Operators Manual

System # 13757
Grief Brothers
Rosemount, MN

Line 1

REVISION # 1
Prepared By:
March 28, 2014

Pat Merchant
Project Manager
Honeywell-Measurex, TAC

Operators Manual
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.

Operators Manual
Table of Contents
INTRODUCTION

RADIATION SAFETY

Safety and Emergency Instructions

SYSTEM DESCRIPTION

System Overview

Operator Consoles

NAVIGATION TOOLBARS AND COMMON DISPLAY OBJECTS

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

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All Off Sheet

13

Radiation Indicator

13

Simple Recipe Change

13

USING RECIPES

14

Recipe Displays
Recipe Synonyms
Loading a Recipe Simple Recipe Change
Recipe Change
Selecting a Recipe
"Current" and "Next" Recipes
Determining Which Recipes are in Use
Selecting the Next Recipe
Editing the Next Recipe
Start Recipe / End Recipe Buttons
Loading the Current Recipe

15
15
15
16
17
17
17
17
18
18
19

Multi Profile
Profile Setup

20
21

Data Display

23

QUALITY SUMMARY

24

ANALYSIS DISPLAYS

25

Trend Plot

25

Plot Combination
Set Selection
Time Scale
Time Range

27
27
28
29

3D Map
3D Graph
3D Map Setup

29
30
31

Profile Control Display

Initialising the Heater Duty Cycle to a Constant Value
Modifying Heater Duty Cycle Values
Turning Individual Heaters ON / OFF Control
Turning Cast Film Profile Control ON

32
34
35
36
37

Profile Control Shutdown Procedures

Turning Cast Film Profile Control OFF

38
38

Status Messages

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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.

Operators Manual

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 its 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.
2.
3.
4.

Select a group of recipes (if you have more than one group defined in your system),
Select a recipe from the list of recipes in the group,
Press OK to end the current recipe and load and start the new one.
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 its 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 recipes 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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Operators Manual
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, tabdelimited, 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 variables 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
ggrreeeenn, yyeelllloow
, and finally rreedd for the highest value. You can select which variables
w,
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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Operators Manual
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 variables data. You can change the scales maximum and minimum by using the Scale
and Autoscale buttons. The variables 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 oclock 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 oclock 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 oclock position with the green face fully visible represents a view at the level of the
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Operators Manual
sheet. The box at the 12 oclock 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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Operators Manual
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:
Set-Point
Maintenance
Button
Set-Point
Entry Button

Variable
Select
Profile
Mapped
To Heaters

Actuator
Controls

Master Control
On / Off Buttons

Heater
Number

Control
Status

Heater
Profile

Actuator
Setpoint
Entry
Button

Low Trim
entry

Actuator
Maintenance
Button

High Trim
entry

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Operators Manual
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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Operators Manual
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
button, the Heaters will initialise at the entered value.

Initialise Heater
Duty Cycle

Normally a % Load value of 10% average is used.

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Operators Manual
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.

Set Actuator Setpoint

, a numeric entry panel will appear. Enter the
Click on 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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Operators Manual
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.

ON
Click on the Loop Status
, 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 preselect 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.

OFF
Click on the Loop Status
, 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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Operators Manual

ON
Click on the Loop Status
, 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 preselect 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.
Off
button, the Cast Film TD Profile will switch onto
Click on Master Status
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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Operators Manual
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.
On
Click on Master Status
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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Operators Manual
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
at the top of the
fault by selecting the Scanner control button
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.

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