grief brothers honeywell operator manual
DESCRIPTION
Grief Brothers Honeywell Operator ManualTRANSCRIPT
Operator’s Manual
System # 13757
Grief Brothers Rosemount, MN
Line 1
REVISION # 1 Prepared By: Pat Merchant Project Manager Honeywell-Measurex, TAC March 28, 2014
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Confidentiality Statement This manual is a product of Honeywell Corporation. It is intended for use only by Honeywell and customer personnel in connection with Honeywell products. It is strictly prohibited to copy this manual or any part thereof or to transfer this manual or any part thereof to any non-Honeywell person or entity, except customer personnel for use in connection with Honeywell products. Persons employed by a third-party service company shall not have access to this manual. Notice All information and specifications contained in this manual have been carefully researched and prepared according to the best efforts of Honeywell Corporation, and are believed to be true and correct as of the time of this printing. However, due to continued efforts in product improvement, we reserve the right to make changes at any time without notice. Trademarks LabVIEW is a registered trademark of National Instruments; Microsoft, MS Windows NT are registered trademarks of Microsoft Corporation. Copyright © 1998 by Honeywell Corporation, One Results Way, Cupertino, CA 95014-5991, U.S.A. All rights reserved. No part of this publication may be reproduced or translated, stored in a database or retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Honeywell Corporation. Printed in the United States of America.
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Table of Contents
INTRODUCTION 5
RADIATION SAFETY 6
Safety and Emergency Instructions 6
SYSTEM DESCRIPTION 8
System Overview 8
Operator Consoles 8
NAVIGATION TOOLBARS AND COMMON DISPLAY OBJECTS 8
Show Status Messages: 10
Category Selection: 10
Upper Horizontal Dispatcher 12
“Contextual Help” 12
“General Help” 12
“Alarm Display” 12
“Print Screen” 12
“System Maintenance” 12
“Mini Profiles” 12
“Mini Trends” 12
“Scanner Control” 13
“All Scan” 13
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“All Off Sheet” 13
“Radiation Indicator” 13
“Simple Recipe Change” 13
USING RECIPES 14
Recipe Displays 15 Recipe Synonyms 15 Loading a Recipe – “Simple Recipe Change” 15 Recipe Change 16 Selecting a Recipe 17 "Current" and "Next" Recipes 17 Determining Which Recipes are in Use 17 Selecting the Next Recipe 17 Editing the Next Recipe 18 Start Recipe / End Recipe Buttons 18 Loading the Current Recipe 19
Multi Profile 20 Profile Setup 21
Data Display 23
QUALITY SUMMARY 24
ANALYSIS DISPLAYS 25
Trend Plot 25
Plot Combination 27 Set Selection 27 Time Scale 28 Time Range 29
3D Map 29 3D Graph 30 3D Map Setup 31
Profile Control Display 32 Initialising the Heater Duty Cycle to a Constant Value 34 Modifying Heater Duty Cycle Values 35 Turning Individual Heaters ON / OFF Control 36 Turning Cast Film Profile Control ON 37
Profile Control Shutdown Procedures 38 Turning Cast Film Profile Control OFF 38
Status Messages 39
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Introduction
The Honeywell measurement and control system is designed to provide superior measurement, display and control of your product as it is being produced. The heart of the system is the scanning sensor packages which consist of a Basis Weight Sensor measuring the Total Weight of the Product. The primary purpose of the Honeywell system is to assist the line operator in producing a higher quality product with greater efficiency. Before proceeding further with this system description, we must emphasize that this system was installed for its expected operational and quality benefits. The benefits can be realized only when the operator fully understands and uses the Honeywell system. For this reason, it is important that the operator become familiar with the equipment and the operating procedures presented in this manual. This manual does not contain maintenance and troubleshooting procedures. The functions of maintaining and troubleshooting the Honeywell equipment are the tasks of the assigned service personnel. If you encounter any problems with the Honeywell equipment, contact the plant service representative who, if necessary, will contact Honeywell Office. Important Note ! The frames shown in this manual are taken from the actual system and are intended to be used for general information and guidance on the operation of the displays. The system flexibility, which allows displays and button panels to be modified simply in the field, makes it difficult to keep the manual up to date.
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Radiation Safety
The measuring head on the scanners for this system uses a radioactive source. All personnel working in the area around the head should become familiar with a few basic common sense precautions regarding these types of devices.
Safety and Emergency Instructions
The Honeywell system has been designed with built-in safety interlocks to handle anticipated hazards. However, there are a few additional common sense rules of safety that must be followed.
All persons authorized to perform their duties with or in the vicinity of the system must read the safety procedures.
Only machine operators and appropriate staff shall operate this system.
Before approaching the sensor head, determine the status of the source shutter by observing the shutter status lights.
Avoid any direct exposure -- do not insert hands, fingers or other parts of your body in front of the beam exit window.
If the head becomes damaged or misaligned, turn the gauge power off and check shutter is closed with appropriate meter before approaching the heads. Qualified service personnel must be notified to remount the head.
Loitering around the heads should not be permitted even though the radiation field is minimal
In the event of a fire, turn the equipment off and put out the fire. Qualified service personnel must examine the equipment before returning it to service.
Unauthorized persons shall perform no test or repair on this system.
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Qualified service personnel must examine the safety interlocks operation every 6 months. A site survey must be performed whenever changes are made to the gauge operating parameters that might affect the radiation field around the sensor.
For further information, consult the yellow Honeywell Radiation Safety Manual.
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System Description
System Overview The Honeywell system consists of the following:-
1 Scanner Total Thickness Scanner and MSS Operator Interface and Pentium PC Profile Heater control Panel Link to Plant Local Area Network
Operator Consoles
Operations Consoles
The operator console provides the operator interface between the Honeywell system and the process line. The operator console in the system has a monitor, Keyboard and a mouse. The monitor provides interactive color displays. The touch screen provides the operator access to the various display functions and allows control of the process.
Navigation Toolbars and Common Display objects The common display objects surround the display screens above, below and to the right of the active display. There are three sections of the common display components: Horizontal Taskbar – on the top, it contains dedicated function and display buttons for common
operations. Refer to descriptions below.
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Navigation Taskbar – on the bottom, it contains Display Select buttons, a category selection
menu and a series of status messages for high priority alerts of system status. Refer to descriptions below.
Title Bar – at the bottom, it contains general information about the current state of the system. - Line or Process Name - Recipe State – “start” or “end” - Recipe Name – the current active recipe name - Scanner Status – “scan”, off sheet” or “off line” - Time and Date
There are many displays that are typically available from the Navigation Bar. Most are available to all of the security levels but a few are available only to the Control Engineer or Developer levels. These displays are grouped together in categories by like functionality or purpose. Some are simply for viewing measurement data while others are available for setup functions or tuning. If you have access to one of the upper levels of security, you can reconfigure the contents of the categories using the Display Setup (under the Setup category).
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Show Status Messages: If you click on the navigation taskbar in the status message area, this display will appear, showing a complete list of the active status messages. Selecting one of these in the list will show you the available help for that status message:
Category Selection: The categories of displays are:
Favorites – usually the “home” menu, contains the most commonly used displays Standard – A group of other common user functions Control – usually reserved for control display Analysis – [Engineer] for process analysis functions Scanner / Sensor – [Engineer] for calibration and sensor setup Engineering – [Engineer] for process I/O calibration and machine-direction control
tuning Setup – [Engineer] for system and recipe setup functions MIS – Management Information Summary reports and Roll Set Displays Custom - for customization on-site by system users
Category selection is accomplished by pressing the Up Arrow at the right edge of the navigation taskbar and then selecting the menu tab of the desired item:
The “Home” category is the one to which the system will default whenever it is first started up or whenever the security level is changed. This special category gives you the flexibility to include whichever displays you like – so it’s contents will vary from system to system and from user to
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user. Each of the displays in the “Home” category can also be found in one of the other category. “Home” is custom-configurable simply for convenience and ease of use.
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Upper Horizontal Dispatcher
“Contextual Help” If help is available for the selected display, this button is available to open the help system to the associated topic. This type of help is the familiar “Windows Help” style with search and index capabilities. If no help is available, the button is grayed out.
“General Help” If “floating” help is available for the selected display, this button is available to show the help window. This help will show help text for display objects over which the cursor is placed. If no help is available, the button is grayed out.
“Alarm Display” Press this button to show the Alarm Window. This is a list of active alarms that shows the priority and time of occurrence. The alarms can be sorted by time, priority or “length”. The sort order is selectable on the display.
“Print Screen” Press this button to copy the currently selected display to the selected printer (refer to Printer Setup on System Maintenance window).
“System Maintenance” Press this button to see available system maintenance and setup options. The selections will change based on user login security level. .
“Mini Profiles” Press this button to display the Mini Profile plot window. This is a moveable window that shows one selectable scan profile. This is useful if you wish to observe a profile graph while performing some other action that does not involve the trend plot display.
“Mini Trends” Press this button to display the Mini Trend Plot window. This is a moveable window that shows one selectable trend graph. This is useful if you wish to observe a trend plot while performing some other action that does not involve the trend plot display.
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“Scanner Control” Press this button to show the Scanner Control window, which is used to select a single scanner for an operation or to inspect details about a scanner if necessary.
“All Scan” Press this button to send all enabled scanners on sheet for measurements. .
“All Off Sheet” Press this button to send all scanners to the off sheet (parked) position. .
“Radiation Indicator” This will show a number for all scanners that currently have an open shutter on at least one radioactive source. This will normally appear during scanning measurements, as well as intermittently during maintenance operations (reference, sample, etc.).
“Simple Recipe Change” Press this button to show the “Simple Recipe Change display”. This display allows you to end the current running recipe, retrieve and load a new recipe and start the new recipe by pressing a single button. If you wish to change the recipe without yet starting the new recipe data accumulation or if you need to inspect or change the recipe information before loading, use the “Recipe Change” display. To use the Simple Recipe Change,
1. Select a group of recipes (if you have more than one group defined in your system), 2. Select a recipe from the list of recipes in the group, 3. Press “OK” to end the current recipe and load and start the new one. 4. Press “Cancel” to exit this display without changing recipes.
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Using Recipes In order to make correct measurements the MXProLine system must know which product you are producing. Even if you have only one line and make only one type of material, you may have several recipes set up in MXProLine. In MXProLine, a recipe is not so much the actual material you are making, as it is the specifications for that material. For example, if you are producing rolls of Tissue for different customers, you may have to make them to different specifications. MXProLine software thinks of each of these different specifications as a different recipe. The specifications in the recipe are called parameters. If you have security access of either “Supervisor” or “Engineer” and you are interested in information about recipe maintenance or setup, please see Recipe Displays.
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Recipe Displays
If you are in one of the upper levels of security (i.e. above “Operator” level), when you touch the pull-down selection list (on the Navigation Bar), you will see an additional category that is not available to the “Operator” level. This is the “Setup” option (sometimes seen as “DSR”). When you choose it, you will see several display options appear on the Navigation Bar. These displays are: Recipe Maintenance, Recipe Setup, and Recipe Change. (Recipe Change is also typically available from the “Home” category which is also accessible from the “Operator” security level.)
Recipe Synonyms There are various terms that may be used interchangeably with “Recipe”. These include “Recipes”, and "Codes". Any one of these may be used and will appear in the software text. For simplicity, we will use "Recipe" throughout this documentation.
Loading a Recipe – “Simple Recipe Change”
Press or click on the “Select Recipe” button on the Horizontal Task Bar. From the list that appears, press or click on the recipe that you want to load. If you have your recipes in groups then you must first select the correct group. Once a recipe has been selected, press the OK button. The recipe chosen will become the current recipe. If you change your mind, press the “Cancel” button instead of OK. For more details, refer to Simple Recipe Change. Alternately, you can load a new “current” recipe from the Recipe Change window:
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Recipe Change
All the typical tasks that you will perform with recipes can be found by pressing the “Recipe Change” button found on the Navigation Bar (typically within the “Home” category, as well as within the “Setup” category available to upper levels of security). Once pressed, the following window will appear on your display. (Your particular display may use the term “Recipe”, “Product”, “Code or some other synonym.)
Recipe-dependent target parameters for the current recipe are displayed in the “Current Setpoint” column. The actual values are displayed in the “Process” column. The target parameters for the next recipe to be run are displayed in the “Next Setpoint” column. This column allows you to enter all required setup information for the next product during the run of the current product. Changes made to the values within this display are only temporary – while the recipe is in the “next” or “current” position – unless you press the “Save Recipe” button.
The column on the far right displays all of the recipes that have already been established. This display is not for creating new recipes. To create new recipes (or to make permanent edits to a recipe) you must use the Recipe Maintenance Display. Also, during the recipe creation process, you may choose to group your recipes based upon fabric type, compound, or some other parameter. If you have done this, you will have a pull-down list above the recipe names from which you can choose the group of recipes with which you wish to work. See Recipe Parameters for an explanation of some of the more commonly used recipe parameters.
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Selecting a Recipe As you are aware, it is very important to match the product your are making with the product MXProLine thinks it is measuring. One of the jobs of an operator is to let MXProLine know each time you want to use a different recipe.
"Current" and "Next" Recipes MXProLine allows you to select which recipe it will use currently and which it will use next. The advantage to having a “Next Recipe” is that sometimes you will want to make slight (temporary) adjustments to a recipe before using it. You do this by editing the next recipe ahead of time. Then, it will be ready to go when you start making that product.
Determining Which Recipes are in Use
To determine which recipes are currently being used, simply view the Recipe Change display (by pressing the “Recipe Change” button). The top line of this window (like many of the display windows) provides you with the name of the “current” recipe. This information may also be found by looking at the top of the second column, under the “Current Target” heading. The name of the “next” recipe can be found at the top of the fourth column under the heading “Next Target”.
Selecting the Next Recipe
To select the “next” recipe that you will use: 1. If the recipe change window (see Recipe Change) is not open, touch the “Recipe
Change” button on the Navigation Bar. 2. From the list on the far right of the recipe change window, select (by touching) the
name of the recipe you want to use “next”. (The selected recipe will become inverse highlighted and it’s name will also appear at the top of the column under the heading “Selected Recipe”.)
3. Press the “Retrieve Recipe” button at the bottom of the display. This will load the
selected recipe into the “Next” position. All of the recipe parameters, as they are set for this recipe, will appear in the “Next Target” column.
You have now set up the next recipe to run. The system, however, is still using the data in the “Current Target” column. You can select the next recipe to run at any time without affecting the system.
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Editing the Next Recipe
Once you have retrieved a recipe into the “Next Target” column, you may make temporary edits to any of the parameters. The edits you make will only be in effect when you load this recipe to the “current” position. Once a different recipe is retrieved and then made current, the edits you make will not be saved. To edit any parameter, simply touch in the box of the parameter which you wish to edit. An appropriate window, either an alphanumeric keyboard, a numeric keyboard, or a true/false window will open. Enter the accurate information and press the “Enter” key. The changes you make will be reflected in the recipe change window (based upon your security level).
Note that only those items whose text appears in green may be edited. Some items appear only on this display for informational purposes only. The text on these items will be yellow. To edit these items you must use on of the upper levels of security and make your changes through the Recipe Maintenance Display. If you wish to permanently save any changes that you have made, you must press the “Save Recipe” button – otherwise the changes will only be temporary, while the recipe is in either the “current” or “next” positions.
Start Recipe / End Recipe Buttons At the bottom left of the recipe change window, you will find two buttons. One is labeled “Start Recipe” and the other “End Recipe” (or something similar, i.e., “Start Recipe” / “End Recipe”). These two buttons allow you to control when you are and when you are not collecting information about your product that you will use in statistical and management information summary (MIS) reports. If you press the “End Recipe” button then, although the scanner may still be collecting data about your product (which can be viewed through the various profile displays), this information will not be included in the statistical information. You would press the “End Recipe” button to end the current recipe MIS reports and/or when you are going to load a new recipe to begin measuring a different material. If you know that the material that is currently being scanned is going to be scrap, you would have the “End Recipe” button pressed. If you press the “Start Recipe” button then any information that the scanner collects about your process will be used in the statistical and MIS reports. You would press the “Start Recipe” button when actual product is being produced.
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Note that you can only change the current recipe (“Load Recipe”) when you are not collecting MIS report information – when you are in the “End Recipe” mode. The current mode (either Start Recipe or End Recipe) can be seen at the Bottom of this window as well as all of the other display windows, so you can always tell what mode you are in.
Loading the Current Recipe
Loading the current recipe means that you are going to tell MXProLine to begin using a new recipe. To select a new current recipe:
1. If the recipe change window is not open, touch the “Recipe Change” button on the Navigation Bar.
2. If you have not already done so, follow the steps in “Selecting the Next Recipe”.
3. Make any necessary edits to the “next” recipe’s parameters.
4. If you are collecting data for statistical purposes and MIS reports, press the “End Recipe” button to stop the collection of that data and to generate reports for the product that was being measured.
5. When the new material to be measured (that matches the recipe in the “next” position reaches the calender, press the “Load Recipe” button. This will cause all of the information (including any parameters that you edited) about this new material to be loaded into the MXProLine system. (The “Next Target” column will transfer into the “Current Target” column.)
6. Once you are no longer making scrap material and you are ready to start collect “report” information about the product you are currently making, press the “Start Recipe” button. The display message will change to “Start Recipe” and accumulations for this product will start.
Recipe Parameters
The basic parameters for the recipes are found on the Recipe Selection window, which appears when you press the “Recipe Change” button on the Navigation Bar. This display is accessible to everyone, regardless of security level. Additional recipe tables and parameters are accessible to the upper levels of security through the Recipe Maintenance Display and the Product Tuning display. Since the parameters that will be included for a recipe is configurable through the Recipe Setup, the parameters you will see will vary from system to system.
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Multi Profile This display shows up to three profiles (in four sets of different combinations) of the primary scanning parameters, typically thickness. When you press the “Multi Profile” button on the Navigation Bar, the following display appears:
The profile display allows three profiles to be viewed on one display. Each profile shows the CD variations for the selected variable. The variable can be selected by pressing the button showing the name of the variable at the top-left of each profile. When you select the variable, you may select the vertical axis representation. The vertical axis may show the value of the variable, the value relative to the Setpoint, or the value relative to the Average. The red lines on the graph are the limit lines used in the Recipe. By pressing and holding your finger on the yellow cursor (yellow vertical line on each graph) and moving left or right you can move the cursor over the profile. The readings at the cursor position are updated at the top right of the graph. This shows the actual slice position and variable value. The white vertical cursor line indicates the position of the scanner as it scans across the sheet. On the right side of each graph you will find the Spread, Average, Maximum, Minimum, and Units values for the variable. If there is an alarm condition, the text of the value will change color to red for a maximum that exceeds the upper limit or for a minimum that exceeds a lower limit. The “Set 1” select button, when pressed, shows a pull-down list for selecting one of twelve groups of profiles, “Set 1”, “Set 2”, “Set 3”, or “Set 4”, thereby allowing up to 48 different
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profiles to be plotted simultaneously. These sets may be renamed in the Profiles Setup (accessible only from the upper security levels.) If you are working from either of the upper security levels, you will have access to a Setup button found in the lower right corner.
Profile Setup If you have access to either of the upper security levels, you will have the “Setup” button displayed on your Profiles display. Once pressed, the following Profile Setup screen will be displayed.
From this display you can completely configure the colors, line thickness, units, and text that will be used on the Profile display. To edit a color simply touch in the colored block area. For each, you are given a standard set of twelve colors from which to choose. There are six different line sizes, which you may choose by either touching on the block containing the line and then choosing the appropriate thickness, or by using the up/down arrows to increment the line size number. (“1” is the thinnest and “6” is the thickest.) For the plotted variable you may choose to either have “Fill” or “No Fill”. This can be toggled using the up/down arrows or by selecting the box that illustrates the fill/no fill condition and choosing the desired one. The standard units from which you may choose are: bins mm micron cm
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mil inch (Your exact selection may vary.) These are selected from the pull-down list that appears when you touch on the box containing the current units name. To edit the “Set” names you must have access to a hardware keyboard. Touch or click in the area where the name of the set is displayed. Delete the existing “Set” name and type in the name you would like to appear with the set of profiles you are displaying. Once you have made all the edits to this screen that you desire, press the “OK” button. If you do not want to save any changes that you have made, press the “Cancel” button.
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Data Display
The Data Display is setup for showing the Sheet width and the Trim Width. You can change the Trim Width on this display. You can also view and change the Calibration Value for Thickness. Increasing the number will make the Thickness larger, Decreasing the number will make the sheet thickness smaller.
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Quality Summary When you select the “Quality Summary” button on the Navigation Bar, the following screen is displayed:
This screen enables you to view a great deal of data from the scanning sensors in one location. To change the data viewed from the Quality Summary display, refer to the Measurement Setup display on the Scanner/Sensor Menu.
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Analysis Displays The typical list of displays available within this set are given below – although the items that you see may vary since this is custom-configurable within each individual system.
Trend Plot The Trend Plot display enables you to trend any scalar (non-dimensional) or array element variable in the system. Up to four variables can be displayed at one time. Variables can be shown separately or combined in one graph When you press the “Trend Plot” button from the Navigation Bar, the following display appears:
Data trending can be either scalar type or array type. Forty buffers are used for scalar data trending and five buffers for array trending. (The trending buffer size is set to be 1024. This number can be changed by someone with security access greater than “Operator”.) The array trending buffer holds the last 50 scans. Data trending is based upon trend events. There are a number of trend events that may be available for trending within these graphs. Each of these events is continuously trended within the database, whether or not it is being displayed. Up to four trend events/variables can be trended on each display. And you can configure four separate sets of trends. Each of the four plots within a set will be differentiated by the color on each graph. Variables can be trended at a rate or at an event. Rates and events can be shown on the same display. The display has a number of Sets to allow for fast switching between different setups. This effectively creates a number of different trend plot displays, each with their own scaling, time base, and selected variables.
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You can choose what information you would like to see displayed in which graph by selecting the item from the pull-down list. (Correlation can be determined by colors as well as location. The first button adjusts the top graph. The second button adjusts the second graph down, etc.) Once you press on the pull-down list, you can scroll between your options (listed above) by moving your finger up and down through the list. (If you can not see the entire list, move to the bottom of the list, the other options will scroll up.) Once the item you want to trend is inverse highlighted, click on the left mouse button to select it. The graphs can be adjusted by using the Scale and Autoscale. On the right side of each graph the maximum and minimum values for the graph are shown. You can also set the Time Scale of the display, can pause the display or move forward and backward in the stored buffer. An optional cursor shows the value of an “index” variable that was trended at the same time. The index variable is typically the distance in the roll. At any time, the shown trend data can be saved to a file in a spreadsheet readable, tab-delimited, format. There is also a Mini Trend window (available from the Vertical Taskbar) that can be brought up at any time to show just one trended variable. If you have access to the higher levels of security, you will have the ability to adjust the variable options shown on this display. To do so, you must work within the Trend Plot Setup which contains a hierarchical database browser that allows for the selection of any variable in the system.
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Plot Combination
Once you have determined which four variables you want to trend, you have the ability to determine if you want them to be trended individually or if you want them to be trended on the same plot as one or more other variables in this set. By pressing on the “plot combination” (the button next to the “Step” / “Line” button in the bottom right corner of the trend display), you will see a pop-up menu which allows selection of different combinations of plots. 1/2/3/4 – If you select this plot combination, each of the four variables (in this set) will be
displayed as individual graphs. (This is the plot combination that the system will default to and which is seen in the graphic on the preceding page.)
1-2/3/4 – This plot combination puts the variables in graphs “1” and “2” (the top two
graphs) into the same graph – plotted against one another. Graphs “3” and “4” remain plotted separately.
1/2/3-4 – This plot combination has graphs “1” and “2” plotted individually and variables
“3” and “4” plotted together on the same graph. 1-2-3-4 – This plot combination creates one large graph which has all four variables
plotted against one another. Regardless of the plot combination for this set, the colors – as reflected in the text color on the button bar of the variables – allow you to differentiate between the variables being displayed.
Set Selection The “Set # ▼” button opens a pop-up list which allows selection between “Set 1”, “Set 2”, “Set 3” or “Set 4”. Each of these sets can be configured with the four different variables (as described above), thereby allowing up to sixteen different trends to be plotted simultaneously. Within each set you may also choose to view different plot combinations – as described in the section above.
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Time Scale
The time scale on the trend plots is adjustable and you can scroll back in time.
Freeze Plot. This button will freeze the trend plot in time. Once pressed, the button changes to red to indicate that the trends are frozen in time. In this mode, you can still use the scroll back and forward buttons to examine the trend history. To un-freeze the display, press the button again.
Fast Reverse. Allows you to scroll rapidly backward along the time axis on the trend plot.
Slow Reverse. Allows you to scroll slowly backward along the time axis on the trend plot.
Slow Forward. Allows you to scroll slowly forward along the time axis on the trend plot.
Fast Forward. Allows you to scroll rapidly forward along the time axis on the trend plot.
Return. Pressing this button immediately brings you back to the current time display.
Whenever you move away from the current time period, a status message is posted, in red, to warn that you are not viewing current data.
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Time Range The time range can be changed by pressing the button labeled “Display range in minutes”. This will cause a numeric keypad to open. Enter the time range you want to display (in minutes) and press the “Enter” button. The current time range in displayed alongside the “Display range in minutes” button.
3D Map From the Analysis set of displays, pressing the “3D Map” button will open the following display:
This display shows a three-dimensional (3D) view of any array variable in the system. The three dimensions show the variable’s value plotted in both the CD and MD directions, giving an overview of that value over the entire sheet. The 3D Map shows the whole trended array buffer at the same time. It does that by creating a 3D display of all the rows and columns of the trended arrays where each row corresponds to one array and each column corresponds to the same index value in each of the buffered arrays. For each point in the display, color represents the value: blue for the lowest value, then gggrrreeeeeennn, yyyeeelll lllooowww, , and finally rrreeeddd for the highest value. You can select which variables to show through the drop-down list. Each variable can be given its own scale or can be scaled automatically. The data in the 3D display can be sized, rotated, and scaled in all directions. For large arrays where too many lines would be shown, the arrays can be sampled every N points. The display updates whenever new data becomes available or the display can be paused.
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The normal use for this display is with the “end of scan” measurement array. In that case, each row the represents one scan and each column represents the measurement over time at a fixed scan position.
If you are in one of the upper levels of security, you have the ability to configure the 3D Map Display through the “Setup” button in the bottom right corner of this display.
3D Graph The graph shows a three-dimensional (3D) view of the selected variable. The Z-axis (yellow) is the value of the variable. The X-axis (red) os the cross-direction (CD) and the Y-axis (blue) is the machine directions (MD).
Maximums and Minimums The four numbers at the lower right corner of the display show the current maximum (upper) and minimum (lower) values of the Y-axis scale and the maximum and minimum of the variable’s data. You can change the scale’s maximum and minimum by using the Scale and Autoscale buttons. The variable’s maximum and minimum are taken from the measured data and cannot be changed.
If you press the View Button just to the right of the auto scale button, you will be able to change the relative view of the Graph.
Overall Size Move the green slider labelled “Size” to the left to enlarge the 3D plot equally in all directions. Move it to the right to make the 3D plot smaller. The graph frame does not change size, only the image within the graph.
Rotation To rotate the 3D plot clockwise or counter-clockwise, turn the Rotation knob in either direction. The small boxes around the knob give you an indication of the viewing angle. For example, the box at the 12 o’clock position with the green face fully visible represents a view in the machine direction, from the front of the sheet, with the cross-direction axis horizontal and the machine-direction axis straight back. The box at the 3 o’clock position with the green face on the left represents a view in the cross direction, from the side of the sheet, with the machine-direction axis horizontal and the cross-direction axis straight back.
Elevation To rotate the 3D plot up or down, turn the Elevation knob in either direction. The small boxes around the knob give you an indication of the viewing angle. For example, the box at the 3 o’clock position with the green face fully visible represents a view at the level of the
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sheet. The box at the 12 o’clock position with the green face on the top represents a view from above the sheet.
Ok Button Press the Ok button to make your settings for size or viewing angles take effect on the 3D graph.
Number of Arrays to Get One array of data for a variable is the set of measurements from one scan in the cross direction, as stored in the history buffer. To graph all the arrays in the history buffer, leave this value set to –1. To graph a certain number of arrays, click on this value to open a numeric keypad and enter the desired number. For example, entering 25 will graph the selected variable from the most recent 25 scans.
Decimation Factor Decimating an array means reducing the number of data points in it by replacing every N measurements by their average. The decimation factor is the number of points (N) to average. The default decimation factor is 10, meaning every 10 points in the array will be replaced one point, their average. Decimation is done only for the purposes of faster graphing. The original array of measurements is still stored in the history buffer and is not changed. Setting the decimation factor very high will average out significant changes in the data, giving the plot too little resolution. However, a reasonable decimation factor will make the graph faster without losing any significant detail.
Allow New Data When enabled, causes new data to be graphed whenever the “index” variable in the array trend buffer changes.
3D Map Setup
The 3D Map and the Color Map displays use the same setup dialog (Array Trending Setup). This setup dialog is used to select an array variable from the RTDR.
See Color_Map_Setup to view this setup display and click on the “hotspots” within that graphic for more information. Or see the Variable Setup for a general description of the various parts of the setup display.
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Profile Control Display
The Profile Control display provides the operator with the status of the profile control as well as the profile control process outputs. The top half of the display shows the profile of the controlled variable along with the target profile. The bottom half of the display presents the status of the process output (typically duty cycling).
Profile
Control
When you press the Profile Control button the following panel appears:
Profile Mapped To Heaters
Heater Profile
Set-Point Maintenance Button
Actuator MaintenanceButton
Actuator Controls
Heater Number
Master Control On / Off Buttons
Control Status
Variable Select
Actuator Setpoint Entry Button
Set-Point Entry Button
Low Trim entry
High Trim entry
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The Profile Control display is used to monitor the status of the Supervisory control, the DDC loop, and individual heaters. It can also be used to monitor various significant parameters such as the value of each individual heater; the average of the heaters; the average, maximum, minimum and spread of the mapped profile; and the thickness setpoints
The Profile Control Display is used to perform the following tasks: • Turn Individual heater Control ON / OFF. • Initialize the Heater Duty Cycle (HDC) to a constant value. • Modify the HDC values. • Turn the CD Supervisory Thickness Controls ON / OFF. The following subsections explain how the Profile Control Display can be used to perform the tasks listed above.
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Initialising the Heater Duty Cycle to a Constant Value
The Die Heaters will switch on control and the bargraph will be displayed in GREEN if the communication link between and Honeywell and the Heaters is established, the cut back heaters signal is not active otherwise the heaters will be shown in PURPLE. The Heater Duty Cycle can be initialised to a constant value by entering an appropriate value as follows:
Click on Actuator Maintenance button and the panel below will appear:
Enter the value you wish the heaters to initialise at and click on
Initialise Heater Duty Cycle
button, the Heaters will initialise at the entered value. Normally a % Load value of 10% average is used.
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Modifying Heater Duty Cycle Values
Individual HDC values can also be modified by completing the following basic steps. Enter the desired heater number in the HEATER field, or click on the
<<
<
>
>>
Fast Decrement Slow Decrement Slow Increment Fast Increment as necessary to select the desired heater. The cursor line on both graphs moves to highlight the position.
Click on the Set Actuator Setpoint , a numeric entry panel will appear. Enter the desired heater % setpoint between 0 and 100 % and press Enter. The Heater bar graph changes to the entered value for the selected heater location.
If the operator enters a new value for an heater, the system assumes the heater should no longer be supervised by the TD control. Therefore, if the selected heater is in CASCADE, it is changed to COMPUTER, and the heater cursor is incremented to the next heater.
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The heater can be put back into CASCADE by completing the following basic steps. Enter the desired heater number in the HEATER field, or click on the
<<
<
>
>>
Fast Decrement Slow Decrement Slow Increment Fast Increment as necessary to select the desired heater. The cursor line on both graphs moves to highlight the position.
Click on the Loop Status ON , the heater will switch back to CASCADE control since it is now being controlled by the Supervisory control loop. The bargraph colour will change from GREEN to YELLOW.
Note that the cursor position is auto-incremented to make it easier for an operator to pre-select a number of contiguous heaters.
Turning Individual Heaters ON / OFF Control
Individual Heaters can be set to COMPUTER or CASCADE by completing the following basic steps: Enter the desired heater number in the HEATER field, or click on the
<<
<
>
>>
Fast Decrement Slow Decrement Slow Increment Fast Increment as necessary to select the desired heater. The cursor line on both graphs moves to highlight the position.
Click on the Loop Status OFF , the heater will switch from CASCADE to COMPUTER control and the heater colour on the bargraph will change from YELLOW to GREEN. In this mode the Operator can set up the heater pattern desired manually.
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Click on the Loop Status ON , the heater will switch back to CASCADE control since it is now being controlled by the Supervisory control loop. The bargraph colour will change from GREEN to YELLOW.
Note that the cursor position is auto-incremented to make it easier for an operator to pre-select a number of contiguous heaters. The above feature will only work if the Cast Film Profile control is switched on.
Turning Cast Film Profile Control ON Follow the steps below to enable the Cast Film TD Profile control: Check that the correct CODE NUMBER as been entered in the system. This is
important since the standard setpoints and also calibration for the Thickness gauge are loaded at code load time
There are several conditions that must be satisfied before the Cast Film Thickness control can be switched on:
Die Heaters must be on Computer. TD Control Ready Contact Input must be made. Cast Film Scanner must be scanning and have good Thickness reading.
Click on the Variable Field and highlight Cast Profile Control, check that the status is
READY, this status is linked to the interlock input “TD Control Ready”.
Click on Master Status Off button, the Cast Film TD Profile will switch onto control, the status message will switch to COMPUTER and the GREEN heater bargraph will change to YELLOW since it is now being supervised by the Cast Film TD
Profile control. The above button will change to On .
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Profile Control Shutdown Procedures
Turning Cast Film Profile Control OFF Follow the steps below to switch off the Cast Film Profile control: Click on the Variable Field and highlight Cast Film Profile, this will update the top
display with the profile for the Cast Film, check that the status is COMPUTER.
Click on Master Status On button, the Cast Film TD Profile will switch OFF control, the status message will switch to READY .
The above button will change to Off .
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Status Messages
Datalogger is turned on and collecting Data.
Scanner 1 is in the Parked position
The scanner has lost Power or Communications. Contact Maintenance.
Profile Control has a mapping error. If you have just started scanning this error might occur for a short period of time. If this error is on all the time there is a problem with the mapping. Contact maintenance personel.
The CDPLC has lost communications. Call Maintenance Personel.
The Nuclear gauge on the Total Weight Scanner had a Nuclear Safety Fault. To correct the problem try clearing the Nuclear Safety
fault by selecting the Scanner control button at the top of the Display, Select the Cast Weight Scanner from the Pull Down Menu at the Top of the Dialog Box, then press the Restart Mss to Clear Sensor Safety Fault Button at the bottom of the Dialog Box, Close the Dialog box and go to the Scanner and Press the Scan button on the end of the Scanner. If this does not clear the problem, Call Maintenance.
The Scanner is in Local Off Sheet. You must go to the scanner and press the scan button at the Scanner.