds worth of data may be excluded from the uncoated area. During that
period, the readings will be substituted by an average of the most recent good readings. If the
uncoated area lasts more than 5 seconds, data after that period will be processed normally.

This feature requires a linespeed tach input, and operates only when Gap Exclusion is
“active.” Gap Exclusion is active when all the following are true:

y The scanner is initialized (scanning systems only)

y The sensor is on sheet (scanning systems only)

y The Gap Exclusion toggle is On

y There is no linespeed alarm

y The shutter is open (systems with shutters only)

If Gap Exclusion is inactive, gauge readings from the uncoated areas will be included in dis-
plays and reports.

10.5.1 Setup

10.5.1.1 Gap Exclusion and Beam Width

GAGE MENU

MOVING AVERAGE
ZERO CALIBRATE (SECS) GAGE SAMPLES
5.00

BEAM WIDTH GAP EXCLUSION

(FT)

10
OFF ON
0.0200

DISPLAY MAIN

Figure 10-11 Gage Menu

1. Move to the Gage menu (Main → Gage, Figure 10-11).

•
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Model 6100TC: Options • 10-13
•
•
•
 2. Set the Gap Exclusion toggle to On to activate Gap Exclusion.

Set this toggle to Off when calibrating AGC, linearizing, zeroing, calibrating and collect-
ing samples.

Note: The Gap Exclusion toggle also appears in the password-protected NDC menu
(Main → More → NDC Maintenance → NDC).

3. Set the Beam Width to the beam width of the sensor, in the T-Gauge’s length units.

Example

Length units is Ft.

Beam width is ½ inch.

The Beam should be set to:

-1- in × -----------
1 ft 1
= ----- in = 0.042 ft
2 12 in 24

10.5.1.2 Min Coating Level

PROCESS

PRODUCT GAGE FACTOR GAGE CONSTANT SPECIFIC GRAVITY

NDC BASIC 1.000 0.00 1.000

TARGET HI ALARM LO ALARM

(MILS) (MILS) (MILS) ALERTS
10.00 1.00 -1.00

MIN COATING LEVEL

(MILS) MORE
0.00

DISPLAY MAIN

10 Figure 10-12 Process Menu

1. Move to the Process menu (Main → Process, Figure 10-12).

2. Set the Min Coating Level to a value that is as close as possible to the uncoated thickness
of the material.

The T-Gauge will discard any reading that is below the Min Coating Level.

•
•
10-14 •• Model 6100TC: Options
•
•
 The Min Coating Level is recipe dependent, so it may vary for different recipes. If the
Min Coating Level is set too high, artificially high gauge readings may result when Gap
Exclusion is turned on.

To determine the maximum allowed Min Coating Level for a given product:

1. Put a sample of the product in front of the sensor.

2. Turn off Gap Exclusion by setting the Gap Exclusion toggle to Off.

3. Set the gauge Moving Average to 0.05.

4. Clear the histogram:

Main → Display Setup → Histogram → Clear Hist Now

5. After the histogram’s Running Time has exceeded one minute, note the Minimum value.

6. Reset the gauge Moving Average to the desired value.

The Min Coating Level must be less than the histogram Minimum in step 5 above.

10.5.1.3 Minimum Linespeed

TACH

PULSES PER FT MINIMUM LINESPEED

LINESPEED
300.00 0.0

DISPLAY EXIT MAIN

Figure 10-13 Tach Menu

1. Move to the Tach menu (Main → More → I/O Setup → Tach, Figure 10-13).
10
2. Set the Minimum Linespeed to a non-zero value.

If the linespeed drops below the Minimum Linespeed (e.g., the line stops), the system will
stop excluding data.

•
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Model 6100TC: Options • 10-15
•
•
•
 10.6 Target Profile
The Target Profile feature allows the user to define a target profile which is built from up to 24
points. For each target profile point, the user enters a cross-web position and a value expressed
as an offset from a reference value. The target profile is in recipe, so a target profile can be
entered for each product.

When the Target Profile feature is turned On:

y The target profile will be plotted as a blue patterned line on the Scan Profile dis-
play.

y The recipe target is set to the average value of the target profile.

y An Error Profile is generated, based on the difference between the actual profile
and the target profile.

y High and low alarms are represented as deviations from the target profile, instead
of from the target.

Example

Target = 20.00 mils

High Alarm = +1.00 mils
The target profile at cross-web position 6.0 is 19.50 mils
The High Alarm limit at cross-web position 6.0 is 19.50 + 1.00 = 20.50 mils

A High Alarm will be generated if the gauge reading at cross-web position 6.0 is
greater than 20.50 mils.

Only the Scan Profile, Polar Profile and Error Profile displays will show low alarm
values in red and high alarm values in yellow. Other displays will show all data in
green.

y Live profile updates will be turned off.

Profile displays will only be updated at the end of a scan or cycle.

The Target Profile feature will not work properly with the Roll Defect feature, as the target
profile is not lagged to the roll windup.

10

•
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10-16 •• Model 6100TC: Options
•
•
10.6.1 Setup

TARGET PROFILE

TARGET PROFILE REFERENCE VALUE TARGET PROFILE

OFF ON 100.0 SETUP

DISPLAY EXIT MAIN

Figure 10-14 Target Profile Menu

1. Move to the Target Profile menu (Main → Display Setup → Target Profile,
Figure 10-14).

2. For the Reference Value, enter the value from which target profile points should be refer-
enced.

3. Touch Target Profile Setup to move to the Target Profile Setup menu (Figure 10-15).

Build the target profile. See Section 10.6.1.1 - Building the Target Profile. (The target pro-
file can be built even if the Target Profile toggle is Off).

Press Exit to return to the Target Profile menu.

4. Enable the target profile feature.

Set the Target Profile toggle to On.

10

•
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Model 6100TC: Options • 10-17
•
•
•
 10.6.1.1 Building the Target Profile

TARGET PROFILE

102.0

101.0

100.0

99.0

98.0
0 40 80 120 160
RESOLUTION
ADD POINT DELETE POINT EXIT
LO MED HI

Figure 10-15 Target Profile Setup Menu

The Target Profile Setup menu (Figure 10-15) shows the target profile display, which is
formed from a number of points joined by straight lines. The display is centered vertically
around the Reference Value.

In order for a line to be drawn from one target profile point to another on the target profile dis-
play, the user must enter cross-web positions for those two points that differ by at least 0.001.
For example, the first point might be +0.01 mils at position 30.000, and the second point could
be +0.09 mils at position 30.001.

The target profile can comprise up to 24 points.

To add points to the target profile:

1. Touch the Add Point button on the Target Profile Setup menu.

The Add Point screen will appear (Figure 10-16).

2. Touch the Position button and enter the cross-web position for that point.

3. Touch the Diff From Reference button and enter the target value at that point.

10 This value is expressed as a numeric offset from the Reference Value (as set in the Target
Profile menu). For example, if the Reference Value is 8.5 and a point is –2.5 at position
25.7, the target profile at that position will be 6.0 (8.5 – 2.5).

4. Touch Add This Point to add the point to the target profile.

The new point will appear as an entry in the table. The value under “Diff” is the
Diff From Reference value, and the value under “Value” is the target value for that point,
calculated as (Reference Value + Diff From Reference value).

•
•
10-18 •• Model 6100TC: Options
•
•
5. Repeat steps 2 to 4 to add more points to the target profile.

ADD POINT
PRINT

# POSITION DIFF VALUE

1 30.000 0.50 100.50

POSITION
30.0

DIFF FROM
REFERENCE VALUE REFERENCE
100.0 0.50

EXIT ADD THIS POINT

Figure 10-16 Add Point screen

The target profile points are stored and displayed in increasing cross-web order. For example,
if there are points at positions 0.5 and 2.0 and a new point is added at position 1.0, the line
which formerly joined 0.5 to 2.0 will now pass through the 1.0 point.

For 6100TC systems, if the Edgeseek option is on, the target profile must extend from one end
of the scanner to the other. If Edgeseek is off, the target profile must extend from one scan
limit to the other. If the first and/or last user-entered positions do not equal the required end-
points, the target profile will be automatically extended to the endpoints, and the reference
value will be automatically set to the value of the endpoints.

10

•
•
Model 6100TC: Options • 10-19
•
•
•
 DELETE POINT
PRINT

# POSITION DIFF VALUE

1 30.000 0.50 100.50

EXIT DELETE

Figure 10-17 Delete Point screen

To delete a point in the target profile:

1. Touch the Delete Point button on the Target Profile Setup menu.

The Delete Point screen will appear (Figure 10-17).

2. Using the arrow buttons, move the highlight bar and select a point.

3. Touch Delete.

The selected point will be removed from the table.

4. If desired, repeat steps 2 to 3 to delete another point.

10

•
•
10-20 •• Model 6100TC: Options
•
•
10.6.2 Target Profile

SCAN PROFILE SCANS PER COMPOSITE : 1

102.4

101.4

Target 100.4
profile
MAX 101.1
AVG 100.4
MIN 99.8
2σ 1.13

98.4
0 40 80 120 160
RESOLUTION
DISPLAY MAIN
LO MED HI

Figure 10-18 Scan Profile Display

The target profile is a complete 720 bucket profile generated from the user-entered target pro-
file points. The target profile is plotted as a patterned blue line on the Scan Profile display
(Figure 10-18).

10.6.3 Error Profile

ERROR PROFILE SCANS PER COMPOSITE : 1

2.0

1.0

0.0

-1.0

-2.0
0 40 80 120
RESOLUTION
160 10
DISPLAY MAIN
LO MED HI

Figure 10-19 Error Profile Display

To view the Error Profile display (Figure 10-19), select Error Profile from the Display menu.
This display shows the difference between the actual profile and the target profile.

•
•
Model 6100TC: Options • 10-21
•
•
•
 10.7 Automatic Target Optimization
ATO applies to systems using Speed or Left/Right control to bring the average to a desired tar-
get thickness or mass. ATO shifts the control target (the target that control is aiming to
achieve) away from the nominal target (the original target value as entered on the Process
menu) such that an acceptable percentage of product exceeds a “threshold” level, which is
some offset from the target. ATO can minimize or maximize the target. By optimizing the tar-
get, raw material use can be decreased, or product mass can be maximized, without increasing
the amount of defective product.

The current control target that ATO adjusts is displayed both numerically and graphically on
the screens.

The following parameters are stored in each recipe, so they may change from recipe to recipe:

y Max Target Change

y ATO Threshold

y % Past Threshold

All other ATO settings do not change from recipe to recipe.

ATO settings are available through Open Access (see the T-Gauge Open Access manual).

10.7.1 Setup

ATO SETUP

MAX TARGET CHANGE ATO THRESHOLD % PAST THRESHOLD

-0.10 -0.20 5.0

ATO GAIN SIGMA MULT MORE SIGMA MULT LESS MINIMUM CYCLES
OPT OPT
1.0 1
3.0 2.0

10 DISPLAY EXIT MAIN

Figure 10-20 ATO Setup Menu

1. Touch Main → Process → ATO Setup to move to the ATO Setup menu (Figure 10-20).

2. Touch Max Target Change and enter the maximum allowed change to the control target
in the same units as the gauge display units (as set in the Units menu).

•
•
10-22 •• Model 6100TC: Options
•
•
 (In the opposite direction, the control target cannot be shifted further than the nominal tar-
get, entered as Target on the Process menu.)

The polarity of Max Target Change should be the same as ATO Threshold.

So, if Max Target Change is negative, ATO Threshold should also be negative.

If Max Target Change is negative, ATO will optimize by lowering the control target.
If Max Target Change is positive, ATO will optimize by increasing the control target.

3. Touch ATO Threshold and enter a target deviation level, expressed as a numeric offset
from the target in the same units as the gauge display units (set in the Units menu).

The acceptable percentage of product that can exceed the ATO Threshold is set by the
% Past Threshold parameter (see step 4).

The polarity of ATO Threshold should be the same as Max Target Change.

4. Touch % Past Threshold and enter the percentage of product that is allowed to exceed
the ATO Threshold.

5 to 10% is recommended. Lower values will make the target optimization less stable.
Higher values will limit the system's ability to respond to large percentages beyond the
threshold.

5. Touch Minimum Cycles and enter the minimum number of cycles (scans) used to evalu-
ate whether or not to shift the control target.

At the end of each cycle, when the system first evaluates whether or not to make a target
shift, the minimum number of cycles are examined. If no shift is indicated, additional
cycles are considered up to the available number of cycles of data or 32.

6. Touch Sigma Mult More Opt and enter a multiple of the standard deviation for increased
optimization (e.g., 3.0).

Allowable values range from 1.0 to 4.0. Larger values cause less frequent optimizing
shifts, that is, more confidence that a shift is required.

The More Opt value sets the confidence level for shifts to increase optimization.

To determine whether or not to shift the target, the system first calculates the sigma of the
percentage of readings that fall beyond the ATO Threshold. This sigma is multiplied by
the More Opt value, and added to the actual percentage of readings that exceed the
ATO Threshold. If the result is less than the % Past Threshold value, the system will
make an optimizing target shift away from the nominal target.

7. Touch Sigma Mult Less Opt and enter a multiple of the standard deviation for decreased
10
optimization (e.g., 2.0).

Allowable values range from 1.0 to 4.0. Larger values cause less frequent shifts toward the
nominal target.

continues

•
•
Model 6100TC: Options • 10-23
•
•
•
 continued from previous page

This sets the confidence level for shifts to decrease optimization. When evaluating
whether to make a target shift, the system calculates the sigma of the percentage of read-
ings that fall beyond the ATO Threshold. This sigma is multiplied by the Less Opt value,
and subtracted from the actual percentage of readings that exceed the ATO Threshold. If
the result is greater than the % Past Threshold value, the system will make a target shift
back toward the nominal target.

8. Touch ATO Gain and enter a gain value between 0.00 and 1.00 (e.g., 0.8).

This value is used to reduce the amount of the control target shift. The target shift will be
multiplied by the ATO Gain before it is applied.

PROCESS

PRODUCT GAGE FACTOR GAGE CONSTANT SPECIFIC GRAVITY

NDC BASIC 1.000 0.00 1.000

TARGET HI ALARM LO ALARM

(MILS) (MILS) (MILS) ALERTS
72.30 1.00 -1.00

ATO
ATO SETUP MORE
OFF ON

DISPLAY MAIN

Figure 10-21 Process Menu

9. Touch Main → Process to move to the Process menu (Figure 10-21).

10. Enable the ATO option by setting the ATO Off/On toggle to On.

ATO only operates if this toggle is On and control is active.

10

•
•
10-24 •• Model 6100TC: Options
•
•
 Example

The following example demonstrates how the ATO Threshold, % Past Threshold and
Max Target Change values affect system evaluation of a target shift.

User-defined Parameters

Target = 5.00 mils

Max Target Change = -0.5

(Max Target Change is negative, so ATO will optimize by decreasing the target.)

ATO Threshold = -0.2 mils

% Past Threshold = 6.0%

More Opt = 3.0

Less Opt = 1.0

Calculations

1. ATO Threshold limit = 5.00 - 0.2 = 4.80 mils

2. Suppose after several cycles, 1000 readings have been accumulated.

Out of the 1000 readings, 30 of them are below the 4.80 threshold.

The percentage of readings below the 4.80 threshold

= 30/1000 x 100%
= 3%

3. The sigma of the percentage of points beyond the ATO Threshold is calculated.

p (1 - p)
sigma =
n

where p = fraction of readings below the ATO Threshold

n = number of readings

10
p = 0.03 (3%)
n = 1000

0.03(1 - 0.03)
sigma = = 0.0054
1000

continues

•
•
Model 6100TC: Options • 10-25
•
•
•
 continued from previous page

4. To evaluate whether to shift the control target back toward the nominal target, the system
estimates the fraction of product beyond the Threshold (from step 2) from the fraction of
readings beyond the Threshold, and the confidence level for decreased optimization (spec-
ified by the Less Opt parameter).

Fraction of product beyond the Threshold, adjusted for decreased optimization factor
= p ± (Less Opt x sigma)

where p = fraction of readings beyond ATO Threshold

p = 0.03
Less Opt = 1.0
sigma = 0.0054

Fraction of product beyond the Threshold

= 0.03 ± (1.0 x 0.0054)
= 0.03 ± 0.0054
= 0.0246 to 0.0354

y The lowest value of this result is compared to the acceptable percentage of product beyond
the ATO Threshold, expressed by the % Past Threshold parameter: 0.06 (6%).
If the lowest value is greater than % Past Threshold, the system will make a target shift
back toward the nominal target.

0.0246 is less than 0.06, so the control target will not be shifted back toward the nominal
target.

y The highest value of this result is compared to the acceptable percentage of product
beyond the ATO Threshold, expressed by the % Past Threshold parameter: 0.06 (6%).
If the highest value is less than the % Past Threshold value, the system will make an
optimizing target shift away from the nominal target.

0.0462 is less than 0.06, so an optimizing target shift is made away from the nominal tar-
get.

10.7.2 Setting up Control

Before ATO can make any target shifts, control parameters must be set up. In particular, the
Deadband value in the Control menu should be set to half the amount of the random variation
in the controlled average. A deadband that is too large will reduce the changes that ATO

10 makes to the control target.

10.7.3 Viewing ATO Data

If ATO is off (either control is off, or the ATO Off/On toggle is off), the screen header will
display “ATO:OFF”.

If ATO is on, the screen header will display the current control target, e.g., “ATO:10.12”.

All displays are plotted centered around the current ATO target (see Trend display in
Figure 10-22). The nominal target is represented by a dashed green line. The High and Low
•
•
10-26 •• Model 6100TC: Options
•
•
 Alarms are referenced to the nominal target. Data outside of the alarm limits are plotted in yel-
low or red.

2 SIGMA TREND CTRL CYCLES PER BAR: 1

72.50

Nominal
72.40
target

72.30

72.20

72.10 18:15:58 18:18:07 18:20:15 18:22:24

RESOLUTION
DISPLAY MAIN
LO MED HI

Figure 10-22 Trend display

10.7.4 Description of Operation

ATO's goal is to adjust the product average from the entered target by as much as the
Max Target Change, always seeking to have the specified percentage of the product beyond
the ATO Threshold.

y After ATO is turned on, or after the control target is shifted, a delay occurs to allow the
process to stabilize. This delay lasts until the average is within the deadband around the
control target.

y After the delay, at the end of every cycle, an evaluation is made on whether the control tar-
get should be shifted. (An evaluation is not made if the cycle maximum or minimum
exceeds the High or Low Alarms, or if there was a change to ATO Threshold or
% Past Threshold during the cycle.)

y The system first looks at the most recent n cycles, where n is the Minimum Cycles value,
to estimate the percentage of product beyond the ATO Threshold.

y If the data does not indicate with enough confidence the need for a target shift, the system
then considers additional cycles until any of the following occurs:

a. A target shift is indicated.

The calculated shift will be reduced by the ATO Gain before it is applied.
10
b. The number of available cycles is exhausted.

c. 32 cycles have been evaluated. A final test is then made on the cumulative total for all
cycles since ATO was restarted (when the control target was reset to the nominal tar-
get), or since the last control target shift was made.

y The control target is constrained such that it cannot be shifted further from the nominal
target than the Max Target Change value. In the opposite direction, it cannot move fur-
•
•
Model 6100TC: Options • 10-27
•
•
•
 ther than the nominal target, entered as Target on the Process menu.

y ATO will restart, and return the control target to the nominal target if any of the following
occurs:

a. Scanning is stopped and resumed after more than 10 minutes.

b. The cycle average is more than 5% from the current target.

(e.g., cycle average is 6.5 mils and the control target is 6.0.
5 % of 6.0 mils = 0.05 x 6.0 = 0.3 mils
Cycle average - control target = 6.5 - 6.0 = 0.5 (> 0.3))

10

•
•
10-28 •• Model 6100TC: Options
•
•
 CHAPTER

11 Maintenance and Troubleshooting 11

11.1 Printing Screens
When troubleshooting the gauge, it may help to print one or more displays or setup screens.
Every display and menu includes a Print button in the upper right corner that orders an imme-
diate printout of that display or menu.

•
Model 6100TC: Maintenance and Troubleshooting •• 11-1
•
•
•
 11.2 Circuit Boards
The system has three boards:

y System Mother Board

y Scanner Extension Board

y Process Extension Board

The board connections are detailed in Appendix C - Board Connections.

‰ System Mother Board

Provides basic support functions for the gauging system, including:

y Computer

y RAM storage for system software

y EEPROMs for system software, BIOS and language

y Non-volatile memory for system configuration and calibration data

y Basic parallel plant I/O for roll cut, control support, etc.

y Counters for line speed tach and beta reference

y Serial ports for touch frames, printers, debug, Open Access, APC, etc.

y VDU driver hardware

y Connectors for Scanner Extension and Process Extension Boards

‰ Scanner Extension Board

Fits into the Mother Board and supports all measurement hardware at one measuring sta-
tion. A maximum of 2 Scanner Extension Boards may be connected to the Mother Board.
(For 6100TC systems, only one Scanner Board is required).

The Scanner Extension Board provides the following functions:

Scanner Support

y Stepper motor drive

y Encoder counter

y Set of limit/reference switch inputs

11 y Parallel i/o for shutter control and sensing

•
•
11-2 •• Model 6100TC: Maintenance and Troubleshooting
•
•
 y Parallel i/o for sensor retract and sensing

y Parallel input bits for sensor breakaway, web sensors and motor state

This support is brought off the Scanner Extension Board on a single IDC connector
(jp40).

Common Gauge Interface (CGI)

This is a connector containing interfaces for all currently used sensors. There are 3
interfaces on each Scanner Extension Board. They are identical, except that the third
interface does not support a Gamma Backscatter Gauge.

CGI interfaces are:

y Gamma Backscatter Gauge support. Voltage supplies, discriminator inputs for

PMT drive

y Counter inputs, analog inputs (to support beta gauges)

y RS422 Serial i/o to support serial type gauges

‰ Process Extension Board

If the 6100TC has two control loops (apart from APC), a Process Extension Board will be
installed. This carries additional i/o that can handle the additional interface requirements.

11

•
•
Model 6100TC: Maintenance and Troubleshooting • 11-3
•
•
•
 11.3 NDC Maintenance Menu

NDC MAINTENANCE

NDC VERSION I/O TESTS SECURITY

SCREEN & PRINTER MISCELLANEOUS

DISPLAY EXIT MAIN

Figure 11-1 NDC Maintenance Menu

The NDC Maintenance menu (Main → More → NDC Maintenance, Figure 11-1) includes
the following buttons:

‰ NDC: NDC is a password protected menu is used by factory technicians to troubleshoot

your system.

‰ Version: This button calls up a display with information about the software in your system
(Figure 11-2).

VERSION

VERSION: 6100 100 902023-BX

Jul 18 2002 11:29:02
(c) 1986-2002 NDC Infrared Engineering Inc.
(c) LANG PROM REV 902008-AT 07/11/02 17:11:57
902 Recipes Available

DISPLAY EXIT MAIN

11
Figure 11-2 Version Page

‰ I/O Tests: This button calls up a menu that allows you to test the analog inputs and out-
puts. See Section 11.4 - I/O Tests Menu.

•
•
11-4 •• Model 6100TC: Maintenance and Troubleshooting
•
•
‰ Security: This button calls up a menu that allows a supervisor to control access to various
menus and displays. See Section 8.8 - Security.

‰ Screen & Printer: This button brings up a new menu with buttons to test and calibrate the
touchscreen, switch between a color or black/white printer, and turn the screen saver func-
tion on or off. See Section 8.5 - Screen and Section 8.6 - Printer.

‰ Miscellaneous: The Miscellaneous menu is reserved for custom features. See Section 8.7
- Miscellaneous.

11

•
•
Model 6100TC: Maintenance and Troubleshooting • 11-5
•
•
•
 11.4 I/O Tests Menu
To test the analog outputs, move to the I/O Tests menu (Main → More → NDC Maintenance
→ I/O Tests). This menu has 2 pages.

11.4.1 I/O Tests Menu Page 1

I/O TESTS

ANALOG CHANNEL ANALOG LEVEL ANALOG TEST

1 2 3 4 LO MED HI OFF ON

SIMULATE ROLL
INPUTS OUTPUTS
SWITCH

DATA ON OVERRIDE
MORE
NO YES

AGC INLINE
EXIT
OFF ON

Figure 11-3 I/O Tests Menu Page 1

Figure 11-3 shows I/O Tests Menu Page 1.

The Analog Channel, Analog Level and Analog Test buttons are used to test the analog out-
put. See Section 11.4.3 - Analog Output Test.

The Inputs button brings up a page that shows the status of the parallel inputs.
See Section 11.4.4 - Parallel Inputs Test.

The Outputs button brings up a page that shows the status of the parallel outputs.
See Section 11.4.5 - Parallel Outputs Test.

The other buttons in I/O Tests Menu Page 1 include:

‰ Simulate Roll Switch: Touching this button produces the same response as closing the
roll switch. Each time this button is touched, the roll number is incremented and a roll
report is generated for the previous roll.

‰ Data On Override: If this toggle is set to Yes, Data mode will be turned on, regardless of
the state of the system. For example, if the sensor is off sheet and this toggle is Yes, Data
mode will be On. This allows gathering of data for reports and histogram.
11 For a description of Data mode, see Section 1.4 - Data mode.

The status of this button is not saved when the system is turned off.

•
•
11-6 •• Model 6100TC: Maintenance and Troubleshooting
•
•
 ‰ More: Touch this button to bring up page 2 of the I/O Tests menu.
See Section 11.4.2 - I/O Tests Menu Page 2.

‰ AGC Inline: This button is visible only on systems with a gamma sensor. This is used pri-
marily by NDC Infrared Engineering personnel to track the movement of the AGC Drive,
for troubleshooting problems with the sensor. This toggle should be set to Off.

When this toggle is On, the Inline display will be retitled “AGC Inline.” The target for the
Inline display will be the AGC Drive value at the time the toggle was turned On. Each ver-
tical bar will represent the high and low AGC Drive values during the period specified by
the Inline Update Time.

The status of this button is not saved when the system is turned off.

11.4.2 I/O Tests Menu Page 2

I/O TESTS - 2

CLEAR BAD FLAGS RESTORE AGC

ANALOG INPUTS

EXIT

Figure 11-4 I/O Tests Menu Page 2

I/O Tests Menu Page 2 (Figure 11-4) includes the following buttons:

‰ Clear Bad Flags: This button is reserved for NDC Infrared Engineering personnel.

It resets any NVRAM indicator variables in recipe. Any or all of these indicator variables
are set to 1 by the system if it detects that data in NVRAM is corrupt or missing on startup.
These variables are stored in recipe as:

• BAD CR - a value of 1 indicates a problem in Current Recipe

• BAD NDC BASIC - a value of 1 indicates a problem in the NDC Basic recipe

• BAD OPT - a value of 1 indicates a problem in option settings

11
• BAD LOADRCP - a value of 1 indicates a problem with recipe field loading
settings

continues

•
•
Model 6100TC: Maintenance and Troubleshooting • 11-7
•
•
•
 continued from previous page

• BAD SECUR - a value of 1 indicates a problem with security settings

• BAD NONRCP - a value of 1 indicates a problem with non-recipe parameters

When the Clear Bad Flags button is selected, this causes any of the indicator variables
above that have a value of 1 to be reset to 0.

‰ Restore AGC: This button is reserved for NDC Infrared Engineering personnel. It is used
to restore the AGC Drive to the value at the time of the last AGC calibration. This is useful
if there is a situation where the gauge is producing inaccurate readings. For example, this
may occur if the sensor is disconnected from the system, causing the AGC drive for the
sensor to drift away to an unreasonable value.

‰ Analog Inputs: This button is used to test an analog input channel.

See Section 11.4.6 - Analog Input Test.

11

•
•
11-8 •• Model 6100TC: Maintenance and Troubleshooting
•
•
11.4.3 Analog Output Test

1. Move to I/O Tests Menu Page 1 (Main → More → NDC Maintenance → I/O Tests,
Figure 11-3).

2. Touch the Analog Channel button and select the channel under test.

3. The Analog Level button sets the output level for the selected channel.

Select:

Hi - to output the maximum possible value

Med - to output the average of the maximum and minimum possible values
Lo - to output the minimum possible value

4. Set the Analog Test toggle to On. Note whether the analog device registers the correct
value.

The analog test will be automatically turned off upon exiting I/O Tests Menu Page 1.

11

•
•
Model 6100TC: Maintenance and Troubleshooting • 11-9
•
•
•
 11.4.4 Parallel Inputs Test

The Inputs page (Figure 11-5) shows the status of the parallel inputs. This page is reached by
touching the Inputs button on I/O Tests Menu Page 1 (Main → More → NDC Maintenance
→ I/O Tests).

INPUTS

MOTHERBOARD SCANNERBOARD
BYTE 1 BYTE 2 BYTE 3 BYTE 1 BYTE 2 BYTE 3
A:0 A:0 A:0 A:0 A:0 A:0
B:0 B:0 B:0 B:0 B:0 B:0
C:1 C:0 C:0 C:1 C:0 C:0
D:0 D:0 D:0 D:0 D:0 D:0
E:0 E:0 E:0 E:0 E:0 E:0
F:0 F:0 F:0 F:0 F:0 F:0
G:0 G:0 G:0 G:0 G:0 G:0
H:0 H:0 H:0 H:0 H:0 H:0

EXIT

Figure 11-5 Inputs Page

The table below shows the input assignments for the parallel interface.

Byte Bit Board Connector External Connector Signal

Cn / Pin Id: chn +/-

0 A Mother jp5 / 47 g4pb: 0 1/2 ROLL CUT

0 B Mother jp5 / 45 g4pb: 1 3/4 EVENT

0 C Mother jp5 / 43 g4pb: 2 5/6 DATA ON

0 D Mother jp5 / 41 g4pb: 3 7/8 --

1 A Mother jp5 / 31 g4pb: 8 17 / 18 OFF SHEET

1 B Mother jp5 / 29 g4pb: 9 19 / 20 CONTROL

ON

1 C Mother jp5 / 27 g4pb: 10 21 / 22 CONTROL2

ON

1 D Mother jp5 / 25 g4pb: 11 23 / 24 --

2 A Sc1 / cg2 jp42 / 10 sc1endbx g2 / 10 INP_B0

11 2

2
B

C
Sc1 / cg2

Sc1 / cg2
jp42 / 21

jp42 / 22
sc1endbx

sc1endbx
g2 / 21

g2 / 22
INP_B1

INP_B2

2 E Sc1 / cg3 jp43 / 10 sc1endbx g3 / 10 INP_C0

2 F Sc1 / cg3 jp43 / 21 sc1endbx g3 / 21 INP_C1

•
•
11-10 •• Model 6100TC: Maintenance and Troubleshooting
•
•
Byte Bit Board Connector External Connector Signal

Cn / Pin Id: chn +/-

2 G Sc1 / cg3 jp43 / 22 sc1endbx g3 / 22 INP_C2

3 A Sc1 / scnr jp40 / 16 sc1endbx sc / 16 MOTOR BAD

3 B Sc1 / scnr jp40 / 18 sc1endbx sc / 18 REF SWITCH

3 C Sc1 / --

3 D Sc1 / --

3 E Sc1 / cg1 jp41 / 10 sc1endbx g1 / 10 INP_A0

3 F Sc1 / cg1 jp41 / 21 sc1endbx g1 / 21 INP_A1

3 G Sc1 / cg1 jp41 / 22 sc1endbx g1 / 22 INP_A2

4 A Sc1 / scnr jp40 / 28 sc1endbx sc / 28 SHUTTER

OPEN

4 B Sc1 / scnr jp40 / 27 sc1endbx sc / 27 SHUTTER

CLOSED

4 C Sc1 / scnr jp40 / 24 sc1endbx sc / 24 EXTENDED

4 D Sc1 / scnr jp40 / 23 sc1endbx sc / 23 RETRACTED

4 E Sc1 / scnr jp40 / 30 sc1endbx sc / 30 BREAKAWAY

4 F Sc1 / scnr jp40 / 31 sc1endbx sc / 31 SC_IN

(Sample
check in)

4 G Sc1 / scnr jp40 / 19 sc1endbx sc / 19 LEFT EDGE

SENSOR

4 H Sc1 / scnr jp40 / 20 sc1endbx sc / 20 RIGHT EDGE

SENSOR

11

•
•
Model 6100TC: Maintenance and Troubleshooting • 11-11
•
•
•
 11.4.5 Parallel Outputs Test

The Outputs page (Figure 11-6) shows the status of the parallel outputs. This page is reached
by touching the Outputs button on I/O Tests Menu Page 1 (Main → More → NDC Mainte-
nance → I/O Tests).

OUTPUTS

MOTHERBOARD SCANNERBOARD
BYTE 1 BYTE 2 BYTE 3 BYTE 4 BYTE 5
A:0 A:0 A:0 A:0 A:0
B:0 B:0 B:0 B:0 B:0
C:1 C:0 C:1 C:0 C:0
D:0 D:0 D:0 D:0 D:0
E:0 E:0 E:0 E:0 E:0
F:0 F:0 F:0 F:0 F:0
G:0 G:0 G:0 G:0 G:0
H:0 H:1 H:0 H:0 H:0
SELECT PORT SELECTED OUTPUT OUTPUT
EXIT
0 E OFF ON

Figure 11-6 Outputs Page

The table below shows the output assignments for the parallel interface.

Byte Bit Board Connector External Connector Signal

Cn / Pin Id: chn +/-

0 E Mother jp5 / 39 g4pb: 4 9 / 10 ALARM A

0 F Mother jp5 / 37 g4pb: 5 11 / 12 ALARM B

(rt Ctrl up)

0 G Mother jp5 / 35 g4pb: 6 13 / 14 ALARM C

(rt Ctrl down)

0 H Mother jp5 / 33 g4pb: 7 15 / 16 --

1 E Mother jp5 / 23 g4pb: 12 25 / 26 AUTO LIGHT

1 F Mother jp5 / 21 g4pb: 13 27 / 28 (Lf) CTRL UP

1 G Mother jp5 / 19 g4pb: 14 29 / 30 (Lf) CTRL

DOWN

1 H Mother jp5 / 15 g4pb: 15 31 / 32 MANUAL

LIGHT

11 2

2
A

B
Sc1 / cg1

Sc1 / cg1
jp41 / 20

jp41 / 22
sc1endbx

sc1endbx
g1 / 20

g1 / 22
OP_A0

OP_A1

2 C Sc1 / cg2 jp42 / 20 sc1endbx g2 / 20 OP_B0

2 D Sc1 / cg2 jp42 / 22 sc1endbx g2 / 22 OP_B1

•
•
11-12 •• Model 6100TC: Maintenance and Troubleshooting
•
•
Byte Bit Board Connector External Connector Signal

Cn / Pin Id: chn +/-

2 E Sc1 / cg3 jp43 / 20 sc1endbx g3 / 20 OP_C0

2 F Sc1 / cg3 jp43 / 22 sc1endbx g3 / 22 OP_C1

3 A Sc1 / scnr jp40 / 26 sc1endbx sc / 26 CALL SHUTTER

3 B Sc1 / scnr jp40 / 22 sc1endbx sc / 22 CALL EXTEND

3 C Sc1 / scnr jp40 / 32 sc1endbx sc / 32 SC_OUT

3 D Sc1 / scnr jp40 / 34 sc1endbx sc / 34 OUT_0

11

•
•
Model 6100TC: Maintenance and Troubleshooting • 11-13
•
•
•
 11.4.6 Analog Input Test

ANALOG INPUTS

ANALOG INPUT SLOPE OFFSET

OFF ON 1.000 0.000

TARGET SCALE CHANNEL UPDATE TIME

100.000 100.000 12 1.00

ANALOG INPUT
GRAPH

DISPLAY EXIT MAIN

Figure 11-7 Analog Inputs Menu

The Analog Inputs menu (Main → More → NDC Maintenance → I/O Tests → More →
Analog Inputs, Figure 11-7) is used to test an analog input channel. A graph is plotted of the
analog input values.

1. Touch the Channel button in the Analog Inputs menu (Figure 11-7) and select the channel
under test.

2. Set the Analog Input toggle to On.

3. Enter values for the Slope and Offset.

These parameters are used to scale the analog input as follows:

New value = Input value x Slope + Offset

4. Set the Update Time to the frequency in seconds at which data points should be updated
on the Analog Input graph.

5. Set the Target to the expected value of the analog input. This is the midpoint value for the
Analog Input graph.

6. The Scale button is used to size the vertical scale for the Analog Input graph. It sets the
distance from the center to the ends of the vertical axis. Enter the desired value for the
Scale.

7. Touch the Analog Input Graph button to view a graph of the analog input values

11
(Figure 11-8).

•
•
11-14 •• Model 6100TC: Maintenance and Troubleshooting
•
•
 ANALOG INPUTS - 12

25.000

15.000

current 5.000 10:54:29

value
DISPLAY EXIT MAIN
11.000

Figure 11-8 Analog Input Graph

Figure 11-8 shows a graph of the analog input. A line is plotted from the analog input value to
the target. The Update Time sets the frequency at which the graph is updated. The number at
the bottom of the graph shows the current value for the analog input.

11

•
•
Model 6100TC: Maintenance and Troubleshooting • 11-15
•
•
•
 11.5 Serial Interface Allocations
The table below shows the serial interface allocations.

Board Channel Protocol Handshake Function Alternate

Function

Mother 0 9600 XonXoff Microbric

debug
(if dip 6)

Mother 1 9600 XonXoff Open Gnu

Access debug
(if dip 3)

Mother 2 9600 XonXoff APC

Mother 3 9600 Rdy/Bsy Printer

Mother 4 9600 XonXoff Touch 1

Mother 5 9600 XonXoff Touch 2

Scn1 0 -- -- Gauge 1

Scn1 1 -- -- Gauge 2

Scn1 2 -- -- Gauge 3

11

•
•
11-16 •• Model 6100TC: Maintenance and Troubleshooting
•
•
11.6 Troubleshooting
11.6.1 Miscellaneous Problems

You can use the following checks and tests to help isolate problems in your gauge. Telephone
the NDC Infrared Engineering Customer Care Department if you need more help.

Symptom Possible Cause/Solution

Unit won’t turn on y Power switch turned off

y Defective power switch

y No incoming power

y Blown fuse on rear panel

y Defective power supply. Check +5 and

± 12 VDC voltages on power supply (± 5%).

Display menu does not Depending on how much of the Starting Display
replace Starting appears on the screen, there may be a variety
Display of causes. Call the NDC Infrared Engineering
Customer Care Department for assistance.

Unit powered on but y Brightness control turned down

screen not lit up.
y Blown rear panel fuse

y Defective power supply. Check voltages

with system under load.

Blown fuse on rear Replace fuse.

panel

Program difficulty y Unworkable setup values. Follow procedure

in Section 5.1 - Loading a Recipe to Current to
reload a copy of NDC Basic to current
working area.

y Bad CPU

y Bad cables

Excessive fluctuation of y Loose connector

display data
y Bad sensor

y Bad sensor cable

y Excessive passline fluctuation

Gauge reading drops

momentarily or
permanently
Sensor cable or connectors
11

•
•
Model 6100TC: Maintenance and Troubleshooting • 11-17
•
•
•
 Symptom Possible Cause/Solution

“Fatal error” message Bug in software. Make a note of all information

on display on the screen and then cycle power off and on.
Follow instructions in Section 5.6 - Printing a Rec-
ipe to print the current recipe and then contact
NDC Infrared Engineering.

Gauge reading is y Sensor cable

negative
y Sensor - high voltage supply

System does not One or more control inhibits preventing control.

control See Section 9.6 - Control Inhibits.

Display does not show Security set to blank some buttons

all buttons described in
manual

Display shows Move to the Gage menu (Main → Gage) and

excessive gauge noise reset the Moving Average to a larger value to
or large but smooth your displays toward the measured
uncorrectable process average.
variations
If the moving average is too low, your displays
will show spikes caused by gauge noise or short-
term random variations in the product. The best
moving average will let the operator focus
attention on those variations that can be
corrected. This moving average applies to
gauge displays and control calculations, but
not to serial and analog outputs, or to inline and
strip chart displays.

Scanner does not Turn the Power switch on and then use the
respond to touch or Fwd/Rev switch to move the sensor. If the
does not respond scanner does not respond to manual control,
properly the problem is related to hardware. Check the
cables, connectors, AC line fuses and the motor
interface board in the motor control box.

If the scanner does operate under manual

control, go to the Scanner Setup Menu Page 2
(Main → More → Scanner Setup → More) and
then follow the screen directions to re-initialize
and recalibrate the scanner.

11

•
•
11-18 •• Model 6100TC: Maintenance and Troubleshooting
•
•
Symptom Possible Cause/Solution

Scanner stalls (TFS2 Scanners only)

This may require adjusting the torque setting for
the motor. (The torque setting has been set at
the factory and should not need adjustment
during normal operation of the scanner.)

1. Turn off power to the scanner.

2. Manually pull the sensor to see if it moves

freely over the area where it is stalling. You
should notice a small resisting force due to
friction and the induced emf from the
motor.

The total resisting force should be between

5 and 10 lbs for constant speed travel. If the
force required to pull the heads is greater
than this, check that the bearing shafts are
clean and that all moving parts such as
belts, pulleys, carriage, and cable carrier
are free from obstruction. Check that the
bearings are well-lubricated and adjust
bearing preload if necessary.

3. If all moving parts are free from obstruction,

turn power back on. Increase the motor
torque and attempt to scan by turning the
torque control dial in the lower left corner of
the scanner’s motor housing clockwise until
scanning begins. The correct setting should
be approximately 10/100 graduations or
10% of the full scale more than the minimum
necessary to achieve reliable scanning.

4. If increasing the torque setting does not

help, check or replace the motor.

11

•
•
Model 6100TC: Maintenance and Troubleshooting • 11-19
•
•
•
11

•
•
11-20 •• Model 6100TC: Maintenance and Troubleshooting
•
•
 APPENDIX

A Okidata Printer Configuration A

Your system may include an Okidata 590 printer that has already been pre-configured by an
NDC Infrared Engineering technician. Printers not supplied by NDC Infrared Engineering
must be configured by the user. The following table describes the standard NDC Infrared
Engineering settings for an Okidata 590 printer used in the U.S.

Okidata printers sold outside the U.S. may use other default values. If you provide your own
printer, see your printer manual for information on configuring the printer to match the follow-
ing values:

Function Setting

Emulation Mode Epson LQ

Print Mode LQ Courier

Pitch 10 CPI

Proportional Spacing No

Style Normal

Size Single

Character Set Set II

Language Set American

Zero Character Unslashed

Code Page USA

Line Spacing 6 LPI

Form Tear-Off Off

Skip Over Perforations No

Page Length 11-inch

Gap Control Auto Gap

Line Spacing 6 LPI

Bottom margin Valid

Page Length 11-inch

Gap Control Auto Gap

•
Model 6100TC: Okidata Printer Configuration •• A-1
•
•
•
 Function Setting

Wait Time 1 Sec

Graphics Bi-directional

Receive Buffer Size 64K

Paper Out Override No

Print Registration 0

A Operator Panel Function

Reset Inhibit
Full Function

No

Print Suppress Effective Yes

Auto LF No

Time Out Print Valid

Auto Select No

Smoothing Valid

Ribbon Selection Black

Printhead Gap Adjust +1

Graphics Speed High

I-Prime Buffer Print

Pin 18 +5V

Auto Feed XT Invalid

Parity None

Serial Data 7/8 Bits 8 Bits

Protocol Ready/Busy

Diagnostic Test No

Busy Line DTR (T-Gauge systems

only)

Baud Rate 9600 BPS

DSR Signal Invalid

DTR Signal Ready on Power Up

Busy Time 200 ms

•
•
A-2 •• Model 6100TC: Okidata Printer Configuration
•
•
 APPENDIX

B Ndcback-Java B
Ndcback-Java is a Java-based program that is run on a computer to back up the parameters in
the T-Gauge. These parameters can be sent to the T-Gauge at a later time to restore the config-
uration of the system.

The connection from the computer to the T-Gauge can be a serial connection or an Ethernet
connection. A serial connection requires the use of a null modem cable. See Section B.1 -
Serial Setup. An Ethernet connection is only available if your T-Gauge system includes the
Ethernet option. See Section 10.3 - Ethernet Option.

2 options are available in Ndcback-Java:

y The Save option is used to save parameters and recipes in the system to a text file.

y The Restore option is used to restore the setup of the system by sending a file previously
saved by the Save option to the system.

Before a software upgrade is performed, Ndcback-Java should be run with the Save option to
save the configuration of the system. After the software has been upgraded in the system,
Ndcback-Java is run again, this time using the Restore option, to restore the parameters and
recipes.

Ndcback-Java should also be run after setup, as a backup.

B.1 Serial Setup

Attach the 9-Pin Female D-Sub connector of the NDC Infrared Engineering-supplied RS-232
null modem cable to the rear port of the T-Gauge chassis labeled “RS-232.” The cable is ter-
minated on the PC side with a 9-Pin Female D-Sub connector.

The configuration of the cable is shown in Figure B-1.

NDC-Supplied
Null Modem Cable

T-Gauge 2 3 PC
9-Pin 3 2 9-Pin
D-Sub Female 5 5 D-Sub Female

Figure B-1 NDC Infrared Engineering-supplied null modem cable

If the connector on the PC side is 25-Pin D-Sub, an additional 9-to-25 Pin adapter is required.
The configuration of the adapter is shown in Figure B-2.

•
Model 6100TC: Ndcback-Java •• B-1
•
•
•
 9-to-25
Pin Adapter

2 3
3 2
5 7

Figure B-2 9-to-25 Pin adapter

B.2 Installing Ndcback-Java

B 1. Insert disk 1 labeled “Ndcback-Java, Disk 1 of 2” in the disk drive, and run “A:\SETUP”.

2. The default installation directory is “C:\Program Files\NDC\Ndcback-Java.”

This directory may be changed, if desired, by clicking Browse.

Select Next, and installation will begin.

3. Insert disk 2 labeled “Ndcback-Java, Disk 2 of 2” when prompted by the installation pro-
gram.

When installation is complete, a shortcut to Ndcback-Java will be placed on the Desktop.

B.3 Running Ndcback-Java

To run Ndcback-Java:

1. Double-click the Ndcback-Java icon on the Desktop.

A screen similar to Figure B-3 will be displayed.

•
•
B-2 •• Model 6100TC: Ndcback-Java
•
•
 B
Figure B-3 Select System Type screen

2. Select T-Gage, then select Next.

A screen similar to Figure B-4 will be displayed.

Figure B-4 Select Connection Type screen

3. Select the type of connection: Serial or Ethernet, then select Next to move to the next
screen.

If Serial was selected, a screen similar to Figure B-5 will be displayed.

If Ethernet was selected, the screen will be similar to Figure B-6.

•
•
Model 6100TC: Ndcback-Java • B-3
•
•
•
B
Figure B-5 Serial Settings screen

Figure B-6 Ethernet Settings screen

4. To establish a Serial connection:

For COM Port, enter the serial port on the PC (e.g., 1 for COM1, 2 for COM2, etc.)

Select 9600 for Baud Rate.

Select 8 for Data Bits.

Select None for Parity.

Select 1 for Stop Bits.

Select XON/XOFF for Handshake.

•
•
B-4 •• Model 6100TC: Ndcback-Java
•
•
 To establish an Ethernet connection:

Enter the hostname that has been assigned to the T-Gauge in the Hostname box.

Enter 20000 in the Port box.

Select Next to move to the next screen (Figure B-7).

Figure B-7 Enter filename screen

5. Enter the name of the file to which the parameters should be saved (for the Save option),
or enter the name of the file which will be used to restore the configuration of the system
(for the Restore option).

Alternately, you can select the Browse button, and a dialog box will appear for selecting a
file (Figure B-8). Navigate to the desired directory, select the file or enter the name of the
file in the File name box, then select Open. The name of the selected file will appear in the
box shown in Figure B-7.

Figure B-8 Select file dialog

Select Next to move to the next screen (Figure B-9).

•
•
Model 6100TC: Ndcback-Java • B-5
•
•
•
B
Figure B-9 Current settings screen

6. Figure B-9 shows a list of the current program settings.

These settings may be edited by selecting the Previous button to scroll back through the
previous screens.

If the displayed settings are correct, select Save to start saving parameters or select
Restore to send the selected file to the system.

7. If the Save option is selected, a dialog box will display the program status, including the
names of the recipes saved (Figure B-10). A label at the top displays the number of lines
of parameters saved.

When Ndcback-Java has completed saving the data, the message “Save Completed Suc-
cessfully” is displayed. Select OK to return to the Current settings screen (Figure B-9).

Figure B-10 Save status dialog

If the Restore option is selected, a dialog box will display the program status, including
the names of the recipes restored (Figure B-11). A label at the top displays the number of
lines of parameters restored.

•
•
B-6 •• Model 6100TC: Ndcback-Java
•
•
 When Ndcback-Java has completed restoring the data, the message “Restore Completed
Successfully” is displayed. Select OK to return to the Current settings screen (Figure B-9).

Figure B-11 Restore status dialog

B
B.4 Connection Error
If the Save or Restore option is selected, and Ndcback-Java is unable to connect to the
T-Gauge, the dialog box will display the message “Backup: Unable to connect to gage”
(Figure B-12). Select OK to close this dialog box.

Figure B-12 Connection error dialog

Check the following:

y Are the Serial or Ethernet settings correct

y If you are using a serial connection:

y is the cable connected to the right port on the T-Gauge

y is the cable connection loose

y is the configuration of the cable correct

y is the correct COM port selected in Ndcback-Java

•
•
Model 6100TC: Ndcback-Java • B-7
•
•
•
 B.5 Quitting Ndcback-Java
To quit Ndcback-Java, select Exit from the File menu, or click the X on the far right of the title
bar.

B.6 Viewing the Version of Ndcback-Java

To view the version of the Ndcback-Java software, select Version from the File menu. A dia-
log box similar to Figure B-13 will be displayed. To close this dialog, click the X on the far
right of the title bar.

Figure B-13 Version of Ndcback-Java

B.7 Description of Files

B.7.1 Parameters File

Figure B-14 shows a sample parameters file that is saved when the Save option is selected for
Ndcback-Java. This is a text file containing all system settings and recipes. This file may be
viewed or edited using any text editor program such as Notepad.

•
•
B-8 •• Model 6100TC: Ndcback-Java
•
•
 B

Figure B-14 Parameters file saved by Save option

B.7.2 Log File

The log file, error.log, is stored in the Ndcback-Java program directory (C:\Program
Files\NDC\Ndcback-Java\ndcback by default). Data is appended to this file every time Ndc-
back-Java is executed. This is a text file that may be viewed using any text editor program
such as Notepad.

•
•
Model 6100TC: Ndcback-Java • B-9
•
•
•
 1
2
3

B
4
5

Figure B-15 Error.log file

Information stored in the error.log file (Figure B-15) includes:

1. date and time when Ndcback-Java was started

2. name of the file saved or restored

3. type of system

4. serial or ethernet settings

5. messages displayed by Ndcback-Java while saving or restoring the data, including

names of recipes saved or restored

•
•
B-10 •• Model 6100TC: Ndcback-Java
•
•
 APPENDIX

C Board Connections C
The following pages show the connections for the mother board, scanner expansion board and
process expansion board.

Figure C-1 Mother Board

•
Model 6100TC: Board Connections •• C-1
•
•
•
C

Figure C-2 Scanner Expansion Board

•
•
C-2 •• Model 6100TC: Board Connections
•
•
 C

Figure C-3 Process Expansion Board

•
•
Model 6100TC: Board Connections • C-3
•
•
•
C

•
•
C-4 •• Model 6100TC: Board Connections
•
•
Warranty

1. All sales of NDC Infrared Engineering products are subject to the following terms, and
Buyer’s acceptance of such products shall constitute Buyer’s assent thereto. This War-
ranty Policy is the complete and exclusive statement of all NDC Infrared Engineering war-
ranties to Buyer.

The warranty terms contained herein are expressly in lieu of any and all other war-
ranties, expressed of implied, including any warranty of merchantability or fitness
for a particular purpose. In no event shall NDC Infrared Engineering be liable for
any incidental, consequential or special damages, including but not limited to, any
loss of business, income or profits, expenses incurred for time when the system is not
in operation, and any labor costs relating to or arising out of the performance, func-
tioning or use of the system.

Purchaser assumes the risk for use of this product and agrees to indemnify and hold
NDC Infrared Engineering harmless for any and all damage to person or to property
resulting therefrom.

NDC Infrared Engineering grants no license under any patent rights except the
right, under only such patents as may be owned or acquired by NDC Infrared Engi-
neering, to use the product sold hereby for the purpose for which it is sold.
NDC Infrared Engineering does not warrant that the product or its use does not
infringe any patent owned by persons other than NDC Infrared Engineering.

2. For a period of one (1) year from the date of delivery, NDC Infrared Engineering guaran-
tees all products to be free from defects in material and workmanship. During this period,
NDC Infrared Engineering will repair or at its option replace, free of all charges for parts
and labor, any NDC Infrared Engineering parts determined by it to have been broken or
damaged due to causes other than improper application, abuse or negligence. NDC Infra-
red Engineering’s obligation to repair or replace shall not extend to expendable parts
which are subject to normal operating wear. Nothing in this paragraph 2 will require
NDC Infrared Engineering to make repairs or replacements where:

A. The product has been repaired, other than by an authorized NDC Infrared Engineering
dealer or an NDC Infrared Engineering employee, or altered in any way without the prior
written consent of NDC Infrared Engineering; or

B. The product has not been properly maintained in accordance with any operating and main-
tenance manual supplied therewith; or

C. The product has been damaged as a result of fire, flood, war, insurrection, civil commo-
tion, acts of God or any other cause beyond the control of NDC Infrared Engineering or
Buyer.

3. NDC Infrared Engineering’s liability shall be limited to the obligations set forth in Para-
graph 2. These shall be the Buyer’s sole and exclusive remedies, whether in contract, tort
or otherwise, provided, however, that in lieu thereof, NDC Infrared Engineering at its

•
•
Warranty • W-1
•
•
•
 option may replace the entire product on an exchange basis or refund the purchase price
against the return of the defective product.

4. NDC Infrared Engineering will not be responsible for failure to provide service or parts
due to shortage of materials, labor or transportation strikes or delays, or any causes beyond
NDC Infrared Engineering’s control.

5. Unless otherwise specified by NDC Infrared Engineering, all warranty repairs will be
made at NDC Infrared Engineering’s facility in Irwindale, California. The customer shall
be responsible for all expenses of packing, freight and insurance in connection with the
shipment of products to NDC Infrared Engineering for repair. NDC Infrared Engineering
will pay the cost of returning the equipment to customer.

If it is mutually determined by the buyer and NDC Infrared Engineering that the
examination, replacement or repair takes place at the buyer's facility, then
NDC Infrared Engineering will undertake the examination, replacement or repair at
no charge to the buyer for labor and/or parts. The buyer will be responsible for
NDC Infrared Engineering's travel and living expenses incurred in traveling to and
from the buyer's facility, and during the time of the visit. These expenses will be
billed to the buyer at actual cost to NDC Infrared Engineering.

6. No person, including any NDC Infrared Engineering distributor, agent or representative, is

authorized to assume any liability on behalf or in the name of NDC Infrared Engineering,
and NDC Infrared Engineering shall not be bound to any understandings, representations,
or agreements with respect to warranties except as set forth in this policy.

7. NDC Infrared Engineering requests immediate notification of any claims arising from
damage in transit in order to determine if carrier responsibility exists. If damaged equip-
ment arrives, save the shipping container for inspection by the carrier and telephone
NDC Infrared Engineering at: Main Phone (626) 960-3300, Customer Care Dept. Phone
(626) 939-3855 as soon as possible.

•
•
W-2 •• Warranty
•
•
Index
A Auto Retract 10-11–10-12
Auto Retract menu 10-11
Abort button 1-1 Extend Probe button 10-11
Abort Print button 6-8 Lift Alarm 10-12
Acceleration Factor 4-9 Lock Extended toggle 10-12
Accum Length 2-16 Lock Retracted toggle 10-12
Accum Weight 2-16 Retract Probe button 10-11
AGC Inline button 11-7 Settle Time (secs) button 10-12
Alarms 7-6–7-12 Simulate toggle 10-11
Acknowledging an alarm 7-9 Auto Screen Print 6-8
Alarm Log 7-12 Auto Screen Print button 6-4
Alarm setup 7-10–7-12 Auto Screen Print menu 6-8
Control inhibit alarm 7-11 Automatic Profile Alignment for Extruders 4-15–4-21
GoTo Fail alarm 7-12 Alignment of the die profile 4-15
Hardware alarm 7-11 Auto Profile Position toggle 4-17, 4-18, 4-20
High Alarm 7-11 Automatic Alignment of Die Profile 4-18
High Value alarm 3-7, 7-11 Bolt Width At Scanner 4-18, 4-21
Length alarm 2-16, 7-11 Convert to Diebolts toggle 4-16
Lift alarm 7-11, 10-12 Die Centerline 4-18, 4-21
Lo Alarm 7-11 Die Setup menu 4-17, 4-20
Lo Speed alarm 7-3 Horizontal Scale button 4-16
Sheet Break alarm 3-6, 4-14, 7-11 Left Deckle 4-19
Stop Failed alarm 7-12 Left Un-numbered Bolts 4-21
Weight alarm 2-17, 7-11 Manual Alignment of Profile Position with Die
Alarms button 7-1 4-17, 4-18
Alerts 3-3, 3-4–3-5, 7-11 Neck In 4-19
Analog button 7-1 Number of Diebolts 4-19
Analog Channel button 7-7, 11-6, 11-9 Process Die Setup menu 4-19
Analog Input Graph button 11-14 Right Deckle 4-19
Analog Input Test 11-14 Right Un-numbered Bolts 4-21
Analog Inputs button 11-8 Scan Display Hi 4-16
Analog Inputs Graph 11-15 Scan Display Lo 4-16
Analog Inputs menu 11-14 Scanner calibration 4-15
Analog Level button 11-6, 11-9 Automatic Target Optimization (ATO) 10-22–10-28
Analog menu 7-6 % Past Threshold 10-23, 10-24, 10-25, 10-26,
Analog Output Test 11-9 10-27
Analog outputs 7-4–7-8 ATO Gain 10-24, 10-27
Analog Test toggle 11-6, 11-9 ATO Off/On toggle 10-24
Auto Alarm Reset 8-9 ATO Setup Menu 10-22
Auto Clear Hist button 2-13 ATO Threshold 10-23, 10-25, 10-26, 10-27
Auto Clear Trend 2-9 control target 10-26
Auto Display Zones 2-18 description of operation 10-27
Auto Print Job toggle 6-4 Max Target Change 10-22, 10-23, 10-25, 10-27
Auto Print Roll/Time toggle 6-4 Minimum Cycles 10-23, 10-27
Auto Print Shift toggle 6-4 nominal target 10-26
Auto Print, Alarm log 7-12 setting up control 10-26
Auto Profile Alignment for Extruders Setup 10-22–10-26
Left Un-numbered Bolts 4-18 Sigma Mult Less Opt 10-23
Right Un-numbered Bolts 4-18 Sigma Mult More Opt 10-23

•
•
Model 6100TC: Index • I-1
•
•
•
 viewing ATO data 10-26 Speed control 9-4–9-7
Away Switch 4-1, 4-2 Spot Error Limit button 9-3
Away Value button 4-8 Control button 1-7
Control cycle 2-9
B Control Cycles per Trend 2-9
Control Off/On toggle 1-6
Basic cycle 2-9 Conversion Factor 8-2
Basic Report Roll/Time toggle 6-4 Convert to Diebolts toggle 2-11, 4-15
Baud rate 7-5 Cross Axis control
Baud rate, printer 8-7 Center Zone Start/End 9-16
board connections C-1–C-3 Center Zone Width 9-16
Control Zones menu 9-16
C Cross Axis Control menu 9-14
Ctrl Zones button 9-15
Deadband 9-14
Calibrate Scanner button 4-4, 4-8
Debug button 9-15
Calibrate Touch Screen button 8-6
Delay Distance 9-14
Calibrating the scanner 4-4–4-5
Gain 9-14, 9-17
Center/Absolute toggle 7-8
Left and Right Pivot Pts 9-15
Ch1 Data button 7-6
Left Backlash 9-16
Channel Settings 7-6, 7-7
Left Full Scale 9-16
Channel Settings menu 7-7
Left Zone Start/End 9-16
Circuit Board Tests 11-17
Left/Right Setup 9-15
Circuit Boards
Left/Right Setup menu 9-15
Bric 11-2–??
Print Ctrl Log button 9-15
Microbric ??–11-3
Right Backlash 9-16
Clear Bad Flags button 11-7
Right Full Scale 9-16
Clear Composite button 2-11
Right Gain 9-17
Clear Hist Now button 2-13
Right Zone Start/End 9-16
Clear Trend Now button 2-9
Roll Diameter 9-15
Clock button 1-8
Rt/Lt Gain Ratio 9-14
Clock menu 8-4
Custom Unit 8-2
Coefficient of Variance, CV 2-12
Custom Unit button 8-1
Common Gauge Interface (CGI) 11-3
Custom Unit menu 8-2
Control
Custom Unit Name 8-2
Auto Gain On/Off toggle 9-5
Cycle Time button 8-3
Auto/Man toggle 9-4, 9-10, 9-17
Cycle Type toggle 8-3
Avg Error Limit button 9-3, 9-6
Cycle, basic 2-9
Backlash 9-8, 9-14
Cycle, control 2-9
Control Inhibits 9-18
Cycles button 1-7
Control Log button 9-3
Cycles menu 8-3
Control Menu 9-3
Cycles per Composite 2-11
Control messages 9-19
Control Mode (Avg/Min) toggle 9-5, 9-8, 9-14
Cross Axis control 9-14–9-17 D
Cycles per Control button 9-3
Deadband 9-5 Data Bits 7-5
Delay 9-19 data moving average 6-11
Gain 9-4, 9-8, 9-14 Data Off/On toggle 1-7
Left Pivot Pt 9-9, 9-15 Data On Override button 11-6
Linespeed/Screwspeed Control toggle 9-5, 9-8, Date, changing 8-4
9-14 Debug button 8-9
Rt/Lt Gain Ratio button 9-15 Debug button, scanner 4-7

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I-2 •
• Model 6100TC: Index
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Decimal Point 8-1 what happens during Edgeseek 4-11
Delete Selected Recipe button 5-6 Edgeseek button 4-6
Die Setup Menu 4-17 Edgeseek menu 4-11
Die Setup Menu button 2-12 Ethernet option 10-8–10-10
Display button 1-1, 1-6, 2-1 Gateway button 10-9
Display Setup button 1-5 Hardware setup 10-8
Display Setup menu 2-8 IP Address button 10-9
Display Zone Setup 2-18–2-20 IP Mask button 10-9
Display Zones ping 10-10
Adding 2-18–2-19 Software setup 10-9
Deleting 2-20 telnet 10-10
Viewing 2-20 Exit button 1-1
Display Zones button 2-8
Displays F
Histogram 2-5
Inline 2-4–2-5 FFT (Fast Fourier Transform) 10-1–10-3
Roll Profile 2-6 Clear FFT Now button 10-1
Scan Profile 2-2–2-3 FFT Composite Display 10-3
Trend 2-4 FFT menu 10-1
Zones 2-6–2-7 FFT Operation 10-2
Dual Gap control 9-8–9-13 Last FFT Display 10-2
Control Calculation 9-11–9-13 Min Displayed Period button 10-1
Control Zones menu 9-10 Period Range button 10-1
Ctrl Zones button 9-9 FFT button 1-8
Deadband 9-8 Find Edges button 1-8
Delay Distance 9-8 Full Scale value, analog outputs 7-7
Dual Gap Control menu 9-8 Fuse 11-17
Gain 9-8, 9-10, 9-11
Left and Right Pivot Pts 9-9 G
Left Backlash 9-9
Left/Right Setup 9-8
Gage button 1-5
Left/Right Setup menu 9-9
Gage Constant 3-2
Print Ctrl Log button 9-9
Gage Factor 3-1
Right Backlash 9-9
Gage Reading/Cycle Avg toggle 7-8
Right Gain 9-11
Gage Samples input 7-13
Rt/Lt Gain Ratio 9-8
Gage Unit button 8-1
Gamma Standardize toggle 4-9
E Gap Exclusion 10-13–10-15
Beam Width 10-14
Edgeseek 4-11–4-14 Gap Exclusion toggle 10-14
Dist from Startup 4-12 Min Coating Level 10-14, 10-15
Edge Run On 4-13 Minimum Linespeed 10-15
Edgeseek Interval 4-12 Gauge output, serial 7-4
Edgeseek on Scan Resume 4-13 Go To button 4-2
Edgeseek On/Off toggle 4-12
Scan After Trim 4-13 H
Scan Before Trim 4-12
Scan Light Edges 4-13
Header 1-1, 1-2
Setup 4-11–4-13
Header button 6-4
Sheet Break Detection with Edgeseek 4-14
Header Info button 2-8
Trim Configuration 4-12
Header Info menu 2-16
Web Width Offset 4-13
Hi Alarm 3-2
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Model 6100TC: Index • I-3
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Hi Alarm button 3-2 Move Tolerance 4-9
Hi Alert 3-4 Moving Average
High Speed 4-6 Analog outputs 7-6
Histogram button 2-8 Gauge 8-8
Histogram display 2-5 Gauge output, serial 7-5
Histogram Setup 2-13 Inline 2-10
Histogram Setup menu 2-13 Moving Average, gauge output, serial 7-5
Horizontal Scale button 2-12 Moving Average, inline 2-10

I N

I/O Setup button 1-7 NDC Basic recipe 5-1

I/O Setup menu 7-1 NDC button 11-4
I/O Tests button 11-4 NDC Maintenance button 1-7
I/O Tests Menu NDC Maintenance menu 11-4
Page 1 11-6–11-7 Ndcback-Java B-1–B-10
Page 2 11-7–11-8 Connection Error B-7
Inline button 2-8 Error.log file B-10
Inline display 2-4–2-5 Installing B-2
Inline Setup 2-10 Log File B-9
Inline Setup menu 2-10 Parameters File B-8
Input B 7-13 Quitting B-8
Input B button 7-1 Running B-2–B-7
Input B menu 7-13 Serial Setup B-1–B-2
Inputs button 11-6 Version B-8
Network button 8-8
L Network menu 10-9

Lagged 2-6 O
Language button 1-6
Length Alarm 2-16 on sheet 4-10
Length Limit 2-16 Open Access 7-5
Lift Alarm 10-12 Open Access Update Time 7-5
Linespeed button 7-3 Open Access Zones 2-11
Live Profiles toggle 2-11 Output Position toggle 7-5
Lo Alarm 3-2 Outputs button 11-6
Lo Alert 3-4, 3-5
Load Selected to Current button 5-3 P

M Parallel Inputs Test

Microbric 11-11
Main button 1-1 Parallel Outputs Test
Main Menu Page 1 1-5–1-6 Microbric 11-13
Main Menu Page 2 1-7–1-8 Parity 7-5
Main Menu Page 3 1-8 Password 8-10
Maximum Gage Value 3-7 Position button 4-4
Minimum Gage Value 3-7, 4-13 Preset Position 4-6
Minimum Linespeed 9-18 Print Basic Report button 6-1
Minimum Roll 8-5 Print button 1-2, 11-1
Miscellaneous button 11-5 Print Job Report button 6-1
Miscellaneous menu 8-8 Print Selected Recipe button 5-5
Mouse Sensitivity 8-6 Print Shift Report button 6-1
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• Model 6100TC: Index
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Printer Baud button 8-7 Roll Report, description of items 6-5–6-7
Printer button 8-7 RS-232 7-4
Printer configuration, Okidata A-1, A-2
Process button 1-5 S
Process Die Setup menu 4-19
Process Die Setup Menu button 3-7 Save Current Recipe button 5-4
Process Extension Board 11-3 Scale button 2-8
Process Menu Page 1 3-1–3-3 Scale menu 2-14
Process Menu Page 2 3-6–3-7 Scan button 4-2
Product ID 3-1 Scan Direction 4-6
Product Width 3-6 Scan Display Hi 2-11
Profile button 2-8 Scan Display Lo 2-11
Profile menu 2-11, 4-16 Scan Display Step button 2-12
Profile Reference 2-11 Scan From button 4-6
Profile Setup 2-11–2-12 Scan Speed 4-6, 4-13
Pulse Tolerance 4-10 Scan To button 4-6
Pulses per __ button 7-2 Scanner button 1-6
Scanner Calibration 4-4–4-5
R Scanner Debug Page 4-10
Scanner Display 4-2–4-3
Recipe button 1-5 Scanner Extension Board 11-2
Recipe Directory, viewing 5-6 Scanner Offsheet button 1-6
Recipes 5-1–5-6 Scanner Reset 4-9
Creating 5-4 Scanner Setup button 1-7
Deleting 5-6 Scanner Setup Menu Page 1 4-6
Editing 5-4 Scanner Setup Menu Page 2 4-8
Printing 5-5 Scanner stalls 11-19
Viewing 5-4–5-5 Scanner Unit 4-4, 4-8
Re-initialize Scanner button 4-8 Scrap 1-9, 8-5
Report menu 6-1 Screen & Printer button 11-5
Report Setup button 6-1 Screen & Printer menu 8-6
Report Setup menu 6-4 Screen Saver 8-6
Reports 6-1 Security 8-10–8-11
Reports button 1-5 Individual button security 8-11
Reset Display Limits button 2-11 Security password, changing 8-11
Resolution button 2-1 Security Settings 8-11
Restore AGC button 11-8 Security button 11-5
Restoring original setup values 5-6 Security menu 8-10
Roll Defects Report 6-11–6-15 Security Settings button 8-11
defect detection 6-11 Selected Recipe button 5-2
reporting of defects 6-12 Serial button 7-1
Roll Defect List 6-14 Serial menu 7-4
Roll Defect Map 6-15 Serial output 7-4–7-5
Roll Defect Map toggle 6-13 Set Security Password button 8-11
setup 6-13 Sheet Break 9-18
Roll Form-Feed toggle 6-3 Shift times 8-4
Roll ID 3-6 Shutter Closed/Open toggle 1-6
Roll Increment 3-7 Sigma 2-4
Roll input 6-1 Sigma Multiplier button 2-8
Roll Label 8-1 Sigma/CV toggle 2-12
Roll Lag Distance 8-5 Simulate Roll Switch button 11-6
Roll Profile display 2-6 Site Layout button 1-7

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Model 6100TC: Index • I-5
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Site Layout menu 8-5 T
SPC (Statistical Process Control) 10-4–10-7
Auto Clear SPC button 10-4 Tach button 7-1
Clear SPC Now button 10-4 Tach menu 7-2
Control Limits, Calculated 10-5 Target 3-2
Control Limits, Range 10-5 Target Profile 10-16–10-21
Control Limits, X-Bar 10-5 Add Point button 10-18
Cpk 10-6 adding points 10-18
Population Size button 10-4 deleting a point 10-20
Ppk 10-6 Diff From Reference button 10-18
Range Display 10-7 Error Profile display 10-21
SPC Limits button 10-4 Position button 10-18
SPC Limits menu 10-5 Reference Value 10-17
SPC Range Scale button 10-5 Scan Profile display 10-21
SPC Sigma Multiplier 10-4 Target Profile menu 10-17
Spec Limits 10-5, 10-7 Target Profile Setup button 10-17
X-Bar Display 10-6, 10-7 Target Profile toggle 10-17
SPC button 1-8 TCP/IP 10-8
Specific Gravity 3-2 Test, Analog Input 11-14
Speed control 9-4–9-7 Test, Analog Output 11-9
Auto Gain toggle 9-5 Test, Parallel Inputs 11-10
Control Mode 9-5 Test, Parallel Outputs 11-12
Deadband 9-5 Thickness/Weight Unit toggle 8-2
Delay Distance 9-5 Time, changing 8-4
Gain 9-4, 9-5 Touch screen, calibrating 8-6
Line Speed Multiplier 9-6 Touch Test 8-6
Print Ctrl Log button 9-6 Trend button 2-8
Screw Delay 9-7 Trend Cycles 2-4
Screw Speed/Linespeed 9-6 Trend display 2-4
Speed Control menu 9-4 Trend Setup 2-9
Speed Control menu 9-4 Trend Setup menu 2-9
Split Roll Reports 6-9–6-10 Troubleshooting 11-17–11-19
Split Roll Rpts toggle 6-4, 6-9
Start Scan input 7-13 U
Starting display 11-17
Startup Switch 4-1, 4-2 Units
Startup Switch toggle 4-1, 4-8 Custom Unit 8-1, 8-2
Startup Value button 4-8 Gage Unit 8-1
Stop button 4-2 Length Unit 8-2
Strip Chart 2-10, 6-2–6-3 Sheet Width Unit 8-2
Off/On toggle 6-1 Tach Unit 7-2
Scale 6-2 Weight Unit 8-2
Strip Chart Input 7-13 Units button 1-7
Strip Chart Output 7-5 Units menu 8-1
Strip Chart Scale button 6-2 Update Time
Strip Chart Setup button 6-1 Inline 2-10
Strip Chart Setup menu 6-2 Inline and Strip Chart 6-2
Update Time 6-2 Strip Chart 6-2
Strip Chart Setup menu 6-2
Switch Speed Factor 4-9
System Mother Board 11-2

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I-6 •
• Model 6100TC: Index
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V

Version button 11-4

Vert Scale
Hi Res 2-14
Lo Res 2-14
Med Res 2-14
View Selected Recipe button 5-5

warranty W-1–W-2
Weight Alarm 2-17
Weight Limit 2-17

Zero Suppress Minimum 8-8

Zones display 2-6, 2-7

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Model 6100TC: Index • I-7
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I-8 •
• Model 6100TC: Index
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