PowerFlow Paper Solutions

ABB DIU / Accuray Integration

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System Overview

ABB (formerly Accuray and later ABB Automation) provides QCS systems widely used in paper mills worldwide. The Dilution Control System integrates with ABB QCS via the Digital Interface Unit (DIU) or direct Modbus TCP connection.

ABB History

ABB acquired Accuray in 1990. Systems may still carry the Accuray brand, particularly older AC6 and AC6000 installations. Configuration is similar for both.

Supported Models

System Interface Notes
ABB Industrial IT 800xA Modbus TCP, OPC Modern system, recommended interface: Modbus TCP
ABB QCS450 Modbus TCP Compact QCS solution
Accuray AC6000 DIU, Modbus TCP Widely installed, DIU preferred
Accuray AC6 DIU Legacy system, requires DIU
AccuRay 1190 DIU, OPC Earlier platform

DIU Interface Setup

The Digital Interface Unit (DIU) provides direct access to profile data from ABB/Accuray systems.

DIU Network Configuration

  1. Physical Connection

    Connect the control PC to the DIU via Ethernet:

    • Use a dedicated Ethernet port on the control PC
    • Connect to the DIU's Ethernet interface
    • Use CAT5e or better cabling

  2. IP Configuration

    Configure the control PC's network adapter:

    DIU IP Address Obtain from ABB system configuration
    Control PC IP Same subnet as DIU (e.g., 192.168.10.x)
    Subnet Mask 255.255.255.0 (typical)

  3. Verify Connectivity

    ping [DIU_IP_ADDRESS]

DIU Configuration in ABB System

The DIU must be configured on the ABB system to export profile data. Contact your ABB service representative to configure:

  • Profile data output (basis weight CD profile)
  • Profile array size (number of databoxes)
  • Update rate (scan interval)
  • Data format (floating point recommended)

Modbus Configuration

For systems supporting Modbus TCP (AC6000, QCS450, 800xA), configure the connection as follows:

Dilution Control Settings

  1. Open Settings > Scanner Configuration
  2. Select Scanner Type: ABB / Accuray
  3. Select Interface: Modbus TCP
  4. Configure connection parameters:

Connection Settings

IP Address [DIU or QCS IP] From ABB configuration
Port 502 Standard Modbus TCP port
Slave ID 1 Default, may vary
Timeout 3000 ms Connection timeout

Profile Settings

Number of Databoxes 200 Match ABB configuration
Profile Register 1000 Starting register for profile array
Data Type Float 32-bit IEEE 754 floating point
Byte Order Big Endian ABB default
Word Order High-Low ABB default

Register Map

Typical Modbus register map for ABB QCS profile data:

Register Count Type Description
1000 400 Float (2 regs) Basis Weight Profile (200 points)
1400 2 Float Profile Average (g/m²)
1402 2 Float Profile 2-Sigma
1404 1 Int16 Scanner Status (0=OK, 1=Error)
1405 1 Int16 Profile Valid Flag (1=Valid)
1406 1 Int16 Left Edge Databox
1407 1 Int16 Right Edge Databox
Register Addresses May Vary

The register addresses shown are typical examples. Actual addresses depend on the ABB system configuration. Consult your ABB documentation or service representative for exact register mappings.

Testing & Verification

After configuration, verify the connection is working correctly:

  1. Test Connection

    Click Test Connection in the Scanner Configuration dialog. Expected result: "Connection successful"

  2. Verify Profile Reception

    Open the Profile Display panel. You should see:

    • Live profile data updating with each scan
    • Profile shape matching the paper web
    • Correct number of databoxes

  3. Check Profile Values

    Verify the profile values are reasonable:

    • Values should be in expected basis weight range (e.g., 40-400 g/m²)
    • Profile average should match QCS display
    • Edge detection should identify web edges correctly

  4. Verify Zone Mapping

    Create a deliberate profile disturbance (if safe to do so) and verify:

    • The disturbance appears in the correct zone
    • Mapping direction is correct (front-side/back-side)

Troubleshooting

Connection Issues

Problem Possible Cause Solution
Connection timeout Network routing issue Verify IP addresses, check routing, confirm DIU is powered
Connection refused Wrong port or Modbus not enabled Confirm Modbus TCP is enabled in DIU/QCS settings
No data received Wrong register addresses Verify register map with ABB documentation
Garbled data Byte order mismatch Toggle Big/Little Endian and Word Order settings

Profile Data Issues

Problem Possible Cause Solution
Profile all zeros Scanner parked or profile not enabled Check scanner status in ABB system
Profile inverted Mapping direction wrong Toggle mapping direction in configuration
Profile offset Mapping offsets incorrect Adjust front/back side offsets
Profile not updating Stale data or communication error Check Profile Valid flag and timestamp
ABB Support

For complex integration issues, contact ABB technical support with your system model and software version. They can provide specific register maps and configuration guidance.