Quality Control QCS800xA

Operation User's Guide

System Version 5.0 SP3
About This Book General

NOTICE
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this
document.

In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of
any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or
consequential damages arising from use of any software or hardware described in this document.

This document and parts thereof must not be reproduced or copied without written permission from
ABB, and the contents thereof must not be imparted to a third party nor used for any unauthorized
purpose.

The software or hardware described in this document is furnished under a license and may be used,
copied, or disclosed only in accordance with the terms of such license.

This product meets the requirements specified in EMC Directive 89/336/EEC and in Low Voltage
Directive 72/23/EEC.

Copyright  2009 ABB

All rights reserved.

Release: December 2009

Document Number: 3BUS212640

3BUS212640 i
General About This Book

TRADEMARKS
Registrations and trademarks used in this document include:

 Windows is a registered trademark of Microsoft Corporation.

 Acrobat Reader is a registered trademark of Adobe Systems Inc.

 IndustrialIT is a trademark of ABB.

ii 3BUS212640
About This Book General

About This Book

General
This book describes the operation of Quality Control QCS800xA. Topics included in this book
include:

 Operator Login

 Quality Control QCS800xA Workplace Operation

 Display Navigation

 Faceplate Operation

 Alarm Descriptions

 Trends

 Hardcopy Reports

 Quality Control QCS800xA Process Display Usage

Intended User
This book is for process operators and other users of the Quality Control QCS800xA product.

Use of Warning, Caution, Information, and Tip Icons

This publication includes Warning, Caution, and Information where appropriate to point out safety
related or other important information. It also includes Tip to point out useful hints to the reader. The
corresponding symbols should be interpreted as follows:

Electrical warning icon indicates the presence of a hazard, which could result in electrical shock.

Warning icon indicates the presence of a hazard, which could result in personal injury.

Caution icon indicates important information or warning related to the concept discussed in the text. It
might indicate the presence of a hazard, which could result incorruption of software or damage to
equipment/property.

Information icon alerts the reader to pertinent facts and conditions.

Tip icon indicates advice on, for example, how to design your project or how to use a certain function.

Although Warning hazards are related to personal injury, and Caution hazards are associated with
equipment or property damage, it should be understood that operation of damaged equipment could,
under certain operational conditions, result in degraded process performance leading to personal
injury or death. Therefore, comply fully with all Warning and Caution notices.

3BUS212640 iii
Document Conventions About This Book

Document Conventions
The following conventions are used for the presentation of material:

The words in names of screen elements (for example, the title in the title bar of a window, the label
for a field of a dialog box) are initially capitalized.

Capital letters are used for the name of a keyboard key if it is labeled on the keyboard. For example,
press the “ENTER” key.

Lowercase letters are used for the name of a keyboard key that is not labeled on the keyboard. For
example, the “space bar”, “comma” key, and so on.

Press “CTRL+C” indicates that you must hold down the “CTRL” key while pressing the “C” key. In
this case, “CTRL+C” copies the selected object.

Press “ESC E C” indicates that you press and release each key in sequence. In this case, “ESC E C”
copies the selected object.

The names of push and toggle buttons are boldfaced. For example, click “OK”.

The names of menus and menu items are boldfaced. For example, the “File Menu”.

The following convention is used for menu operations: “MenuName > MenuItem >
CascadedMenuItem”. For example: select “File > New > Type”.

The “Start menu” name always refers to the “Start” menu on the Windows Task Bar.

System prompts or messages are shown in the Courier font. For example, if the user enters a value out
of range, the system might reply with the following message:

Entered value is not valid. The value must be 0 to 30.

User responses or inputs are shown in the boldfaced Courier font. For example, a user may be
required to enter the string “TIC132” in a field. The string is shown as follows in the procedure:

TIC132

Variables are shown using lowercase letters.

sequence name

iv 3BUS212640
About This Book Terminology

Terminology
The following is a list of terms associated with the Operation User's Guide that you should be
familiar with. The list contains terms and abbreviations that are unique to ABB or have a usage or
definition that is different from standard industry usage.

Term Description

ActiveX Microsoft standard for integration of user interface components, based on

definition of software interfaces.

Aspect An aspect is a description of some properties of a real world entity. The

properties described could be mechanical layout, how the object is
controlled, a live video image, name of the object etc. In the Aspect
Integrator Platform is an aspect residing in an Aspect Object. Some
examples are circuit diagram, process display, and control logic.

Aspect Objects A computer representation of a real world entity like a pump, a valve, an
order or a virtual object like a service. This computer representation is
implemented by the Aspect Integrator Platform. An Aspect Object works
like an information container for its aspects.

Aspect Server PC server that hosts the various QCS Object/Aspects and serves as the
primary gateway to external aspects systems.

Connectivity PC server that hosts MeasureIT and ControlIT applications and serves as
Server the primary “connection” between the QCS LAN and the outside world.

IndustrialIT IndustrialIT is ABB’s solution, which creates a business enterprise where

your plant automation, asset optimization, and collaborative business
systems are seamlessly linked in real time.

Quality Control ABB’s Quality Control Solution using the Industrial IT System 800xA
QCS800xA platform and AC800M controllers.

Node A computer communicating on a network e.g. the Internet, Plant, Control

or IO network. Each node typically has a unique node address with a
format depending on the network it is connected to.

OPC An application programming interface defined by the OPC Foundation.

The standard defines how to access large amounts of real-time data
between applications. The OPC standard interface is used between
automation/control applications, field system/devices and business/office
applications.

OperateIT The name for the collection of products for daily operation and supervision
of an automated process.

Plant Explorer An application that is used to create, delete and organize Aspect Objects
and Aspects within the Aspect Integrator Platform. The plant explorer
organizes the Aspect Objects in structures of the plant.

Process Portal A Product containing functionality for efficient control and supervision of an
automated process. Key functions are presentation of process graphics,
process dialogs and presentation of alarms and trends.

Property A data field on an aspect on Aspect Object that can be accessed through
OPC using the standard Aspect Object reference syntax. A data field on

3BUS212640 v
 About This Book

Term Description

an ActiveX control accessible from the Visual Basic editor.

Structure A hierarchical tree organization of Aspect Objects. Each structure is used

to define a certain kind of relation between Aspect Objects. The functional
structure for example, defines how a function can be divided into sub
functions, the location structure defines how different objects are executed
by tasks, controllers etc. An Aspect Object can be located in several
structures, for example both in a functional structure and in a location
structure.

View An Aspect can have several ways to be presented depending on the task
performed, like viewing or configuration. Each presentation form is called a
view.

vi 3BUS212640
About This Book Abbreviations

Abbreviations
Term Description

DVD Digital Versatile Disk

CPU Central Processing Unit

DHCP Dynamic Host Configuration Protocol

DNS Domain Name Server

DPI Dots per inch

GB GB Gigabyte

IP address Internet Protocol address

MB Megabyte

Mbps Megabits per second

MHz Megahertz

NetBIOS Network Basic Input Output System

NTFS NT File System

OEM Original Equipment Manufacturing

OPC OLE for Process Control

OLE Object Linking and Embedding

OS Operating System

PC Personal Computer

RAM Random Access Memory

SCSI Small Computer System Interface

SVGA Super Video Graphics Adapter

TCP/IP Transmission Control Protocol/Internet Protocol

WINS Windows Internet Name Services

3BUS212640 vii
Related Documentation About This Book

Related Documentation
Category Title Description

800xA System Industrial IT, 800xA System 3BSE034679

Installation Version 5.0 SP2,
Automated Installation

Industrial IT, 800xA System 3BSE034678

Version 5.0 SP2,
Installation

Industrial IT, 800xA System 3BSE036342

Version 5.0 SP2, Upgrade
and Installation

Industrial IT, 800xA System 3BUA000156

Version 5.0 SP2, Post
Installation Setup

800xA System Industrial IT, 800xA 3BSE037410

Administration System, Administration and
Security

800xA Industrial IT, 800xA 3BSE034463

Software System, Automation
System Network Design
and Configuration

Industrial IT, 800xA 3BSE038018

System, System Guide

Industrial IT, 800xA 3BSE038357

System, Release Notes

The above Industrial IT System 800xA documentation is available on the respective installation CD’s.

viii 3BUS212640
About This Book Quality Control Documentation

Quality Control Documentation

Category Title Description

Quality Control Quality Control QCS800xA This book describes the release notes
QCS800xA Release Notes associated with Quality Control QCS800xA and
Installation includes any last minute updates, hardware
requirements etc.

Quality Control QCS800xA This book describes how you install the Quality
Installation Guide Control QCS800xA

Quality Control QCS800xA This book describes how you upgrade from
Upgrade Guide Industrial IT Quality Control 4.1 to Quality
Control QCS800xA 5.0 SP3

Quality Control QCS800xA This book describes how you configure the
Administrators Guide Quality Control QCS800xA application and how
you then perform maintenance.

Quality Control QCS800xA This book describes how an operator can

Operation User Guide control and operate Quality Control QCS800xA.

Quality Control QCS800xA This book is a guide for plant engineering

Engineering Methods functions related to Quality Control QCS800xA.
Reference

Quality Control QCS800xA This book describes the theory of operation for
Theory of Operation Guide Quality Control QCS800xA and provides
troubleshooting guidance.

Quality Control Quality Control QCS800xA This book contains information regarding use of
QCS800xA CD Actuator Interface software applications that control measurement
Features Guide profiles.

Quality Control QCS800xA This book describes how to setup and tune the
CD Tuning Guide Quality Control QCS800xA CD Control feature.

Quality Control QCS800xA This book describes how to setup and tune the
MCD Tuning Guide Quality Control QCS800xA MCD Control
feature.

Quality Control QCS800xA This book describes how to configure and verify
Coat Weight & Computed coat weight, calculated measurements and
Sensors Guide synchronized scanning.

Quality Control QCS800xA This book describes how to configure, verify

Color Control Guide and tune Color Controls.

Quality Control QCS800xA This book describes how to operate Color

Color Measurement Measurement.
Operations User Guide

Quality Control QCS800xA This book provides answers to commonly

Frequently Asked asked questions.
Questions

3BUS212640 ix
Quality Control Documentation About This Book

Category Title Description

Quality Control QCS800xA This book describes how to operate and

Generic Control Grid Guide configure the Generic Control Grid ActiveX
control.

Quality Control QCS800xA This book describes how to setup and tune the
MD Tuning Guide Quality Control QCS800xA MD Control
features.

Quality Control QCS800xA This book describes how to configure, verify

Multi-Ply Controls Tuning and tune Multi-Ply Controls.
Guide

Quality Control QCS800xA This book provides a guide for editing OPC
OPC Transporter User Transporter files in order to exchange data
Guide between multiple OPC servers.

Quality Control QCS800xA This book information regarding use of software

Process Simulator Guide applications that simulate frame and sensor
operations, actuator interfaces, and MD and CD
process behaviors.

Quality Control QCS800xA This book describes how to install and

SP Service Workstation configure the standalone version of the Quality
Getting Started Guide Control QCS800xA Smart Platform Service
Workstation software.

Quality Control QCS800xA This book describes how to install and operate
xP Actuators Installation xP Actuators
and Operations User Guide

The Quality Control QCS800xA 5.0 SP3 manuals are available in the “Documentation” directory on
the Quality Control QCS800xA installation DVD; and are automatically copied in Acrobat pdf format
to the “Program Files\ABB Industrial IT\Quality Control Solutions\Doc” directory as part of either a
complete or typical install.

x 3BUS212640
About This Book Quality Control Documentation

Table of Contents

CHAPTER 1 INTRODUCTION .....................................................................................1

1.1 Product Overview................................................................................................................ 1
1.1.1 Product Scope ......................................................................................................... 1
1.2 Prerequisites and Requirements ........................................................................................ 1

CHAPTER 2 QUALITY CONTROL QCS800XA WORKPLACE ..................................2

2.1 Operator Login .................................................................................................................... 2
2.2 Quality Control QCS800xA Workplace............................................................................ 2
2.2.1 Overview................................................................................................................. 2
2.2.2 Fixed Display Area ................................................................................................. 2
2.2.3 Display Navigation Techniques.............................................................................. 2
2.2.4 Faceplate Operation .............................................................................................. 11
2.2.5 Direct Entry Operation.......................................................................................... 12
2.2.6 Alarms................................................................................................................... 12
2.2.7 Trend Displays ...................................................................................................... 12

CHAPTER 3 PROCESS DISPLAY OPERATION....................................................... 14

3.1 Machine Overview............................................................................................................. 14
3.1.1 Profile Display Panel ............................................................................................ 14
3.1.2 Level 2, CD Control and Level 1 Controls ........................................................... 16
3.1.3 Grade Information................................................................................................. 16
3.2 Scanner Operation ............................................................................................................ 20
3.2.1 Global Scanner Faceplate – Reduced View.......................................................... 22
3.2.2 Global Scanner Faceplate – Normal View............................................................ 23
3.2.3 Scanner Faceplate – Reduced View...................................................................... 24
3.2.4 Scanner Faceplate – Normal View ....................................................................... 25
3.2.5 Scanner Faceplate – Extended View..................................................................... 26
3.2.6 Scanner Icon Summary ......................................................................................... 30
3.3 Scanner Overview Display................................................................................................ 31
3.4 Profile Displays .................................................................................................................. 32
3.4.1 Profile Measurement Selection ............................................................................. 33
3.4.2 Plot Range Selection ............................................................................................. 34
3.4.3 Show/Hide Individual Profile Traces ................................................................... 35
3.4.4 Centreing / Auto arranging the profile traces ....................................................... 35
3.4.5 Profile Snapshot .................................................................................................... 35
3.4.6 Profile Data Point Marker..................................................................................... 37
3.4.7 Profile Zoom Functions ........................................................................................ 37
3.4.8 Profile off spec indication..................................................................................... 39
3.5 Measurement Overview.................................................................................................... 40
3.6 Excel® Measurement Analysis......................................................................................... 42
3.6.1 Activating Excel® Measurement Analysis........................................................... 42
3.6.2 Excel Calibrate Sample Analysis.......................................................................... 42

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Quality Control Documentation About This Book

3.6.3 Excel Check Sample Analysis .............................................................................. 43

3.6.4 Excel Standardize Analysis .................................................................................. 43
3.7 Reports ............................................................................................................................... 44
3.7.1 Production Reports................................................................................................ 44
3.7.2 Roll/Set Feature (Optional)................................................................................... 45
3.7.3 Sensor Reports ...................................................................................................... 50
3.7.4 Color Sensor Reports ............................................................................................ 50
3.7.5 Display and Hardcopy........................................................................................... 50
3.7.6 Navigation............................................................................................................. 51
3.7.7 Screen Hardcopy Printing ..................................................................................... 51
3.7.8 Capturing Display Image ...................................................................................... 51
3.8 System Overview ............................................................................................................... 52
3.8.1 Scanners Overview Panel ..................................................................................... 52
3.8.2 Grade Panel........................................................................................................... 53
3.8.3 Profile Panel.......................................................................................................... 53

CHAPTER 4 MACHINE DIRECTION CONTROL DISPLAYS .................................... 55

4.1 Introduction ....................................................................................................................... 55
4.2 MD Control Operation ..................................................................................................... 55
4.2.1 Drystock................................................................................................................ 55
4.2.2 Dryer Ratio/Ratio.................................................................................................. 56
4.2.3 Level 2 Control ..................................................................................................... 56
4.2.4 MD Controls Overview Display ........................................................................... 59
4.2.5 Speed Control Display .......................................................................................... 59
4.2.6 Speed Level 2 Control .......................................................................................... 60
4.2.7 Speed Optimization Summary Display................................................................. 61
4.2.8 Expert Speed Setpoint Handler............................................................................. 62
4.2.9 Speed Optimization (Normal Mode) .................................................................... 64
4.2.10 Dryer Limited Speed Optimization....................................................................... 64
4.2.11 Auto Grade Change Display ................................................................................. 66
4.2.12 Multi-frame Scan Level Control (MFSLC) .......................................................... 70
4.3 Level 1 Control Operation................................................................................................ 75
4.3.1 Level 1 Control Interface ...................................................................................... 75
4.3.2 Level 1 Control Faceplate..................................................................................... 75
4.4 Multi-stock Operation....................................................................................................... 77
4.4.1 Ply Loading Summary Display ............................................................................. 77
4.4.2 Multiply Auto Grade Change Overview............................................................... 84
4.4.3 Consistency Compensation Summary .................................................................. 86

CHAPTER 5 CROSS DIRECTION CONTROL DISPLAYS ........................................ 88

5.1 CD Control Overview ....................................................................................................... 88
5.1.1 Plot Windows........................................................................................................ 88
5.1.2 High-Resolution Profile Sub-Window.................................................................. 89
5.1.3 Mapped Profile Sub-Window ............................................................................... 91
5.1.4 Actuator Sub-Window .......................................................................................... 92
5.1.5 Statistics Window ............................................................................................... 102
5.1.6 Profile Combination and Control Counter Window ........................................... 102

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About This Book Quality Control Documentation

5.1.7 Message Window................................................................................................ 103

5.1.8 CD Control Mode ............................................................................................... 104
5.2 CD Target Profile Setup Display ................................................................................... 105
5.2.1 Target Profiles..................................................................................................... 107
5.2.2 Editing Target Profile ......................................................................................... 107
5.3 Smooth Target Profile..................................................................................................... 116
5.3.1 Target Indices...................................................................................................... 117
5.3.2 Target Profile Mode............................................................................................ 119
5.4 CD Control Coater Operations ...................................................................................... 120
5.4.1 Blade Logic......................................................................................................... 121
5.4.2 Splice Event ........................................................................................................ 122
5.4.3 Preset Setpoint Options....................................................................................... 123
5.4.4 Coater Operation Messages ................................................................................ 126
5.5 Local Variability (LV) Control Operations .................................................................. 127
5.5.1 Using LVC Monitoring....................................................................................... 128
5.5.2 Using LVC Optimization.................................................................................... 129
5.5.3 CD Control Profile Information.......................................................................... 130
5.5.4 LVC Messages .................................................................................................... 131

CHAPTER 6 MULTIVARIABLE CD CONTROL DISPLAYS .................................... 133

6.1 MCD Control Overview Display.................................................................................... 133
6.1.1 Measurement Plot Window................................................................................. 133
6.1.2 Actuator Plot Window ........................................................................................ 134
6.1.3 Measurement CD Information Table .................................................................. 140
6.1.4 Measurement MD Information Table ................................................................. 141
6.1.5 Actuator Information Table ................................................................................ 141
6.1.6 Control Status Table ........................................................................................... 142
6.1.7 Message Window................................................................................................ 143
6.2 MCD Measurement Target Display .............................................................................. 146
6.2.1 Measurement Target Plots .................................................................................. 147
6.2.2 Measurement CD Target Table........................................................................... 147
6.2.3 Measurement MD Target Table.......................................................................... 147
6.2.4 Measurement Target Handling Table ................................................................. 148
6.2.5 Measurement Target Operation Buttons............................................................. 149
6.2.6 Display Links ...................................................................................................... 149
6.2.7 Editing Measurement Target Profiles ................................................................. 150
6.3 MCD Actuator Target Display....................................................................................... 151
6.3.1 Actuator Target Profiles...................................................................................... 152
6.3.2 Target Setup Table.............................................................................................. 152
6.3.3 Edge Mode Selection Tables .............................................................................. 153
6.3.4 Edge Parameters Table ....................................................................................... 153
6.3.5 Control Width Status Table ................................................................................ 154
6.3.6 Actuator Target Operation Buttons..................................................................... 154
6.3.7 Display Links ...................................................................................................... 155
6.3.8 Editing Actuator Target Profiles......................................................................... 155
6.4 MCD Actuator Overview Display.................................................................................. 156

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Quality Control Documentation About This Book

6.4.1 Measurement Plot Window................................................................................. 156

6.4.2 Actuator Plot Window ........................................................................................ 156
6.4.3 Measurement Information Table......................................................................... 157
6.4.4 Control Status Table ........................................................................................... 157
6.4.5 Actuator Information Table ................................................................................ 158
6.4.6 Message Window................................................................................................ 158
6.4.7 Display Links ...................................................................................................... 159
6.5 MCD Control Messages .................................................................................................. 159
6.5.1 General Messages ............................................................................................... 159
6.5.2 Abort Conditions................................................................................................. 160
6.5.3 Suspend Conditions ............................................................................................ 161

CHAPTER 7 CD ACTUATOR INTERFACE DISPLAYS .......................................... 163

7.1 General Information ....................................................................................................... 163
7.2 CD Actuator Interface Overview................................................................................... 164
7.2.1 Actuator Plot Window ........................................................................................ 164
7.2.2 Actuator data grid window.................................................................................. 173
7.2.3 Scalar data grid window...................................................................................... 182
7.2.4 Message Window................................................................................................ 188
7.2.5 Command Buttons .............................................................................................. 199
7.3 SteamPlus Profiler Steambox Status Display ............................................................... 201
7.3.1 Steambox Control Setup Data Window.............................................................. 201
7.3.2 Steam Pressure PID Data Window ..................................................................... 203
7.3.3 Steam Temperature PID Data Window .............................................................. 204
7.3.4 Interlocks Window.............................................................................................. 205
7.3.5 Steambox Control Window................................................................................. 206

CHAPTER 8 GRADE CODE SETUP........................................................................ 209

8.1 On-line Grade Tool ......................................................................................................... 209

xiv 3BUS212640
About This Book Quality Control Documentation

List of Figures
Figure 2-1 Operator Workplace Application Bar ....................................................................2
Figure 2-2 Aspect Menu (Favorites) ......................................................................................3
Figure 2-3 Organize button....................................................................................................3
Figure 2-4 Organize Aspect Menu window ............................................................................4
Figure 2-5 Add button ............................................................................................................4
Figure 2-6 Select Aspect window...........................................................................................5
Figure 2-7 Aspect Menu (Favorites) Tool after addition of new aspect..................................5
Figure 2-8 Menu display with Aspect Links............................................................................6
Figure 2-9 Display shortcuts on application bar .....................................................................7
Figure 2-10 Drop down menu Aspect List activated by list symbol........................................8
Figure 2-11 Select an aspect, action, or referenced display from the context menu .............9
Figure 2-12 Aspect History list allows users to view previously viewed displays .................10
Figure 2-13 Examples of PID faceplates .............................................................................11
Figure 2-14 Direct entry fields are shown in blue background .............................................12
Figure 2-15 Direct entry fields white background when selected.........................................12
Figure 2-16 Example of a MD control trend .........................................................................13
Figure 3-1 Machine Overview..............................................................................................14
Figure 3-2 Level 1 and Level 2 Controls ..............................................................................16
Figure 3-3 Grade controls....................................................................................................16
Figure 3-4 Next Grade selection overlap display .................................................................17
Figure 3-5 Confirm “On Grade” or “Off Grade” action..........................................................18
Figure 3-6 System is currently “On Grade” ..........................................................................18
Figure 3-7 Confirm manual grade change ...........................................................................18
Figure 3-8 Grade Change in progress .................................................................................19
Figure 3-9 Grade Change complete ....................................................................................19
Figure 3-10 Scanner Overview 1 .........................................................................................20
Figure 3-11 Scanner Overview 2 .........................................................................................21
Figure 3-12 Global Scanner Faceplate ................................................................................22
Figure 3-13 Global Scanner Faceplate – Normal View........................................................23
Figure 3-14 Scanner Faceplate Reduced View ...................................................................24
Figure 3-15 Scanner Faceplate Normal View ......................................................................25
Figure 3-16 Scanner Faceplate Extended View - Status Panel ...........................................26
Figure 3-17 Scanner Faceplate Extended View – Single Point Panel .................................27
Figure 3-18 Scanner Faceplate Extended View – Standardize Panel .................................28
Figure 3-19 Scanner Faceplate Extended View – Setup Panel ...........................................29
Figure 3-20 Scanner Overview Display ...............................................................................31
Figure 3-21 Overview of Profile Display Elements...............................................................32
Figure 3-22 Profile Scanner selection..................................................................................33
Figure 3-23 Profile Measurement selection .........................................................................33
Figure 3-24 Profile Type selection .......................................................................................34
Figure 3-25 Show/Hide profiles ...........................................................................................34
Figure 3-26 Show/Hide profiles ...........................................................................................35
Figure 3-27 Centred/ Auto arranged profile trace presentation............................................35
Figure 3-28 Profile Snapshot ...............................................................................................36
Figure 3-29 Profile Data Point marker .................................................................................37
Figure 3-30 Zooming a Profile .............................................................................................37
Figure 3-31 Profile Zoomed .................................................................................................38

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Quality Control Documentation About This Book

Figure 3-32 Zoom Controls..................................................................................................38

Figure 3-33 Profile Off Spec indications ..............................................................................39
Figure 3-34 Measurement Overview....................................................................................40
Figure 3-35 Scanner Specific Measurement Overview Button ............................................40
Figure 3-36 Higlighting individual measurement display elements ......................................41
Figure 3-37 Basis Weight Profile display .............................................................................41
Figure 3-38 Large system Measurement Overview display .................................................41
Figure 3-39 Activating Excel Measurement Analysis ...........................................................42
Figure 3-40 Excel Calibrate Sample Analysis ......................................................................43
Figure 3-41 Excel Check Sample Analysis ..........................................................................43
Figure 3-42 Excel Standardize Analysis ..............................................................................43
Figure 3-43 Report Display Controls....................................................................................44
Figure 3-44 Available Historical Reports..............................................................................45
Figure 3-45 Current Roll/Set Overview Display ...................................................................46
Figure 3-46 RollSet Measurement Limits entry window.......................................................46
Figure 3-47 Extended Statistics window ..............................................................................47
Figure 3-48 Extended Statistics window ..............................................................................47
Figure 3-49 Off Spec Roll/Set values...................................................................................48
Figure 3-50 Roll/Set configuration values ............................................................................48
Figure 3-51 Incorrect roll trim entry alarm............................................................................49
Figure 3-52 Last RollSet Overview Display .........................................................................49
Figure 3-53 Available Historical Reports..............................................................................50
Figure 3-54 Available Historical Reports..............................................................................50
Figure 3-55 System Overview display .................................................................................52
Figure 3-56 Scanners Panel ................................................................................................52
Figure 3-57 Profile Overview ...............................................................................................53
Figure 4-1 MD Control Overview display .............................................................................55
Figure 4-2 MD Control Drystock Interface ...........................................................................56
Figure 4-3 MD Dryer Ratio/Bias example ............................................................................56
Figure 4-4 MD Level 2 Control faceplate .............................................................................57
Figure 4-5 MD Level 2 control detail ....................................................................................58
Figure 4-6 MD Level 2 abort & suspend conditions .............................................................58
Figure 4-7 MD Controls Overview Display...........................................................................59
Figure 4-8 MD Speed Control Overview ..............................................................................60
Figure 4-9 MD Speed Optimization Summary Display.........................................................62
Figure 4-10 MD Speed Optimization Abort & Suspend conditions ......................................64
Figure 4-11 MD Dryer Limited Speed Optimization Abort & Suspend conditions ................65
Figure 4-12 MD Auto Grade Change Overview ...................................................................66
Figure 4-13 Product Code Selection Dialog.........................................................................66
Figure 4-14 AGC Level 2 Interlock Conditions.....................................................................67
Figure 4-15 AGC Level 1 Interlock Conditions.....................................................................67
Figure 4-16 AGC Interlocks .................................................................................................68
Figure 4-17 AGC General Interlock Indicator.......................................................................68
Figure 4-18 AGC Interlock Conditions .................................................................................69
Figure 4-19 MFSLC feedback controllers ............................................................................71
Figure 4-20 MFSLC feedback controllers ............................................................................73
Figure 4-21 MD Level 1 Control Direct Setpoint Entry .........................................................75
Figure 4-22 MD Level 1 Control PID faceplate ....................................................................76
Figure 4-23 Ply Loading Summary Display..........................................................................77
Figure 4-24 Stockflow Operating Mode ...............................................................................78

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Figure 4-25 Stock flow Redistribution ..................................................................................79

Figure 4-26 Furnish Types...................................................................................................80
Figure 4-27 Stock Initialization.............................................................................................80
Figure 4-28 Drystock and Instrument Number Grid .............................................................81
Figure 4-29 Multiply Auto Grade Change Overview.............................................................84
Figure 4-30 Consistency Compensation Summary Display.................................................86
Figure 4-31 Consistency Status Selection ...........................................................................86
Figure 5-1 CD Control Overview..........................................................................................88
Figure 5-2 CD overview plot window ...................................................................................89
Figure 5-3 Physical references of the high-resolution profile plot ........................................89
Figure 5-4 Left click to find alignment between an actuator and a profile region .................90
Figure 5-5 High resolution profile tool tip .............................................................................90
Figure 5-6 Show tool tips .....................................................................................................91
Figure 5-7 Physical references of the mapped profile plot...................................................91
Figure 5-8 Mapped profile tool tip ........................................................................................92
Figure 5-9 Actuator setpoint, feedback and status representation.......................................92
Figure 5-10 Control width indicators ....................................................................................92
Figure 5-11 Selecting actuators with “Ctrl” key ....................................................................93
Figure 5-12 Selecting actuators with “Shift” key ..................................................................94
Figure 5-13 Selecting all actuators ......................................................................................95
Figure 5-14 Actuator dialog window.....................................................................................97
Figure 5-15 Method to open actuator dialog window ...........................................................97
Figure 5-16 Changing actuator mode in the dialog window .................................................99
Figure 5-17 Changing manual actuator setpoint in dialog window.....................................101
Figure 5-18 Actuator tool tip ..............................................................................................101
Figure 5-19 Statistics window ............................................................................................102
Figure 5-20 MD measurement and control counter ...........................................................102
Figure 5-21 CD control overview message window with normal status .............................104
Figure 5-22 CD control modes...........................................................................................104
Figure 5-23 CD control mode change confirmation window ..............................................105
Figure 5-24 CD control test mode change confirmation window........................................105
Figure 5-25 CD control operation with target profile mode active ......................................106
Figure 5-26 CD target profile setup display .......................................................................106
Figure 5-27 Profile types on the target setup display.........................................................107
Figure 5-28 Physical reference of target profile plot ..........................................................108
Figure 5-29 Selecting multiple target profile handles with “Ctrl” key ..................................109
Figure 5-30 Select multiple target profile handles with “Shift” key .....................................109
Figure 5-31 Selecting all target profile handles..................................................................110
Figure 5-32 Target profile dialog window...........................................................................111
Figure 5-33 Method to open target profile dialog window ..................................................112
Figure 5-34 Target profile created by setting a few target handles....................................112
Figure 5-35 Fixed and non-fixed target profile handles......................................................113
Figure 5-36 Changing target handle fixed mode with dialog window .................................114
Figure 5-37 Building a target profile with the drag-and-drop operation ..............................115
Figure 5-38 Building target profile with dialog window .......................................................116
Figure 5-39 Impact of “Smoothness” option on the smooth target profile ..........................117
Figure 5-40 Target profile smoothing.................................................................................117
Figure 5-41 Save target profile to an index........................................................................118
Figure 5-42 Load target profile from an index....................................................................118
Figure 5-43 Specifying an active target profile index .........................................................119

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Figure 5-44 Target profile option button.............................................................................119

Figure 5-45 Target profile mode change confirmation window ..........................................120
Figure 5-46 CD control coater operations overview display...............................................120
Figure 5-47 Output buffer dialog window ...........................................................................124
Figure 5-48 LV control operations overview display ..........................................................128
Figure 6-1 MCD Control Overview Display ........................................................................133
Figure 6-2 Actuator setpoint, feedback and status representation.....................................134
Figure 6-3 Control width indicators ....................................................................................134
Figure 6-4 Selecting actuators with “Ctrl” key ....................................................................135
Figure 6-5 Selecting actuators with “Shift” key ..................................................................135
Figure 6-6 Selecting all actuators ......................................................................................136
Figure 6-7 Actuator dialog table.........................................................................................136
Figure 6-8 Method to open actuator dialog window ...........................................................138
Figure 6-9 Changing actuator mode in the dialog window .................................................139
Figure 6-10 Measurement CD Information Table ..............................................................140
Figure 6-11 Measurement MD Information Table ..............................................................141
Figure 6-12 Actuator Status Information Table (SC left, PM right).....................................142
Figure 6-13 Control Status Table (SC left, PM right) .........................................................142
Figure 6-14 Message Window ...........................................................................................144
Figure 6-15 MCD Measurement Target Display ................................................................146
Figure 6-16 CD Target Table.............................................................................................147
Figure 6-17 MD Target Table ............................................................................................148
Figure 6-18 Target Handling Table ....................................................................................148
Figure 6-19 Target Operation Buttons ...............................................................................149
Figure 6-20 Display Links ..................................................................................................149
Figure 6-21 Edit Dialog ......................................................................................................150
Figure 6-22 MCD Actuator Target Display.........................................................................151
Figure 6-23 Target Setup Table.........................................................................................152
Figure 6-24 Edge Selection Tables....................................................................................153
Figure 6-25 Edge Parameters Table..................................................................................153
Figure 6-26 Control Width Status Table.............................................................................154
Figure 6-27 Actuator Target Operation Buttons.................................................................154
Figure 6-28 Display Links ..................................................................................................155
Figure 6-29 MCD Actuator Overview Display ....................................................................156
Figure 6-30 Measurement Information Table.....................................................................157
Figure 6-31 Control Status Information Table....................................................................157
Figure 6-32 Actuator Status Information Table ..................................................................158
Figure 6-33 Message Window ...........................................................................................158
Figure 6-34 Display Links ..................................................................................................159
Figure 7-1 CD Actuator Interface Overview .......................................................................164
Figure 7-2 Actuator setpoint, feedback and status representation.....................................165
Figure 7-3 Selecting actuators with “Ctrl” key ....................................................................166
Figure 7-4 Selecting actuators with “Shift” key ..................................................................166
Figure 7-5 Selecting all actuators ......................................................................................167
Figure 7-6 Actuator dialog window.....................................................................................169
Figure 7-7 Method to open actuator dialog window ...........................................................169
Figure 7-8 Changing actuator setpoint in dialog window ...................................................172
Figure 7-9 Actuator tool tip ................................................................................................173
Figure 7-10 Actuator data grid window ..............................................................................173
Figure 7-11 Scalar data grid window .................................................................................182

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Figure 7-12 CD Actuator Interface Overview message window.........................................188

Figure 7-13 Select mode off ..............................................................................................199
Figure 7-14 Select mode on ..............................................................................................199
Figure 7-15 Select mode change confirmation window .....................................................199
Figure 7-16 Clear Errors ....................................................................................................200
Figure 7-17 Clear Errors confirmation window...................................................................200
Figure 7-18 SteamPlus Profiler Steambox Status Window................................................201
Figure 7-19 SteamPlus Profiler Steambox Control Setup Data Window............................202
Figure 7-20 SteamPlus Profiler Steam Pressure PID Data Window ..................................203
Figure 7-21 SteamPlus Profiler Steam Temperature PID Data Window............................204
Figure 7-22 SteamPlus Profiler Message Window.............................................................205
Figure 7-23 Steambox Control Window .............................................................................206
Figure 7-24 Steambox Mode Confirmation Window ..........................................................207
Figure 8-1 System Overview Selection Menu....................................................................210
Figure 8-2 On-line grade tool.............................................................................................211
Figure 8-3 Selecting and changing a grade entry ..............................................................212
Figure 8-4 A changed grade entry .....................................................................................213

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Quality Control Documentation About This Book

List of Tables
Table 4-1 MD Status Speed Conditions for Speed Level 2 Control .....................................61
Table 4-2 MD Status Stock Conditions for Speed Level 2 Control ......................................61
Table 4-3 MD Status OK Conditions for Auto Grade Change..............................................69
Table 4-4 MFSLC feedback control modes .........................................................................71
Table 4-5 MFSLC feedback control modes .........................................................................73
Table 5-1 Actuator status color indication............................................................................98
Table 5-2 Performance measure based storage variables ................................................125
Table 6-1 Actuator Status Color Indication ........................................................................138
Table 6-2 Measurement CD Information............................................................................140
Table 6-3 Measurement MD Information ...........................................................................141
Table 6-4 Actuator Information Table ................................................................................142
Table 6-5 Control Status Table..........................................................................................143
Table 6-6 Measurement CD Target ...................................................................................147
Table 6-7 Measurement MD Target...................................................................................148
Table 6-8 Measurement Target Handling ..........................................................................148
Table 6-9 Measurement Target Operation Buttons ...........................................................149
Table 6-10 Actuator Target Plots.......................................................................................152
Table 6-11 Actuator Target Setup .....................................................................................152
Table 6-12 Actuator Target Edge Mode Selection .............................................................153
Table 6-13 Actuator Target Edge Parameters ...................................................................153
Table 6-14 Actuator Target Width Status...........................................................................154
Table 6-15 Actuator Target Operation Buttons ..................................................................155
Table 6-16 Measurement Information Table......................................................................157
Table 6-17 Control Status Information ...............................................................................157
Table 6-18 Actuator Status Information .............................................................................158
Table 7-1 Actuator status color indication..........................................................................170
Table 7-2 AccuRay Serial Protocol/VIB Steambox ASCII Serial Protocol Actuator Status 173
Table 7-3 AccuRay Serial Protocol/VIB Steambox ASCII Serial Protocol Feedback Status
.....................................................................................................................................174
Table 7-4 MX 200/100 Serial Protocol Actuator Status......................................................174
Table 7-5 Actuator Status ..................................................................................................174
Table 7-6 MX 200/100 Serial Protocol Feedback Statuses ...............................................175
Table 7-7 Slice Profiler/CoatWeight Profiler/Dilution Profiler Actuator Status....................175
Table 7-8 Slice Profiler/CoatWeight Profiler/Dilution Profiler Feedback Status .................176
Table 7-9 Smart Weight Profiler/Smart CoatWeight Profiler/Smart Consistency Actuator
Status ..........................................................................................................................177
Table 7-10 Smart Weight Profiler/Smart CoatWeight Profiler/Smart Consistency Profiler
Feedback Status..........................................................................................................179
Table 7-11 Calender Profiler/Smart Calender Profiler actuator status ...............................180
Table 7-12 SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution/Induction
Profiler Actuator Status................................................................................................181
Table 7-13 SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution/Induction
Profiler Feedback Status .............................................................................................181
Table 7-14 AccuRay Serial Protocol/VIB Steambox ASCII Serial Protocol/MX 200/100
Serial Protocol data .....................................................................................................182
Table 7-15 Slice Profiler/CoatWeight Profiler/Smart Weight Profiler/Smart CoatWeight
Profiler data .................................................................................................................183

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Table 7-16 Dilution Profiler/Smart Consistency Profiler data .............................................184

Table 7-17 Calender Profiler/Smart Calender Profiler data ...............................................185
Table 7-18 Variable ...........................................................................................................185
Table 7-19 SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution Data ....185
Table 7-20 Induction Profiler Data .....................................................................................186
Table 7-21 ABB Serial Protocol messages........................................................................188
Table 7-22 VIB Steambox ASCII Serial Protocol messages..............................................190
Table 7-23 MX 200/100 Serial Protocol messages............................................................191
Table 7-24 Slice Profiler/CoatWeight Profiler/Smart Weight Profiler/Smart CoatWeight
Profiler .........................................................................................................................192
Table 7-25 Dilution Profiler/Smart Consistency Profiler .....................................................193
Table 7-26 Calender Profiler/Smart Calender Profiler .......................................................195
Table 7-27 SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution messages
.....................................................................................................................................196
Table 7-28 Induction Profiler Messages ............................................................................197
Table 7-29 SteamPlus Profiler Steambox Control Setup Data Window.............................202
Table 7-30 SteamPlus Profiler Steam Pressure PID Data Window ...................................203
Table 7-31 SteamPlus Profiler Steam Temperature PID Data Window .............................204
Table 7-32 SteamPlus Profiler Messages..........................................................................205

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Chapter 1 Introduction Product Overview

Chapter 1 Introduction

1.1 Product Overview

Quality Control QCS800xA is a set of features for measurement and control of the paper making
process. The User Interface for Quality Control QCS800xA is based upon the ABB Process Portal
product for IndustrialIT.

This User’s Guide describes how to operate Quality Control QCS800xA.

1.1.1 Product Scope

The Operation User’s Guide features information on displays and navigation for Quality Control
QCS800xA.

1.2 Prerequisites and Requirements

This User’s Guide assumes that the reader has some knowledge of the basic operation of the Industrial
IT System 800xA Process Portal A User Interface and the paper making process.

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Operator Login Chapter 2 Quality Control QCS800xA Workplace

Chapter 2 Quality Control QCS800xA Workplace

2.1 Operator Login

Operator Login is the same as Windows 2000/3 Login.

Enter the user name

Enter the password

2.2 Quality Control QCS800xA Workplace

2.2.1 Overview

Quality Control QCS800xA Workplace gives a window to the process. It allows you to navigate and
control items and view and acknowledge alarms and events for your process.

2.2.2 Fixed Display Area

The fixed display area resides permanently at the top of the display area. This part of the display
typically shows an alarms and events area to the left and general machine data to the right. Here, the
general machine data is a snapshot of the reel number and speed.

2.2.3 Display Navigation Techniques

Overview

This guide includes brief examples of standard Industrial IT System 800xA Process Portal A
navigation methods applied to Quality Control QCS800xA process graphic displays.

More information about navigation is available in the Industrial IT System 800xA Process Portal
Operator’s Guide. Quality Control QCS800xA Solution adds another navigation option to the
standard Process Portal A navigation techniques.

Favorites Menu Navigation

Figure 2-1 Operator Workplace Application Bar

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On the Application Bar, clicking on the button will open the Aspect Menu (Favorites) tool as an
overlap.

Figure 2-2 Aspect Menu (Favorites)

A folder can be expanded by clicking on the + beside its name to show the favorites and folders
within that folder.

Folders and favorites can be organized by clicking the Organize button at the top of the Aspect Menu.

Figure 2-3 Organize button

This opens the Organize Aspect Menu window as a separate overlap. This enables addition of new
folders, deletion of existing folders, renaming of existing folders and moving favorites and folders
from one folder to another by clicking the relevant button to the right of the upper pane. It also
enables deletion of favorites, renaming of favorites and moving of favorites from one folder to another
by clicking the relevant button to the right of the lower pane.

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Quality Control QCS800xA Workplace Chapter 2 Quality Control QCS800xA Workplace

Figure 2-4 Organize Aspect Menu window

Favorites can be added by clicking the Add button at the top of the Aspect Menu window.

Figure 2-5 Add button

This causes the Select Aspect window to open in a new overlap. This window allows the user to select
an aspect to be added to the Favorites list. The user can browse to the aspect they wish to add, select
that aspect in the pane on the right, and click OK.

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Chapter 2 Quality Control QCS800xA Workplace Quality Control QCS800xA Workplace

Figure 2-6 Select Aspect window

This aspect is then added to the list of favorites in the Aspect Menu (Favorites) tool.

Figure 2-7 Aspect Menu (Favorites) Tool after addition of new aspect

Double clicking on an aspect in the Aspect Menu (Favorites) tool causes that aspect to open in a new
window.

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Quality Control QCS800xA Workplace Chapter 2 Quality Control QCS800xA Workplace

What are Aspects and Objects?

In this manual, the terms Aspect Objects (also known as Objects) and Aspects are frequently used.
Objects are physical items in a process. For example, an object can be a paper machine, a size press, a
CD actuator system, or a chemical preparation area. Each of those Objects has several pieces of
information describing parts of the item. For example, a paper machine has stock flow, reel speed,
grade running, and grade time associated with it. Those pieces of information are called Aspects.
Aspects are items of interest about those Objects.

To make it easier and more logical to navigate, the Aspects an Object “owns” can be seen using right
mouse click menus. If you’d like to find more information paper machine reel, you would right click
over the reel Aspect using the mouse. A pop-up menu would appear showing available Aspects for
that Object. More information can be found in the Context Menus section.

Aspect Links

The Aspect Link in a display is a shortcut to another aspect. This Aspect Link button takes you to a
different page to get the information you want. Quality Control QCS800xA Workplace default start-
up display is normally a graphic display that contains Aspect Links for selecting Quality Control
QCS800xA process graphic aspects. The short cuts in this display are only shown when this display is
visible. Here is a typical main menu display with Aspect Links to main section displays Figure 2-8.

Figure 2-8 Menu display with Aspect Links

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Chapter 2 Quality Control QCS800xA Workplace Quality Control QCS800xA Workplace

Shortcut Menus

You use Display Shortcuts for one-click access to a specific display. These display shortcuts are
another way to get to the page you need. The display is an Aspect of an Aspect Object. At the top of
every display, an Aspect List (a drop down menu) is available when you left click on the small list
symbol . It presents a list of other aspects of the aspect object you’ve selected.

The shortcuts in the application bar are always visible at the top of the display. Click on the wanted
aspect name and the corresponding aspect view will be displayed. When the cursor is placed on top of
a Shortcut, a tool-tip (represented as a small yellow box) is activated. The tool-tip displays the aspect
object name and the aspect. By using Display Shortcuts, you can access display groups as well as their
related displays (display hierarchies). The picture below shows some Display Shortcuts on the
application bar Figure 2-9.

Figure 2-9 Display shortcuts on application bar

There is a drop-down menu Aspect List activated by clicking on the list symbol (down arrow symbol)
Figure 2-10.

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Quality Control QCS800xA Workplace Chapter 2 Quality Control QCS800xA Workplace

Figure 2-10 Drop down menu Aspect List activated by list symbol

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Chapter 2 Quality Control QCS800xA Workplace Quality Control QCS800xA Workplace

Context Menus

After you see the object about which you want more information, right click to brink up the Context
Menu Figure 2-11. You can select an aspect, action or a referenced display for the object from the
context menu. You can also left-click on an object in a graphic display to open the default aspect. The
picture below shows the context menu for a Reel History object.

Figure 2-11 Select an aspect, action, or referenced display from the context menu

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Quality Control QCS800xA Workplace Chapter 2 Quality Control QCS800xA Workplace

History List

Another way to get to the display you want is to click on the history list. Click on the Aspect History
drop down list to get a listing of the most recently viewed displays (Figure 2-12). The latest used
display on top. Click on the display (aspect) you want to present.

You can move back to the previous display in the Aspect History list by clicking on the Back to
Previous Display button. If the button is disabled, it is not possible to go backward.

You can move forward to the next display in the History list by clicking on the Forward to Next
Display button. If the button is disabled, it appears faded and it is not possible to go forward.

The picture below Figure 2-12 shows the Aspect History List. The Back to Previous Display button
and the Forward to Next Display button are both enabled.

Figure 2-12 Aspect History list allows users to view previously viewed displays

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Chapter 2 Quality Control QCS800xA Workplace Quality Control QCS800xA Workplace

2.2.4 Faceplate Operation

The control loops used for level 1 and level 2 MD control each have an associated faceplate which
allows you to view and interact with the particular control loop. The associated faceplate will appear
by selecting the MV, SP or Mode on the particular controller on a graphic display. The faceplate will
appear in one of three forms, which are reduced, standard, and extended. These three types are shown
in the following figure, Figure 2-13. For details on how to interact with each faceplate see MD
Control Level 1 and Level 2 control sections.

Reduced Standard Extended

Figure 2-13 Examples of PID faceplates

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Quality Control QCS800xA Workplace Chapter 2 Quality Control QCS800xA Workplace

2.2.5 Direct Entry Operation

You can use several display elements used on the Paper Machine Quality Control graphic displays to
enter data directly on the display element without first opening an associated faceplate. For example,
Level 2 next grade targets, tuning parameters, and preliminary targets can be directly entered without
a faceplate. Generally, a parameter which has the ability to be entered directly is shown in blue text,
with a white background when selected, as shown in the following Figure 2-14. (The exception to this
rule is Level 1 and Level 2 setpoints as these entries must be made via the Level 1 and Level 2
faceplates as shown above.)

Figure 2-14 Direct entry fields are shown in blue background

Once a value is selected, a second small window will appear next to the parameter that is to be
modified. This is known as the direct entry window. The entire field will be highlighted allowing any
entry to overwrite the entire field, as shown in the following figure. The existing value can be
modified by selecting the highlighted field and then using the right/left curser movement keys. Use
the ‘Esc’ key to cancel the currently selection and restore the original value. To accept the new entry
use the ‘Enter’ key as shown in Figure 2-15.

Figure 2-15 Direct entry fields white background when selected

2.2.6 Alarms

Refer to the Industrial IT System 800xA Process Portal User’s Guide for information on alarm
handling.

2.2.7 Trend Displays

Refer to the Industrial IT System 800xA Process Portal User’s Guide for a detailed description of the
trend display. In general the Trend displays supplied with Industrial IT System 800xA can be used to
display any variable that is in the Quality Control QCS800xA system. See the “Trending” chapter in
the “Engineering Methods Reference Manual” for a description of how to add process measurements
to the trend display. An example of a trend configured for MD weight and moisture control is shown
in Figure 2-16.

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Chapter 2 Quality Control QCS800xA Workplace Quality Control QCS800xA Workplace

Figure 2-16 Example of a MD control trend

Some of the basic operations that can be done on a configured trend include:

 Clicking in the trend display will create a vertical line which updates the Ruler Value and Ruler
Time columns

 The Style column can be used to change the appearance of each measurement display

 The scaling used for the trend is shown in the High Range and Low Range columns, which can be
changed at any time.

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Machine Overview Chapter 3 Process Display Operation

Chapter 3 Process Display Operation

This section of the User’s Guide describes the operation of Quality Control QCS800xA operator
process displays. Tuning and setup displays are described in other documents (feature tuning guides).

3.1 Machine Overview

The Machine Overview page provides a summary overview of machine conditions of general interest
for most machine operations. The page consists of a profile display area, a list of The Level 1 and
Level 2 machine direction controls, grade information and CD control summary.

Figure 3-1 Machine Overview

3.1.1 Profile Display Panel

The Profile Display panel section of the Machine Overview display allows measurement profile data
to be displayed. For detailed instructions for operation, please refer to section 3.3 Scanner Overview
Display

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Chapter 3 Process Display Operation Machine Overview

Figure 3-20 Scanner Overview Display

The Scanner Overview display shows the scanners configured for the system.

Clicking on the Global scanner information will trigger the display of the Global Scanner faceplate.
Similarly clicking on any of the individual scanner elements will cause the Scanner faceplate for the
associated scanner to be displayed.

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Machine Overview Chapter 3 Process Display Operation

Profile Displays.

3.1.2 Level 2, CD Control and Level 1 Controls

Level 1 and Level 2 Controls

Level 2 controls are the supervisory MD control loops for sheet properties, for instance BW and
moisture. Level 1 controls manipulate i.e., stock flow or steam pressure in response to supervisory
controls, or by manual entry. The details of operating these functions are described in Chapter 4.2,
MD Control Operation.

Figure 3-2 Level 1 and Level 2 Controls

CD Controls

The CD Controls panel on Machine Overview provides summary operations of CD controls on the
machine. Information is included for current control performance in profile 2-sigma units. Mode
control buttons allow for selection of automatic and manual operation.

For further details for CD controls, see Chapter 5 Cross Direction Control Displays.

3.1.3 Grade Information

The grade information section allows you to select paper grades and to change the active grade.

Figure 3-3 Grade controls

Active Grade

The active or current grade code and associated grade description are displayed directly to the right of
the “Current Grade” text label.

Preliminary Grade

The preliminary or next grade code and associated grade description are displayed directly to the right
of the “Next Grade” button.

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Chapter 3 Process Display Operation Machine Overview

Next Grade Selection

The “Next Grade” button allows a new preliminary grade to be selected from the list of available
grades defined for the system.

Pressing the “Next Grade” button will launch an overlap display. This display will present a list of all
the grade codes which have been defined for the system. To select a different preliminary grade
simply click on the appropriate entry in the list and then press the “Use Selected Code” button.

Figure 3-4 Next Grade selection overlap display

Pressing the “Use Selected Code” button causes the system to load the selected grade code
information. The preliminary grade information in the panel will update to reflect the choice that was
made. You are free to continue selecting different grades, however when finished you should close the
overlap display by clicking on the windows close button in the top right of the display.

On Grade/Off Grade Operation

When the system initially starts the QCS is deemed to be off grade and this is reflected by the state of
the grade buttons, none of them are displayed with the button green.

When the system is producing product which meets the the targets/tolerances defined by the active
grade, the system is said to be “on grade”. To indicate that this is the case the “On Grade” button
needs to be pressed, which puts the QCS in to the “On Grade”. Once the system is on grade
production quality data will be accumulated.

The active grade code or specification is changed by performing a grade change. When a grade
change is performed the system will automatically taken “off grade”, a grade report is generated
detailing the production data for that production run. The production accumulations are then reset and
will only begin accumulating again once the system is placed back on grade.

On Grade Button

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Machine Overview Chapter 3 Process Display Operation

The “On Grade” button allows the system to be placed “on” or “off” grade. When the system is “on
Grade” this button will be displayed as filled green.When you press the “On Grade” button a popup
appears which allows you to confirm the action to be performed; either to go “On Grade” or to go
“Off Grade” depending on the current grade status.

Figure 3-5 Confirm “On Grade” or “Off Grade” action

In Figure 3-5 the “Off Grade” action button is displayed depressed indicating that the system is
currently off grade (note also that “On Grade” button is NOT filled green indicating we are currently
off grade) and selecting this option simply leaves the system off grade.

Selecting the “On Grade” option will cause the system to go on grade, the “On Grade” button will
then be displayed as shown below. Product accumulation will now commence.

Figure 3-6 System is currently “On Grade”

Manual Grade Change Button

The “Manual Grade Change” button allows the system to change grade. Essentially the existing
preliminary grade will be transferred to become the active or current grade to be used by the QCS.

When you press the “Manual Grade Change” button a popup appears which requires you to confirm
that a manual grade change should indeed be performed.

Figure 3-7 Confirm manual grade change

Selecting the “No” option simply cancel the request and leaves the system in its current state (note: a
manual grade change can be performed when the system is on or off grade).

Selecting “Yes” will initiate the grade change. The grade change process involves transferring the
currently selected preliminary grade specification to the active (i.e. current) grade specification. While
the grade change process is in progress the “Manual Grade Change” button is displayed as filled green
and the “On Grade” button becomes unfilled indicating that the system is no longer on grade.

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Chapter 3 Process Display Operation Machine Overview

You should also note that the “Manual Grade Change”, “On Grade” and “Next Grade” buttons will all
be disabled while the the process is active (see Figure 3-8 below). This is designed to prevent
undesired user interactions during the grade change process.

Figure 3-8 Grade Change in progress

Once the actual process of changing grade is complete the “Manual Grade Change” button will be
displayed as unfilled and all three buttons will once again become enabled.

Figure 3-9 Grade Change complete

As can see seen above, the preliminary grade has been transferred to the active grade specification
(i.e. Grade 2 is now the current grade). The state of the buttons (none filled green) indicates that the
system is currently off grade but no grade change is currently in progress. It should be noted that this
is the state the QCS initially adopts when it starts.

Auto Grade Change Button

For detailed information on the Automatic Grade Changes feature and how to use it please refer to
section 4.2.11 Auto Grade Change Display.

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Scanner Operation Chapter 3 Process Display Operation

3.2 Scanner Operation

Scanner operation is normally viewed and accessed by means of scanner display elements. Each of the
scanner display elements presents the scanner name, an animated scanner position display and status
indicators for the scanner.

Figure 3-10 Scanner Overview 1

As can be seen in the above screen shot the scanner “SP1200_1” is currently performing a
standardize; is in Independent mode and has a warning condition active.

Scanner “SP1200_2” is currently offsheet; is in Global mode and has no alarms or warnings active.
The remaining scanners are all in local and in global mode.

When a scanner is scanning across the sheet the position of the head is indicated by the “radiological
symbol” moving across the sheet.

Scanner operations are controlled by means of faceplate display elements. Clicking on the Global
Scanner display element or any one of the individual scanner display elements will cause the
associated faceplate to be presented.

Note: Refer to section 3.2.6 for a detailed description of the scanner icons and their meaning.

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Chapter 3 Process Display Operation Scanner Operation

Figure 3-11 Scanner Overview 2

As can be seen in the above screen shot the scanner “SP1200_1” is currently performing in local
because a sheet break has been detected.

All remaining scanner are currently scanning in global mode. As can bee seen when scanning the
radiological symbol indicates that the shutter is open and its location representes the head position of
that scanner.

Note: If a scanner does not contain any sensor which uses a radiological source then the “radiological
symbol” will be replaced by a plain circular icon. The color of the icon represents when it is
measuring or not.

Refer to section 3.2.6 for a detailed description of the scanner icons and their meaning.

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Scanner Operation Chapter 3 Process Display Operation

3.2.1 Global Scanner Faceplate – Reduced View

Global scanner operations are controlled by a scanner faceplate that will pop up by left clicking the
mouse cursor anywhere on the global scanner display element.

The following illustration shows the global scanner faceplate. Note that the global scanner icon and
corresponding face plate is available only for multi scanner systems, and the purpose is only to
provide a common control point for all physical scanners. Tool tips exist for all the scanner mode
control and are displayed when the mouse is hovered over an individual button.

Figure 3-12 Global Scanner Faceplate

The faceplates can be extended or reduced to include more or less functionality by selecting the one,
two or three dot views. The global scanner has only two available views. The following picture shows
the added functions in highest level of extension for global scanner face plate.

Refer to section 3.2.6 for a detailed description of the scanner faceplate icons and their meaning.

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3.2.2 Global Scanner Faceplate – Normal View

The Global scanner faceplate can be accessed by pressing the faceplate button which display the two
dots (“..”)

Figure 3-13 Global Scanner Faceplate – Normal View

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Scanner Operation Chapter 3 Process Display Operation

3.2.3 Scanner Faceplate – Reduced View

The physical scanners in a system each have their own individual icons and associated face plates. For
a single scanner installation on a machine, only one icon and face plate is available. Upon activation,
the face plate will come up in a reduced view as shown below. One, two or three dots on the bottom
of the panel allow for extension of the face plate with more information. The following illustration
shows the principle of operation of the icon and faceplate.

Figure 3-14 Scanner Faceplate Reduced View

The faceplate for an individual scanner will be displayed when the user clicks on a scanner display or
indeed any display elemenet associated directly with a particular scanner.

The user can control the scanner from this face plate only when the scanner in question is operating in
Independent mode (as shown above). When in global mode the scanner command buttons will be
displayed as control is only permitted via the Global scanner faceplate.

Refer to section 3.2.6 for a detailed description of the scanner faceplate icons and their meaning.

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3.2.4 Scanner Faceplate – Normal View

The “normal” scanner faceplate view which is accessed by clicking on thegfaceplate button containing
the two dots. This view allows presents additional scanner information and provides additional levels
of control for an individual scanner.

Figure 3-15 Scanner Faceplate Normal View

Note: When the scanner is in global mode the Synchronised Scanning button will be disabled as these
requested should be performed at the global scanner faceplate.

Refer to section 3.2.6 for a detailed description of the scanner faceplate icons and their meaning.

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3.2.5 Scanner Faceplate – Extended View

The scanner faceplate extended view (three dots) has significantly more scanner information, and it is
mainly used for service or systems operations and some sensor procedures. The additional right hand
panels provide insight into frame status, setup of scanner and sensor clean/dirty standardize selection.

Status Panel

The status information panel in the view below contains frame diagnostics and digital input
information.

Figure 3-16 Scanner Faceplate Extended View - Status Panel

If any of the scanner alarm conditions are active then the associated entry on the status panel will be
displayed with using a red filled status indicator. In addition a red alarm triangle will be displayed in
the indicator area at the top of the faceplate.

If any scanner warning conditions are active (i.e. the three “service” check conditions) then the
associated entry on the status panel will be displayed with using a yellow filled status indicator. In
addition a yellow warning triangle will be displayed in the indicator area at the top of the faceplate.

If an alarm and warning condition(s) are active simultaneously then in terms of the indicator area at
the top of the faceplate, alarm conditions take precedence and a red alarm triangle will be displayed.

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If either the Sheet Break or Reel Turnup digital inputs are active they will be displayed using a green
filled status indicator. In the case of a sheet break being active the indicator area at the top of the
faceplate will display the sheet break active status indicator.

Single Point Panel

The Single point information panel in the view below contains setup parameters from running the
frame in single point mode.

Figure 3-17 Scanner Faceplate Extended View – Single Point Panel

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Scanner Operation Chapter 3 Process Display Operation

Standardize Panel

The Standardize panel on scanner extended faceplate allows the user to select the interval between
each scanner standardize. The user can also select either ‘Clean’ or ‘Dirty’ standardize.

Figure 3-18 Scanner Faceplate Extended View – Standardize Panel

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Setup Panel

The setup panel on the scanner faceplate extended view includes scanning setup parameters and
readout of values from the scanner.

Figure 3-19 Scanner Faceplate Extended View – Setup Panel

When you click on the “Sheet Break Override” option you will be prompted to turn it on/off. When it
is turned on the “Sheet Break Override” option will be highlighted in yellow and will remain so until
it is turned off. In addition a yellow warning indication will be displayed in the status area at the top
of the scanner faceplate.

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3.2.6 Scanner Icon Summary

The following table illustrates each of the images displayed by the scanner display elements and
faceplates with a description of their meaning.

Request Off sheet Request Single Point

Request Scan mode Request Standardize

Shutter Open (Measuring - Shutter Closed (Not measuring -

radiological source on scanner)) radiological source on scanner))

Measuring (no radiological source on Not measuring (no radiological source on

scanner) scanner)

Scanner in Global Mode (Indicator) Scanner in Independent Mode (Indicator)

Request Global Mode (Button) Request Independent Mode (Button)

Turn on Auto Edge of Sheet Turn off Auto Edge of Sheet

Synchronized Scanning Enabled Synchronized Scanning Disabled

Scanner in Remote Scanner in Local

Scanner in Workstation Control mode Scanner does NOT contain radiological

source (Faceplate display only)

Sheet Break in progress

Alarm condition active Warning condition active

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3.3 Scanner Overview Display

Figure 3-20 Scanner Overview Display

The Scanner Overview display shows the scanners configured for the system.

Clicking on the Global scanner information will trigger the display of the Global Scanner faceplate.
Similarly clicking on any of the individual scanner elements will cause the Scanner faceplate for the
associated scanner to be displayed.

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3.4 Profile Displays

The profile display element provides selectable insight in CD profiles of the process. There are
essentially two types of profile controls available in the system with different look and feel. A new
design based on Process Graphic 2, and a classic style profile control used by CD control and MCD
control, are both available in the system.

The following section only deals with the new Process Graphics 2 profile displays and the general
functionality of this display is illustrated below.

Figure 3-21 Overview of Profile Display Elements

The profile display element provides numeric information for each selected measurement profile in
the bottom portion of the element, these are:
 Target: The currect grade code measurement target
 High: Peak high data box value in the profile.
 Low: Peak low data box value in the profile.
 2 Sigma: 2 * Standard deviation of the profile data.
(Note: The sigma multiplier is defined in the system coldstart data file)

The following display features should be note:

 The profile average is normally displayed using the same color used for the profile trace
itself. When the profile average is out side the grade defined “average off spec limit” it
will be display in red (as shown above).
 The profile timestamp will normally be display with a gray background, however no new
profile data is received within a predefined period the background changes to a light red
color to draw attention to the last time an update was received (as shown above)
 The profile validity indicator is display in a similar manner to the timestamp. If the profile
is invalid the text changes and the background switches to a light red color.
 Three different versions of the profile display element exist which are capable of showing
one, two or four measurement profiles on the same plot.

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3.4.1 Profile Measurement Selection

The selection of a measurement for display on the profile element involves selecting the scanner on
which the measurement resides, the actual measurement and finally the type of profile data to use
(Composite, Single Scan or Mapped profile data) in this order.

To select a new measurement the user presses the “Profile Selection” button associated with the
profile whose measurement is to be changed.

When the profile selection button is pressed a profile selection dialog is displayed. It should be noted
that the header text in the profile selection dialog always matches the profile color with which it is
associated.

Initially only the “Scanner” selection drop down list is enabled. When activated it displays a list of all
scanners that are configured in the system. To select a scanner simply click on the appropriate entry in
the list.

Figure 3-22 Profile Scanner selection

Once a scanner has been selected the “Measurement” selection list will be come available. The
Measurement list displays all the measurement on the selected scanner that support profile data. Once
again the desired measurement is selected from the list.
Note: You can at this stage go back and select a different scanner, in which case the list of available
measurements will be updated to reflect the sensor compliement of that scanner.

Figure 3-23 Profile Measurement selection

Once a measurement has been selected the Profile Type list will become active. The actual type of
profile data that can be selected is displayed in this list and typically contains the options
“Composite”, “Single Scan” and if configured for the select measurement “Mapped” profile data.

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Figure 3-24 Profile Type selection

After the Scanner, Measurement and Profile Type have been selected the “Apply” button will be
enabled. In order have your selection applied you must click this button. The “Cancel” selection
button can be pressed at any stage in the selection process and will cancel the operation.

3.4.2 Plot Range Selection

The range of the profile plot for a given profile can be changed by the user. To do this click on the
profile plot upper range value for the associated profile trace. When you click on this value a dat entry
window will be displayed in to which the new profile range can be entered.

Figure 3-25 Show/Hide profiles

Once the new range has been entered pressing “Enter” applies it to the plot.

Note: The values entered for each of the profile plot ranges are persisted user settings. A persisted
user setting implies that this value will be preserved between display invocations and between
workplace invocations. In short you can switch displays and/or close the workplace and then when
this display is called up again the profile plot ranges will be the same values as when it was last
shown.

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3.4.3 Show/Hide Individual Profile Traces

Individual profile traces can be selectively hidden or displayed. To show/hide an individual profile
simply press the “Show/Hide Profile” button which is located to the right if the profile type selection
entry.

Figure 3-26 Show/Hide profiles

Note: The state of the “Show/Hide” profile buttons is a persisted user setting. A persisted user setting
implies that this state will be preserved between display invocations and between workplace
invocations. In short you can switch displays and/or close the workplace and when this display is
called up the “Show/Hide” will be in the same state as when it was last shown.

3.4.4 Centreing / Auto arranging the profile traces

The “Centre/Auto Arrange” button control the presentation of the actual profile traces on the display.
By default the profile traces will be diplayed centred in the plot. By pressing the “Centre/Auto
Arrange” the profile traces will be automatically be displayed separated from each other (as shown
below). Turning off the “Centre/Auto Arrange” feature will once again leave the profile traces centred
in the plot.

Figure 3-27 Centred/ Auto arranged profile trace presentation

Note: The state of the Centre/Auto Arrange” button is a persisted user setting.

3.4.5 Profile Snapshot

The profile display element supports taking a “snapshot” of the current profile trace. Pressing the
“Snapshot” button for a profile will result in a frozen copy of the current profile trace to be displayed
on the plot. This “snapshot” trace will not update when the original profile trace changes at the next
edge of sheet but will remain as a fixes profile until it is removed.

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The “snapshot” profile trace is presented on the plot using a darker shade of the original profile color.
On profile plots with several traces using this darker shade of the original profile color allows the user
to readily associate it to its original source measurement profile.

Figure 3-28 Profile Snapshot

This primary use of the profile snapshot feature is to allow the comparision between an older and the
most recent profile trace. The “Snapshot” profile is removed when the “snapshot” button is turned off.

Note: The state of the “Snapshot” for a profile trace and the actual snapshot profile trace are
persisted user settings.

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3.4.6 Profile Data Point Marker

When the cursor is moved over the profile plotting area a data point marker is automatically
displayed. The data point marker is presented as a vertical line on the profile plot. The data box
number and data box value for all visible (non hidden) profiles will also be shown adjacent to the
marker line.

Figure 3-29 Profile Data Point marker

3.4.7 Profile Zoom Functions

Profile Zoom allows the user to focus in on a particular section of the profile plot and examine the
profile traces in greater detail.

Zooming is activated by a left clicking on the profile plot area and while holding the left mouse button
down dragging over the plot to select the desired area. As you drag the mouse the selected profile area
that will be zoomed will be highlighted in the plot.

Figure 3-30 Zooming a Profile

When the mouse is released the profile plot will zoom to display the selected area.

After the profile plot has been “zoomed” the first and last data box numbers will be updated to reflect
the area of the profile which is now visible. In addition a “zoom control bar” will be displayed along
the bottom edge of the plotting area. This control bar allows the user to interact with the zoomed data
area of the profile display.

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Profile Displays Chapter 3 Process Display Operation

Figure 3-31 Profile Zoomed

Figure 3-32 Zoom Controls

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3.4.8 Profile off spec indication

When the grade information for a measurement contains profile off spec values then these will be
reflected on profile plots displaying the measurement in question only when part of the profile is
actually off spec.

Figure 3-33 Profile Off Spec indications

When a portion of the profile is off spec the profile plot will display one or both of the profile off spec
limit lines associated with the measurement. If the profile is exceeding only the upper off spec limit
then only the upper off spec limit line will be displayed, if it exceeds only the lower limit then only
that line will be displayed. In the above screen shot the profile is exceeding both the upper and lower
off spec limits, hence the presence of both line.

In addition the actual profile high value and profile low value are highlighted to indicate that they are
off spec. Once again if only the upper limit is exceed then only the profile high value will be
highlighted.

Hints:

1. On profile plots with multiple profile traces displayed simultaneously the highlighting of the
profile high and low values indicate which of the profile traces is actually off spec. For
example in Figure 3-33 above the profile high and low for the green profile are not
highlighted therefore the green profile is not off spec.

2. Using the “Hide/Show” profile button you can easily isolate the off spec profile traces. Or
alternatively use the “Centre/Auto Arrange” button to separate the profile traces which will
again server to clear identify which profile(s) are off spec.

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Measurement Overview Chapter 3 Process Display Operation

3.5 Measurement Overview

The Measurement Overview display is designed to provide basic information for all scanners and
measurements which have been configured for a system. An example of the Measurement Overview
for a system with three scanners is shown in Figure 3-34 below.

Figure 3-34 Measurement Overview

Within the Measurement Overview display the individual scanners (name entry) are presented using
button elements. Pressing one of these scanner buttons will cause a scanner specific measurement
overview display to be presented as an overlap display. This scanner specific measurement overview
presents the same information as the main measurement overview display except its contents is
restricted to the sensor compliement of the specific scanner.

Figure 3-35 Scanner Specific Measurement Overview Button

The primary reason for this is for those cases where the system contains a large number of scanners
and large sensor compliement and there is insufficient space on the main measurement overview
display to display an entry for each and every one of them.

The measurement overview displays will also provide easy access to measurement specific displays.
When the cursor is placed over individual measurement display elements shown on the display the
item will if appropriate become “highlighted” to indicate that clicking on the item will result in a
measurement specifc display being presented.

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Figure 3-36 Higlighting individual measurement display elements

In most cases when it is activated a dedidcated profile display will be presented for the associated
measurement. For those measurements that do not support profile data (i.e. Color measurement) the
Color Measurement Status display will be presented.

Figure 3-37 Basis Weight Profile display

Notes:

1. These particular profile displays are fixed displays in so far as the measurements presented on
them are not user selectable. They are dedicated to a specific measurement.

2. For systems which have such a large number of scanners and associated sensors that all the
information cannot be displayed on a single page then the main measurement overview
display will, by default, only show the scanner entries. The individual sensor compliement
can be viewed via the scanner specific measurement overview displays.

Figure 3-38 Large system Measurement Overview display

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Excel® Measurement Analysis Chapter 3 Process Display Operation

3.6 Excel® Measurement Analysis

Information about sensor standardize performance and sample results can be visualized and analyzed
in standard spread sheet environment. This analysis will automatically pull up historical up to most
recent information stored in SQL data base and display in Excel. It also includes pre-made logic for
graphing essential sensor information. Utilization requires that Excel is installed on the machine.

3.6.1 Activating Excel® Measurement Analysis

For each sensor in the system, an associated aspect is available for Excel® sensor analysis. The
following illustration shows how right clicking on one particular sensor brings up an aspects menu
navigation access to the Excel measurement analysis. In this example the Measurement Overview
Report was used for start of the navigation.

Figure 3-39 Activating Excel Measurement Analysis

3.6.2 Excel Calibrate Sample Analysis

The Calibrate Sample reports from the scanner are separately available for each sensor in the system.
The information included in these reports is individualized per sensor. Most current data is on the top
row. The following example shows example information from one sensor.

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Figure 3-40 Excel Calibrate Sample Analysis

3.6.3 Excel Check Sample Analysis

The Check Sample reports from the scanner are separately available for each sensor in the system.
The information included in these reports is individualized per sensor. Most current data is on the top
row. The following example shows example information from one sensor.

Figure 3-41 Excel Check Sample Analysis

3.6.4 Excel Standardize Analysis

The Standardize reports from the scanner are separately available for each sensor in the system. The
information included in these reports is individualized per sensor. Most current data is on the top row.
The following example shows example information from one sensor.

Figure 3-42 Excel Standardize Analysis

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Reports Chapter 3 Process Display Operation

3.7 Reports
The Measurement Application Framework server provides the following complement of hardcopy and
display reports:

1. Production Reports

a. Reel Report

b. Grade Report

c. Day/Shift Report

d. Color Shade Report (optional feature)

e. Roll/Set Report (optional feature)

2. Sensor Reports

a. Standardize Report

b. Sample Check Report

c. Calibrate Sample Report

3. Color Sensor Reports

a. Color Standardize Report (optional feature)

b. Color Sample Check Report (optional feature)

c. Color Calibrate Sample Report (optional feature)

3.7.1 Production Reports

All reports are configured using a similar layout. The below figure illustrates the Crytal Report
controls that are common to all production and sensor reports.

Figure 3-43 Report Display Controls

 Select the printer icon to print a report.

 Select the envelope icon to export the report to HTML pages, Lotus Notes or other applications.

 Select the lightning bolt icon to refresh the report display.

1. Select a size from the drop down list box to zoom in or out on a report view.

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Figure 3-44 Available Historical Reports

Each production report has a list of Available historical reports (See Figure 3-44). Scroll up and down
to see the entire report history. There is a “Sort Order” selection area to help you organize the list of
Available Reports. For example, reel report Sort Order selection area provides sorting by Reel Turn
Up Time, Reel Number or Product Number.

3.7.2 Roll/Set Feature (Optional)

The Roll/Set feature consists of one or more “packages”. Each package produces production and
statistical information about sets of rolls which can be obtained from the reel as it is being produced.

The Current Roll/Set display provides information about the current set and its rolls as they are being
produced. The display consists of three main components:

 Set Average Profile panel

 Roll Statistics for each of the measurements assigned to the package

 Set and Roll configuration area

Set Average Profile

The profile display the average profile for the current set as it is being produced. It also provides a
visual indication of which portions of the profile are being used to calculate the statistical values for
each of the indivisual rolls which have been defined for the set.

In terms of user interaction and operation the set average profile area is almost identical to a standard
profile plot (see section 3.3 for operational details). There are a number of differences which are
specific to the Roll/Set feature;

 The measurements assigned to the profiles cannot be changed by the user. The measurements
assigned to individual roll/set packages during configuration determine the measurements that
appear on the profile display.

 The Roll/Set feature does not support grade specific “average off spec” or “profile off spec”
limits and hence these are not supported by the set average profile plot.

 Roll/Set does support defining absolute high, low and peak to peak limit values for each
measurement assigned to a roll/set package. The set average profile plot does support a visual
indication if the high or low limits values are exceeded.

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Reports Chapter 3 Process Display Operation

 The roll/set profile plot displays vertical lines which represent the position of the various rolls
within the profile. These “roll lines” are designed to visually indicate the portion of the profile
whose data is being used to calculate the individual roll statistics.

Figure 3-45 Current Roll/Set Overview Display

Pressing the “Roll/Set Measurement Limits” button will display a dialog for the associated measuremt
which allows the user to set the high, low and peak to peak limit value for that roll/set measurement.
The individual limit names (i.e. High Limit, Low Limit and Range Limit are color coded to reflect the
measurement they are associated with).

Figure 3-46 RollSet Measurement Limits entry window

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Roll Statistics

The central portion of the Roll/Set display contains the calculated measurement statistics for each of
the rolls within the Set. This area displays the standard compliment of roll statistical values namely
the roll Average, High, Low, Range and 2 Sigma.

Figure 3-47 Extended Statistics window

The Roll/Set feature also calculates an “extended” set of roll statistics which are not shown on the
main roll/set display. These extended statistics can be viewed by via an overlap display which is
presented when the “Extended Statistics” button is pressed.

The extended statistics are: Average + 2 Sigma, MDL 2 Sigma, CD 2 Sigma, MDS 2 Sigma, Total
Range, Max CD Range, Average CD Range and MD Range.

Figure 3-48 Extended Statistics window

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Reports Chapter 3 Process Display Operation

It should be noted that the average set profile and the roll statistics will highlight any values that are
outside the limits values set for the associated measurement. In the case of the average set profile the
off spec portions of the profile will be displayed as red and the associated profile high, low and/or
peak to peak value will be highlighted.

The associated values for each individual roll will be displayed in red if they exceed the limits set for
the measurement.

Figure 3-49 Off Spec Roll/Set values

Set and Roll Configuration

The lower section of the Roll/Set display shows information for both the “Current” and “Next” sets.
The values displayed for the “Current Set” represent the actual production values in use and cannot be
altered. These include the target set length, the elapsed footage, set number and the number of rolls.

Directly below these are “Next Set” configuration data entry fields, these allow the “Next Set”
parameters to be entered. Entries include the target set length, the number of rolls for the set and the
reel trim.

Figure 3-50 Roll/Set configuration values

Trim values for the individual rolls are entered in the associated roll trim data entry boxes which are
displayed below the “Next” set configuration section. The number of roll trim data entry boxes which
are displayed is directly related to the number of roll specified for the “Next Set”. The sum of these
roll trims for the next set must match the reel trim value entered for the next set.

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An alarm message as shown below will appear below the current grade name and code if the rolls
trims are entered incorrectly. If a roll change ocurr while this alarm is active, a roll trim equal to the
total trim divided by the number of rolls will be used.

Figure 3-51 Incorrect roll trim entry alarm

Last Roll/Set Overview Display

When a set complete the “Last Roll/Set” display shows the final values associated with that set when
the set completed. The information shown on this display remains in place and updates only when a
new set is completed.

Figure 3-52 Last RollSet Overview Display

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Reports Chapter 3 Process Display Operation

3.7.3 Sensor Reports

Figure 3-53 Available Historical Reports

Each sensor report has a list of the “Latest Available Data” reports list and a “History Reports” lists.
See Figure 3-53. You can select from a list of scanners within the “Latest Available Data” box. By
selecting a specific scanner, the most recent sensor report for the scanner will be displayed. For
example, if the Standardize History aspect is displayed and the user selects SP1 from the “Latest
Available Data” list, then the latest standardize report for SP1 will be presented. By selecting a sensor
in the “History Reports” list, the entire sensor data history will be displayed in the report. For
example, if the Standardize History aspect is displayed and the user selects “SP1 Basis Weight” from
the “History Reports” list, then the entire standardize history for the “SP1 Basis Weight” will be
presented.

3.7.4 Color Sensor Reports

Figure 3-54 Available Historical Reports

Each color sensor report has a list of Available historical reports. See Figure 3-54. Scroll up and down
to see the entire report history. There is a “Sort Order” selection area to help you organize the list of
Available Reports. For example, if the Color Sensor Standardize History aspect is displayed, a list of
the entire history of color sensor standardize reports will be shown in the “Available Color
Standardize Reports” list. Use the “Sort Order” controls to sort the color sensor standardize reports by
Standardize Time or Scanner Name.

3.7.5 Display and Hardcopy

Printed reports in the Measurement Application Framework server are copies of video displays. Each
report has an associated display aspect that can be viewed from any operator station. The automatic
event-driven output of a printed hardcopy of any report is available but must be configured by a
Systems Engineer.

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3.7.6 Navigation

Sensor report display Aspects are generally accessed by right-click on a sensor object and select the
desired report Aspect.

3.7.7 Screen Hardcopy Printing

Hardcopy printing can be done by choosing the “Shift” and “Prnt Scrn” buttons simultaneously. If a
printer is configured for the system, the screen copy will be seen on the printer.

3.7.8 Capturing Display Image

Capturing Display Images can be done by choosing the “Shift” and “Prnt Scrn” buttons
simultaneously. If the printer is not configured for the system, the screen copy may be pasted into a
Word® document, Paint® screen, or other file to be used at a later date.

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System Overview Chapter 3 Process Display Operation

3.8 System Overview

The System Overview is a combination display that allows operation/viewing of the scanners and
measurements and interaction with the grade codes. There are three operator control panels; the
scanner overview panel; the grade panel; the profile panel (Figure 3-55).

Figure 3-55 System Overview display

3.8.1 Scanners Overview Panel

The Scanners Overview Panel contains two types of graphic element that help the operator to control
the scanner; the global scanner element and the individual scanner element.

The global scanner element displays the current mode of operation as shown below.

Thie individual scanner elements display give an indication of the current head position, scanner
mode (i.e. if the measurement source is exposed or not) and an indicator to show if the scanner is
operating in global or independent mode.

Global mode

Independent Mode

Figure 3-56 Scanners Panel

A left click on either of thew graphic elements will launch the associated scanner faceplate. The
operation of these faceplates is described in section 3.2.

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3.8.2 Grade Panel

The grade change panel allows you to select paper grades, perform grade changes, and to start
production accumulation. Refer to section 3.1.3 Grade Information for more information.

3.8.3 Profile Panel

The Profile displays the cross sheet profile of any measurement within the system. The name of the
measurement, the frame the measurement resides on and the type of measurement are displayed along
with the measurement target, high value, low value and standard deviation value for the current
profile (Figure 3-57).

Windows with multiple profiles display the data for each measurement in a different color for easy
recognition.

Figure 3-57 Profile Overview

Operation

Please refer to section 3.3 for a detailed description of the operation of the profile panel.

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Chapter 4 Machine Direction Control Displays Introduction

Chapter 4 Machine Direction Control Displays

4.1 Introduction
The following sections describe the basic operation of the MD control features, which include Level 2
Scan Level Control, Level 1 Control (PID), Coordinated Speed Change, and Auto Grade Change.

4.2 MD Control Operation

The MD Overview display (Figure 4-1) is used to change the mode or setpoint of any of the displayed
level 1 (e.g. Stock flow, steam pressure, etc) or level 2 control loops (e.g. Weight, Moisture, etc).

Figure 4-1 MD Control Overview display

4.2.1 Drystock

The drystock button is located in the Level 2 control area and is used to enable drystock control
(Figure 4-2). The Stock flow and consistency measurements must be valid and the stock flow must be
in E1 mode for drystock activation. When drystock control is active any stock flow consistency
changes cause a proportional change in the stock flow setpoint to eliminate the fiber flow disturbance.
Without drystock control the fiber disturbance would have to be measured at the weight control
measurement scanner before a stock flow correction is made.

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Stock Drystock
Consistency Enable

Figure 4-2 MD Control Drystock Interface

Drystock control will automatically be shut off and an alarm will be reported when:

1. Consistency measurement becomes invalid

2. Stock flow measurement becomes invalid

3. Consistency change exceeds specified tuning limit

4.2.2 Dryer Ratio/Ratio

The dryer coordination section allows a ratio or bias to be applied to several steam sections from a
master steam section setpoint. The master steam section is defined as the main section that the
associated MD moisture control interfaces with. When the master steam section is placed in Auto
mode the corresponding dependent (slave) steam sections in the same group will go to External
setpoint mode if they were currently in Auto mode.

The ratio or bias can be entered once the dependent steam section is in External setpoint mode. The
dependent steam section setpoint will then change if the master steam section setpoint is changed or if
the ratio/bias entry is changed. In Figure 4-3 an example is shown with Ratio Bias 1 being the master
for moisture 1 with Ratio Bias 2 dependent on Ratio Bias 1. Also, Ratio Bias 3 is the master section
for moisture 2 with Ratio Bias 4 being the dependent steam section under Ratio Bias 3. Ratio Bias 5 is
the master section for moisture 3 with no dependent ratio bias controls.

Figure 4-3 MD Dryer Ratio/Bias example

4.2.3 Level 2 Control

Any of the level 2 control loops (e.g. weight, moisture, etc) can be selected with a mouse click on the
controller mode. This will bring up a level 2 faceplate that can be used to enter a setpoint or change
the mode (Figure 4-4).

Mode Request: The mode of the controller can be changed by selecting any of the request
pushbuttons in the lower middle section of the faceplate.

Current Mode: The current mode of the controller can be viewed in Current Mode window shown in
the upper section of the faceplate. The current mode is also displayed on the control overview

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displays. The modes possible are balance (BAL), manual (MAN), automatic (AUTO), external mode
1 (E1), external mode 2 (E2 used for speed optimization only).

Setpoint: When the controller is in Auto mode the setpoint can be selected and modified directly from
the overview display. When control switches to Auto mode, the setpoint will change to blue in colour
and may be changed directly on the level 2 display area by selecting and modifying the setpoint value
as shown in Figure 4-5 MD Level 2 control detail.

Output: The output can be selected and modified from the controller faceplate only while the
controller is in Manual mode.

Abort - Suspend Conditions: The Abort Suspend conditions can be viewed by clicking the Level 2
control status line (Figure 4-5) for each control. This will pull up an Abort_Suspend aspect listing all
abort and suspend conditions for the associated control (Figure 4-6). Active alarms are indicated by a
filled green status indicator.

Close Window: To close the faceplate window select the box in the upper right corner.

Figure 4-4 MD Level 2 Control faceplate

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Current control mode – right click on mode or MV element

will launch control faceplate

Yellow colour indicates Direct Entry Left click Status line to launch
interlock condition active Setpoint Abort/Suspend summary display

Figure 4-5 MD Level 2 control detail

Figure 4-6 MD Level 2 abort & suspend conditions

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4.2.4 MD Controls Overview Display

Figure 4-7 MD Controls Overview Display

4.2.5 Speed Control Display

The Speed Control display (Figure 4-8) is used to perform coordinated speed changes. The main
purpose of this page is to provide the operator with level 1 control loop information, participating
coordinated speed control loop status, and speed change progress. Coordinated speed changes can be
performed from the Speed Control display as well as the MD Control Overview display (Figure 4-1).

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Figure 4-8 MD Speed Control Overview

4.2.6 Speed Level 2 Control

The Level 2 Control section of the Speed Control Summary display is very similar to the Level 2
section on the MD Control Overview (Figure 4-1). See the MD Control Overview section for a
detailed description of how to change control modes and setpoints.

Starting a Coordinated Speed Change

A coordinated speed change can be requested by selecting and changing the speed setpoint in the level
2 configuration section. Any level 1 control which has a filled status square (left hand side of Level 1
section) will be ramped in a coordinated manner with the requested speed setpoint change.

Speed Control

The speed control section includes parameters which determine how the coordinated speed change
will operate.

Level 1 Control

The Level 1 control section summarizes the Level 1 PID control loops that will be associated with the
coordinated speed change. Each column is described as follows:

Require

The require check box is used to allow the corresponding level 1 controller to participate in the
coordinated speed change. When this check box is filled the Level 1 controller on the same line must
be in E1 mode before the coordinated speed change can be performed.

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Status Speed

This box is green filled when the feed forward from speed to the corresponding level 1 control loop is
enabled and the level 1 control loop is in E1 (external) mode. If the feed forward is enabled and the
level 1 is not in external mode the square will be yellow and the coordinated speed change will be
suspended.

Table 4-1 MD Status Speed Conditions for Speed Level 2 Control

Mode Condition

Speed change will be feed forward to corresponding level 1

controller

No feed forward from speed setpoint change will be applied to

level 1 controller. Requirement (Req) check box is unfilled.

Corresponding level 1 control loop is required (Req. checked)

but is not in external mode. Speed change is suspended for
this case.

Status Stock

This box is green filled when the feed forward from stock to the corresponding level 1 control loop is
enabled and the level 1 control loop is in E1 (external) mode. If the feed forward is enabled and the
level 1 is not in external mode the square will be yellow and the coordinated speed change will be
suspended. The requirement (Req) column does not directly affect the stock flow status column. This
is based on whether the stock flow to level 1 actuator feed forward is enabled in scan level control.

Table 4-2 MD Status Stock Conditions for Speed Level 2 Control

Mode Condition

Stock flow change will be feed forward to corresponding level

1 controller. Requirement (Req.) does not need to be checked
for this condition.

No feed forward from stock flow setpoint change will be

applied to level 1 controller. Stock flow feed forward to level
1 actuator is not enabled.

Level 1 control loop is required (stock flow feed forward to

level 1 control is enabled) but is not in external mode. Speed
change is suspended for this case.

Setpoint Ramp

The setpoint ramp is a bargraph which will update while a coordinated speed change is in progress.

4.2.7 Speed Optimization Summary Display

The Speed Optimization Summary display (Figure 4-9) is used to enable/disable normal mode speed
optimization, expert speed setpoint handler and dryer limited speed optimization. This display

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provides the same information as the coordinated speed change control display. Two additional grids
are added, one provides information on the maximum feasible speed calculation with respect to each
individual level 1 control, the second grid is used to enable/disable speed optimization, expert speed
setpoint handler and dryer limited speed optimization. Abort/Suspend displays are also provided for
both normal mode speed optimization and dryer limited speed optimization (see Figure 4-10 and
Figure 4-11 respectively)

Figure 4-9 MD Speed Optimization Summary Display

4.2.8 Expert Speed Setpoint Handler

The ‘Expert Speed Change’ feature can be enabled by clicking on the ‘Expert Speed Change’ button
on the Speed Optimization Control Setup (see Figure 4-9), changing the button colour from grey to
green. This indicates that the feature is active. The calculated maximum feasible speed is now used as
the setpoint high limit for the coordinated speed controller.

If the maximum feasible speed drops below the present operator setpoint, the setpoint will be
decreased to the value of the calculated maximum feasible speed and a coordinated speed change will
be initiated.

If the expert setpoint handler is turned off, indicated by a grey color on the button, the setpoint of the
coordinated speed change controller will only be limited by the setpoint limits of the machine speed
(level 1 controller).

Calc Maximum Feasible Speed

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This is calculated continuously and is displayed on the speed optimization summary display. The
maximum feasible speed is calculated from the available control range of the each level 1 actuator that
is configured to take part in the maximum feasible speed calculations. The maximum feasible speed is
the minimum of each level 1 actuator calculated maximum speed based on the available range of the
actuator. The following conditions must be true for each level 1 actuator maximum speed to be
calculated:

• The maximum feasible speed calculation enable on the ‘Max Feasible Speed Calculation’ grid
must be checked (see Figure 4-9). This checkbox also appears on the speed optimization tuning
display.

• The level 1 require checkbox from speed to the level 1 actuator must be enabled.

• From the process model of speed and the level 1 actuator, an increase in speed results in an
increase in the level 1 actuator setpoint.

If any of the above conditions are NOT true, the level 1 speed setpoint high limit is used as the
maximum speed associated with the corresponding level 1 actuator.

Fixed Max Ramp Rate

This is a tuning value which also appears on the Speed Optimization Tuning Display. The units are in
Engineering Units/second. (e.g. meters/min or feet/min)

Calculated Max Ramp Rate

This calculation is based on the available control range of the actuators. As the actuator approaches its
setpoint limit, the calculated speed ramp rate is reduced. The active speed setpoint ramp rate will use
the calculated ramp rate when Expert Setpoint Handling is active. The calculated ramp rate is the
minimum of all the calculated speed ramp rates for each level 1 actuator. For each ramp rate to be
calculated, the conditions used to calculate the maximum feasible speed must be met. If any of those
conditions are not satisfied, the speed ramp for that particular level 1 actuator will be taken from the
ramp rate entered on the Speed Control Tuning display.

Available Control Range

This is presented in actuator units. This is used for determining the maximum feasible speed.

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4.2.9 Speed Optimization (Normal Mode)

When the coordinated speed controller indicates it is in the AUTO mode, follow the steps below to
turn speed optimization on. The speed optimization setpoint is displayed on the Speed Optimization
Summary display and should be checked before the control is turned on. Speed optimization can only
be enabled from the speed optimization summary display.

Normal mode speed optimization can be enabled by clicking on the ‘Speed Optimization Control’
button on the Speed Optimization Control Setup section of the speed optimization summary display
(see Figure 4-9). This will place the coordinated speed change controller into E2 mode. This indicates
that the coordinated speed controller receives it’s setpoint from speed optimization. The speed
optimization target is taken from the maximum feasible speed that is calculated from the associated
level 1 available control range. The status of Speed Optimization is indicated by the ‘Speed Opt
Active’ indicator (see Figure 4-9). When this indicator is green filled, it indicates that speed
optimization is active, unfilled indicates that the control is not active.

Abort - Suspend Conditions: The Abort Suspend conditions can be viewed by left-clicking the alarm
line next to the Speed Opt Abort/Suspend on the Speed Optimization Control Setup grid on the Speed
Optimization Summary Display (see Figure 4-9). This will open the abort-suspend window (Figure
4-10).

Figure 4-10 MD Speed Optimization Abort & Suspend conditions

4.2.10 Dryer Limited Speed Optimization

When the coordinated speed controller indicates it is in the AUTO mode, follow the steps below to
turn on dryer limited speed optimization. The speed optimization setpoint is displayed on the Speed
Control Summary display and should be checked before the control is turned on.

1. Enable normal mode speed optimization (as described in 4.2.9 above).

2. Enable dryer limited speed optimization. Dryer limited speed optimization can be enabled by
clicking on the ‘Dryer Limited Speed Opt Enable’ button on the Speed Optimization Control
Setup grid that appears on the speed optimization summary display (see Figure 4-9).

With dryer limited speed optimization the machine speed will be ramped to the calculated maximum
speed until a steam pressure controller becomes either output or setpoint limited. Once a steam
pressure loop is limited, the dryer limited active checkbox (see Figure 4-9) will become checked
which means that MD weight will now be controlled by machine speed and MD moisture will be
controlled by stock flow. If the dryer limited active checkbox is not filled (not active), speed
optimization will try to maintain some available range in each level 1 loop while increasing the
machine speed to maximum calculated speed (dryer section will not remain limited). The moisture
loop that is currently operating in dryer limited mode is indicated by ‘Dryer Limited Speed Opt

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Active Moisture’ string. Refer to the MD Control Tuning Guide for a detailed discussion on dryer
limited speed optimization control.

Abort - Suspend Conditions: The Abort Suspend conditions can be viewed by left-clicking the alarm
line next to the Dryer Limited Speed Opt Abort/Suspend on the Speed Optimization Control Setup
grid on the Speed Optimization Summary Display (see Figure 4-9). This will open the abort-suspend
window (Figure 4-11).

Figure 4-11 MD Dryer Limited Speed Optimization Abort & Suspend conditions

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4.2.11 Auto Grade Change Display

The auto grade change display (Figure 4-12) is used to perform coordinated speed changes. The main
purpose of this page is to provide the operator the ability to setup and execute an Automatic grade
change (AGC).

Figure 4-12 MD Auto Grade Change Overview

Setting up Auto Grade Change

Load a new product into the system by clicking the the Next Grade button:

 Select the Next Grade push button which will open a dialog that will allow the new product code
to be selected as shown in Figure 4-13.

Figure 4-13 Product Code Selection Dialog

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 The Code identifier or Code Description can be used to find the new product code.

 Press ‘Use Selected Code’ to select the new product code and close the dialog window.

After the new product code is loaded the active product targets are compared to the new product
targets. The new level 1 controller setpoints (e.g. stock and steam pressure) are then calculated and
displayed in the New SP column of the Level 1 section of the auto grade change page. This
calculation is continuously updated, which allows you to change individual New Product Targets
(New SP) after a new product has been loaded.

Enter the setpoint bias for the controller targets to add or take away from the calculated new level 1
controller setpoints (e.g. stock and steam pressure).

The Level 2 Control required (Req) check boxes display level 2 control loops requirements before the
auto grade change can begin. If a level 2 control requirement is not met, the ‘AGC Interlocks’ element
will display the word Interlock in yellow for the control that does not meet the requirements. This will
interlock the auto grade change push-button (button will turn yellow) If a Level 2 Control require
diamond is filled, the associated control loop will remain in auto during the auto grade change and the
loop will participate in the grade change. The actual interlock condition causing AGC to be
interlocked can be viewed by clicking on the associated AGC Interlock element for each control. This
will launch a separate overlap aspect (Figure 4-14) which will indicate any active interlock conditions.

Figure 4-14 AGC Level 2 Interlock Conditions

If the Level 2 Req checkbox is not checked and the control loop is in auto, the loop will suspend. If
the Req checkbox is not checked and the control loop is in manual, the loop will not participate in the
grade change.

The new calculated stock and steam pressure setpoints are compared to the high/low setpoint limits. If
a limit is exceeded, the new setpoint will turn red and the ‘AGC Interlocks’ element in the associated
row will display the word Interlock in yellow. The auto grade change will also be interlocked at this
time. You can override this condition by checking the setpoint limit acknowledge check-box.

The Level 1 Control require check-boxes show which level 1 control loops must be in E1 before the
auto grade change can begin. If a level 1 requirement is not met, the ‘AGC Interlocks’ element in the
associated row will display the word Interlock in yellow and the auto grade change push-button will
be interlocked. The level 1 interlock conditions can be view in the same way as the level 2 conditions
(Figure 4-15).

Figure 4-15 AGC Level 1 Interlock Conditions

An example of the level 1 and level 2 AGC interlocks as they appear on the Auto Grade Change
summary display are shown in Figure 4-16

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Figure 4-16 AGC Interlocks

In the Current Grade Change section of the display, the calculated grade change time is the time that
the auto grade change will take to achieve the new product targets. This time is calculated as the
minimum time required under the modeling characteristics of the machine and ramp rates that are
allowed. The auto grade change push-button will turn yellow and interlock auto grade change when
the calculated grade change time exceeds the maximum grade change time.

When filled, the coordinated grade change check-box allows auto grade change to apply the modeling
characteristics of the paper machine in the calculation of the stock, pressure, and machine speed
responses. This will give a smooth transition and coordination for the product target ramps. If this
diamond is not filled, the auto grade change will use a quick ramp that does not use the paper machine
modeling characteristics. This quick ramp will not ensure the product measurements will make a
smooth transition, but will give a very fast ramping action.

Grade Change Interlock Indicators

Auto Grade Change also has a number of more general interlock conditions as well as the level 1 and
level 2 control interlocks conditions described above. An indication that one of these interlock
conditions is active is shown by the element to the right of the ‘Auto Grade Change’ button which
will display the word Interlock in yellow as shown below.

Figure 4-17 AGC General Interlock Indicator

Similar to the level 1 and level 2 controls, the actual interlock condition causing AGC to be
interlocked can be viewed by clicking on the associated AGC Interlock element. This will launch a
separate overlap aspect (Figure 4-18) which will indicate any active interlock conditions.

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Figure 4-18 AGC Interlock Conditions

The interlock conditions that are displayed in the message box are also shown by the OK column
shown in the Level 2 control section of the auto grade change display. A description of each state is
shown in Table 4-3.

Table 4-3 MD Status OK Conditions for Auto Grade Change

Mode Condition

All current conditions are met for this level 2 and

corresponding level 1 control loop

There are no requirements for this level 2 and corresponding

level 2 control loop

One of the following conditions is not being met:

- The level 2 control is not in Auto mode
- The level 1 control is not in External mode
- The calculated New SP for the level 1 control loop is outside
of the current setpoint limits. The Setpoint Bias or Setpoint
Limit Acknowledge check box can be used to correct this
interlock..

Ramping Auto Grade Change

Once all of the auto grade change setup conditions are met, the auto grade change push-button shows
normal black text and grey background (not interlocked). If the operator is satisfied with the new
targets, the grade change can be started by selecting the auto grade change push-button

1. While the auto grade change is ramping, the small target ramp bar graphs will begin updating.
They will begin updating at different times when a coordinated grade change is occurring.

2. The actual grade change time will show the actual time elapsed since the auto grade change was
activated.

3. The time off-specification will begin to update when the weight or moisture are not within the
average off-specification limit from the product code data. This time will stop when the weight
and moisture are all within the new average off-specification limits.

4. The auto grade change will complete when the actual grade change time is equal to the calculated
time.

If the auto grade change push-button is turned off before the time is completed, the auto grade change
is aborted. This leaves all the Level 1 controller setpoints at the last updated setpoint. The Level 2
controllers will be put into manual and the new product targets will be transferred into the active
targets.

If one of the requirements have changed while the grade change is active, the push button turns yellow
and the grade change aborts. In general, level 1 and level 2 controller modes can be changed during an
Auto Grade Change as long as the corresponding requirement check boxes are first unfilled. This will
prevent an interlock and the resultant aborted Auto Grade Change.

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Auto Grade Change Completion

After the auto grade change has successfully completed, the auto grade change push-button will turn
off. You must manually put the product on grade by selecting and turning on the On Grade push-
button. Until you do this, the new product will remain off grade.

Auto Grade Change Abort Conditions

When the Auto Grade Change aborts the preliminary level 2 targets are transferred and the level 2
scanning controls are placed in Manual. The Message window will also display the reason the grade
change aborted in red text. This red text will not clear until the next grade change is requested or the
Alarm Acknowledgement check box is selected. The following conditions will abort an Auto Grade
Change in progress:

 A level 1 requirement is violated.

This can occur if a level 1 controller (stock flow, pressure, clay, etc.) is taken out of E1 by the
operator while the corresponding Level 1 Require Loop check-box is filled. This may also occur
if the level 1 controller has excessive error checking which can cause it to go from E1 to manual
automatically. The level 1 setpoint can be modified by the operator during an auto grade change
by un-checking the “require” level 1 check-box before making the setpoint change.

 A level 2 requirement is violated.

This can occur if a level 2 controller is taken out of Auto while the Level 2 Require Loop check
box is filled. This usually occurs when an operator changes the Level 2 mode without first
emptying the require Loop check-box.

Since the Level 2 controllers will show E1 during Auto Grade Change even when it is in Auto or
Man, you can determine the mode as follows:

If the Require Loop diamond is filled and the level 2 control shows as E1 without the suspend X,
the control is in Auto.

If the Require Loop diamond is unfilled and the level 2 control shows E1 with the suspend X, the
control is in Auto and suspended.

If the Require Loop diamond is unfilled and the level 2 control shows E1 without the suspend X,
the control is in Manual.

If the level 2 controller is in “Bal”, it will remain in “Bal”.

 The delay coordination exceeds the maximum delay coordination. This will normally occur when
the machine speed is slowed down significantly

4.2.12 Multi-frame Scan Level Control (MFSLC)

Multi-frame scan level control (MFSLC) is a special implementation of scan level control (Level 2
feedback control). Unlike standard Level 2 control, MFSLC uses two feedback MD measurements to
make control decision for a single common actuator with the primary objective of making control
actions sooner for upstream disturbances. Each of the two feedback MD measurements has their own
control mode. MFSLC is typically associated with controlling the sheet weight property where one
MD measurement is taken at a downstream location and the other MD measurement is taken at an
upstream location. The two MD measurements must hold the following relationship.

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 MD measurements are correlated or for the same sheet property (i.e. basis weight, conditioned
weight)

 MD measurements are taken from locations that have a measureable delay difference (i.e. reel
and wet press)

The first or primary MD measurement is used the same way as it would be used in a standard Level 2
control. This measurement is one that has product quality importance and is controlled to a
specification target (i.e weight at the reel). The second MD measurement is used for detecting
disturbances that occur ahead of the measurement location of this second measurement. This
measurement is one that is located upstream from the primary MD measurement and is correlated to
the primary MD measurement (i.e. weight near the wet press). Because of the requirements for
selecting the second MD measurement, disturbances occuring upstream are now detected sooner and
control actions are made without having to wait for the upstream disturbance to reach the
measurement location of the primary MD measurement. For disturbances occuring between the two
measurement locations (i.e. coater disturbances), the disturbance will appear in the primary MD
measurement and therefore will be corrected. Since this latter type of disturbance will not appear in
the second MD measurement, the correction applied for disturbance in the primary MD measurement
will result in a steady-state shift in the second MD measurement. As example, the primary weight
measurement sees a coater disturbance that increases the weight by 1 unit. MFSLC applies stock flow
decreasing control actions to remove the 1 unit increase and brings the primary weight measurement
back to target. The decreased stock flow translates to a decrease in the upstream weight measurement.

Because MFSLC is a special Level 2 implementation it provides additional features that are associated
with using two feedback MD measurements versus one. These additional features affect operation of
MFSLC when it is operates as a Level 2 control and when it participates in Automatic Grade Change,
and the following subsections are reserved for discussing these operational changes. All the standard
operations of Level 2 control and Automatic Grade Change that MFSLC preserves are described in
there respective sections. Reference to these standard operations will be made in the following
subsection but not re-stated.

Level 2 Control Operation

The additional features associated with Level 2 control operation are tied to the control mode of the
two MD measurements. The following illustration shows the Level 2 and Level 1 tables with
information displayed for MFSLC weight. In the Level 2 table, separate lines are used to display
control information for the two MD measurements (reel weight and wet press weight). In the Level 1
table, the same actuator (stock 1) information is displayed and aligned with the two MD
measurements.

Figure 4-19 MFSLC feedback controllers

The following table identifies the different mode of operation that MFSLC supports and the functions
support by each of the mode of operation.

Table 4-4 MFSLC feedback control modes

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Mode

Downstream Upstream (i.e. Supported Operations

(i.e. reel weight) wet press
weight)

BAL BAL  Level 1 actuator (i.e. stock flow) is not in a remote state
 No control actions can be sent from either the downstream
or upstream Level 2 control

MAN MAN  Level 1 actuator is in a remote state

 Manual output change can be sent from either the
downstream or upstream Level 2 control
 Output value for both Level 2 controls are updated with the
same value

AUTO MAN  Level 1 actuator is in a remote state

 Automatic control performed only on the downstream
measurement (i.e. reel weight)
 Downstream target can be changed and the measurement is
controlled to the entered target
 Manual output change cannot be changed for the upstream
control. All manual change values are ignored and the
output value is update with the current Level 1 setting.
 Automatic control is not performed on the upstream
measurement (i.e. wet press weight). Upstream control
target can be changed but it is ignored because control is
not performed while this loop is in MAN.

MAN AUTO  Level 1 actuator is in a remote state

 Automatic control performed on the upstream measurement
(i.e. wet press weight)
 Upstream target can be changed and the measurement is
controlled to the entered target
 Manual output change cannot be changed for the
downstream control. All manual change values are ignored
and the output value is update with the current Level 1
setting.
 Automatic control is not performed on the downstream
measurement (i.e. reel weight). Downstream control target
can be changed but it is ignored because control is not
performed while this loop is in MAN.

AUTO E2  Level 1 actuator is in a remote state

 Automatic control performed on both the downstream and
upstream measurements
 Downstream target can be change and the measurement is
controlled to the entered target

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Mode

Downstream Upstream (i.e. Supported Operations

(i.e. reel weight) wet press
weight)

 Upstream measurement is controlled to a model reference

for the purpose of detecting occurrences of upstream
disturbances.
 Upstream target cannot be changed. This target is
computed and updated by MFSLC. The steady-state target
computed for the upstream control is equal to the
downstream control target multiplied by the ratio of the
upstream measurement to the downstream measurement

Upstream E2 Target = (SPd) x (MVu/MVd)

 Upstream control target is latched to the last update of the
E2 target when this control changes from E2 mode to any
of the other modes

Automatic Grade Change Operation

The additional features associated with Automatic Grade Change operation are tied to a tuning setup
that determines which of the two MD measurements and targets Automatic Grade Change will base its
Level 1 setpoint calculation and ramping of the Level 1 and Level 2 setpoints. Similar to the last
subsection, the following illustration shows the Level 2 and Level 1 tables with information displayed
for MFSLC weight. In the Level 2 table, separate lines are used to display control information for the
two MD measurements (reel weight and wet press weight) along “Req” checkboxes and “OK” status
for each of the controls. In the Level 1 table, the same actuator (stock 1) information and “Req”
checkbox are displayed and aligned with the two MD measurements.

Figure 4-20 MFSLC feedback controllers

Since the “Req” checkbox for the Level 1 actuator is the same on both lines, it does not matter which
checkbox is selected and changed. When one checkbox is checked the other is also checked and vice
versa. When checkbox is checked, it means that the Level 1 actuator must be in an E1 mode for the
actuator to be “OK” to participate in the grade change

The following table defines the significance of “Req” checkbox and “OK” status for the two Level 2
controls.

Table 4-5 MFSLC feedback control modes

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Location Downstream Upstream

That (i.e. reel (i.e. wet
Determines weight) press weight) Supported Operations
the Grade
Change “Req” “Req”

Operation condition: Grade change Level 1 setpoints

Downstream   and grade change ramps are computed based on the
downstream control target. The upstream control
information is ignored.
 Downstream control must be in AUTO for “OK”
status to be set “GOOD” green filled
 Upstream control “Req” checkbox is ignored
(“OK” status is set to “GOOD”)
Operation condition: Grade change Level 1 setpoints
Downstream   and grade change ramps are computed based on the
downstream control target. The upstream control
information is ignored.
 Downstream control can be in MAN or AUTO
mode because the control is not required to
participate in feedback mode during the grade
change. The “OK” status is set to “GOOD”
green unfilled.
 Upstream control “Req” checkbox is ignored
(“OK” status is set to “GOOD”)
Operation condition: Grade change Level 1 setpoints
Upstream   and grade change ramps are computed based on the
upstream control target. The downstream control
information is ignored.
 Upstream control must be in AUTO for “OK”
status to be set “GOOD” green filled
 Downstream control “Req” checkbox is ignored
(“OK” status is set to “GOOD”)
Operation condition: Grade change Level 1 setpoints
Upstream   and grade change ramps are computed based on the
upstream control target. The downstream control
information is ignored.
 Upstream control can be in MAN or AUTO
mode because the control is not required to
participate in feedback mode during the grade
change. The “OK” status is set to “GOOD”
green unfilled.
 Downstream control “Req” checkbox is ignored
(“OK” status is set to “GOOD”)

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4.3 Level 1 Control Operation

4.3.1 Level 1 Control Interface

The controller setpoint can be changed directly on the level 1 control display grid when the Level 1
loop is in Auto mode by selecting the setpoint field and then entering a new value. An example of
direct setpoint entry is shown in Figure 4-21. Onll a value between the current setpoint limits can be
entered. A red box will appear to around the setpoint entry if the operator tries to enter a value outside
these limits.

Direct Entry
Figure 4-21 MD Level 1 Control Direct Setpoint Entry Setpoint

The controller mode can only be changed via the level 1 control faceplate.

4.3.2 Level 1 Control Faceplate

Any of the level 1 control loops (e.g. stock flow, steam pressure, etc) can be selected with a left mouse
click on the control mode field. This will bring up a PID faceplate, which can be used to enter a
setpoint or change the mode (Figure 4-22).

The following common operations can be performed on PID faceplate:

Mode Request: The mode of the controller can be changed by selecting any of the request
pushbuttons in the lower middle section of the faceplate.

Current Mode: The current mode of the controller can be viewed in Current Mode window shown in
the upper section of the faceplate.

Setpoint: When the controller is in Auto mode the setpoint can be selected and modified. If the
entered setpoint is outside of the current setpoint limits the setpoint dialog box will not close and a
valid setpoint will need to be entered.

Output: When the controller is in Manual mode the output can be selected and modified.

Close Window: To close the faceplate window select the box in the upper right corner.

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Figure 4-22 MD Level 1 Control PID faceplate

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4.4 Multi-stock Operation

4.4.1 Ply Loading Summary Display

The Ply Loading Summary display contains information for ply/stock loading control, multi-drystock
control, stock initialization, multi-ply grade change and level 1 stockflow controls.

Figure 4-23 Ply Loading Summary Display

Changing Ply/Stock Loading Operation Modes

Stockflow can operate in anyone of four operation modes described below. The Ply Mode mode is
displayed on the Ply Loading Summary grid. A brief description of each mode of operation follows
below:

Part - This stock participates in basis weight error corrections and ply redistribution make-up. It also
participates in speed changes and speed optimization to maintain the basis weight target. Finally, this
stock participates in grade changes and stock initialization.

NonPart - This stock does not participate in basis weight error corrections or ply redistribution
make-up; however, it can be redistributed when the operator enters a new target. This stock does
participate in speed changes or if Stock Initialization Control (SIC) is active to the extent that the
setpoint will maintain a flow/speed ratio. This stock also participates in grade changes.

Constant - This stock does not participate in anything. It simply provides the ability for the operator
to set a flow target into the system and have the system control to that target. Redistribution will
happen when a new target is entered. This stock will be accounted for in the summed dry fiber flow
calculations.

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Off - This stock is presumed not in operation and will not be accounted for. If this mode is entered,
flow may go to zero.

To change the operating mode for a particular stockflow, perform the following steps:

1. Left-click the Ply Mode on the Ply Loading Summary grid. A drop down list will appear as shown
in Figure 4-24.

2. Left-click on the desired mode (Part, NonPart, Constant or Off).

Figure 4-24 Stockflow Operating Mode

Changing Ply/Stock Loading Control Modes

You can use the operator interface to put ply/stock loading control in the following control modes:

• Balance (BAL) - controller not ready, no entry accepted

• Manual (MAN) - output controlled by the operator

• Automatic (AUTO) - controlling to the operator-entered set point

• External (E1) - controlling to an external set point

If ply/stock loading (SLC) is in BAL, it is not ready to go to AUTO or E1 and will not allow set point
entry or stock redistributions.

If SLC is in MAN, it is ready to go to a higher state but the operator will not be allowed to redistribute
the stockflows. To enter MAN from BAL, at least one participating stock must be in AUTO or E1 and
that stock’s flow measurement and consistency must be valid.

If SLC is in AUTO, the operator can enter redistributions and total flow set points.

If SLC is in E1, the basis weight control will change the total flow set point, but the operator can still
enter redistributions.

Ply/Stock Loading mode (located below the total stock flow calculation) can be changed in the same
way as any other level 2 control. The procedure for changing the mode of a level 2 control is
described in Section 4.2.3.

Note: If ply/stock loading is in Automatic (Auto), at least one participating stock flow will be in
External (E1). If all stock flows are in Manual (Man), ply/stock-loading control will be in
BAL. If at least one participating stock flow is in Auto, ply/stock-loading control will be in
Man. If any of the stock consistency measurements are invalid, ply loading control will be
locked in Balance (BAL) mode.

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Changing Total Stock Flow

Follow the steps below to change the total flow set point when Ply/Stock Loading is in Auto.

 Left-click the total stock set point value and enter the new total stock setpoint value

Or

 Left-click the Ply Loading set point value and enter the value

Or

 Left-click the Ply Loading controller mode. The will bring up the controller faceplate. The
setpoint can be changed via the controller faceplate as described in section 4.2.3.

The change in stock flow will be equally distributed to all participating stock flows, which are in E1

Redistribution

Stockflow redistribution allows a change to be made to a participating, nonparticipating, or constant

stockflow and any participating stock flow will change accordingly to maintain the total dry fiber
flow. This allows ply weight changes to occur without affecting the total weight of the sheet. The
redistribution will be equally distributed to the participating stock flows, which are in E1.

For a redistribution to occur, perform the following steps:

1. Ensure the Ply Loading Status is E1 or Auto. For this to be true at least one participating stock
flow must be in E1. Stockflow modes are changed using the control faceplates.

2. Enable the ‘Target Change Enable’ checkbox for the stockflow to be changed. This will change
the color of the associated Stock Setpoint, Dry Fiber, Target Weights and Percent from it’s default
read-only green to Turquoise (Figure 4-25). This indicates that these entries can accept operator
entries. If one entry is changed,the other three will update to reflect this change.

Figure 4-25 Stock flow Redistribution

3. Select the stock flow to be changed by selecting a participating, nonparticipating or constant stock
that is in E1 under the Stock Set Point, Dry Fiber, Weight Target, or Percent Target column. The
column chosen depends only on the units with which the operator is comfortable.

4. Select the redistribution target and enter the desired value and press <CR>.

5. Uncheck the ‘Target Change Enable’ checkbox. The remaining participating flows that are in E1
will now ramp to new targets to maintain the total dry fiber flow.

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Changing Furnish Type

For the purpose of multi-ply grade change, each stock will have a furnish type. The names of these
furnish types may vary for this application. The generic furnish are as follows:

• Filler (Filler)

• Top Liner (Top Liner)

• Bottom Liner (Bot Liner)

• Top Underliner (Top Under Lnr)

• Bottom Underliner (Bot Under Lnr)

Figure 4-26 Furnish Types

Each liner type represents a liner basis weight in the product code file. You can change the furnish
type by selecting the furnish type for a particular stock flow. A drop down list will appear with the
Furnish Types. Select the appropriate furnish type as shown in Figure 4-26.

Changing Stock Initialization

Stock initialization ramps the stock flow from a beginning flow distribution and dry fiber flow to a
desired dry fiber flow based on a desired speed and basis weight. On the Ply Loading Summary
display, stock initialization set points are grouped with the ply loading data. When a new set point
exceeds the actuator limits, the display will change to red. The operator can recalculate the initial
stock set point based on the basis weight and initial speed by clicking the Calculate New Flows button
or by entering the set points individually. See Figure 4-23 and Figure 4-27.

Figure 4-27 Stock Initialization

Changing Initial Speed

Follow the steps below to enter a new initial speed value.

1. Select the ‘Initial Speed’ value, enter a new value and press <CR>.

2. Press the ‘Calculate New Flows’ button on.

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3. The Stock Initial Setpoint column (See Figure 4-23) will update with new values for stock flows,
which are in E1.

Entering Stock Initial Set Points

1. Left-click the stock flow under the Stock Initial Set Point column.

2. Enter a new value and press <CR>.

Turning Stock Initialization On

The ‘Initialize Stock Flows’ button is used to enable stock initialization. For stock initialization to be
active the ply/stock loading control must be in Auto or E1 and basis weight, speed, and redistribution
must be inactive.

Changing Drystock

Drystock flow control maintains the dry fiber flow in the presence of thick stock consistency
variations. For drystock control to be active, both the drystock button needs to be on and the
associated stock control actuator, located at the bottom of the Ply Loading Summary (Figure 4-23),
needs to be in E1. To turn drystock on, left-click on the Dry Stock button on the Drystock Summary
grid as shown in Figure 4-28. The button will change colour to green and the button text will change
from ‘Off’ to ‘On’.

Figure 4-28 Drystock and Instrument Number Grid

Changing the Instrument Number

The instrument number under consistency allows the operator to re-configure the consistency
measurement for a particular stock.

To change the Instrument Number, select the Instrument Number for a particular stock flow as shown
in Figure 4-28 and entered a different number (dependent on the number of consistencies present in
the system) and press <CR>.

Consistency Measurement

The consistency measurement is the compensated consistency read from the consistency
compensation package. The consistency is filtered based on the value shown of the Consistency
Compensation display. If an error occurs in the consistency measurement, this value will turn red and
the associated stock flow will not receive distribution changes. This consistency measurement is used
to calculate the Dry Fiber Flow Target and is used for Drystock control. An invalid consistency
measurement will force ply loading control to switch to Balance mode.

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Grade Change Targets

The grade change section displays the new ply weight, stock flow, bias, and stock flow targets. The
new stock flow set point is calculated from the set point bias and the new ply weight only if the
corresponding stock flow is in E1.

The new ply weight target is determined as follows:

• If the stock flow is not in E1, the new stock flow will be set equal to the active stock flow, and the
new ply weight will be calculated based on the active stock flow and new speed target.

• If the stock flow is in E1 and the furnish type is a liner (top liner, top under liner, bottom under
liner, bottom liner), the new ply weight target will come from product code data.

• If the stock flow is in E1 and the furnish type is a filler, the new ply weight target will be
calculated to give the correct new total weight.

S (Filler Ply Weights) = Total Weight - S (Liner Weight)

The only time the operator can enter a new ply weight is when the stock flow is in E1 and the furnish
type is a liner. Any other condition the operator entered ply weight will be overwritten by the system
with the calculated ply weight.

To change a new ply weight for a liner stock in E1, simply select the new ply weight target, enter the
new liner weight and press <CR>.

The filler stock flows, which are in E1, will calculate new ply weights and stock flows to maintain the
overall new weight target.

To change the calculated stock flow, use the bias entry:

1. Select the bias value, enter new bias and press <CR>.

2. The new stock flow will be recalculated to reflect the bias change.

Changing New Speed

You can change the new speed value by selecting the number in the Stock Initialization section
(Figure 4-27) and entering the new value. A new preliminary speed will cause the calculated grade
change targets to change.

No Load Change

On heavy board machines, the production is often run at a dryer limited condition. The multi-ply
grade change will continuously calculate a no load change speed target for the operator’s
convenience.

CoatWeight Target Compensation

For on-machine coating the active ply loading weight targets are based on the active weight target
minus the active coatweight target as shown in Figure 4-23. This allows the ply weights to represent
the wet end stock flow distribution weight units correctly. The preliminary ply weight targets are also
based on the preliminary weight target minus the preliminary coatweight target, which is shown in the
Grade Change section of the Figure 1-1.

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4.4.2 Multiply Auto Grade Change Overview

The top portion of the Multiply Auto Grade Change (AGC) Overview is the same as the singleply
version . Two extra sections highlighted red are added to the multiply AGC display (Figure 4-29).

1. Multiply Auto Grade Change Overview

2. Dryline Control Overview (optional)

Figure 4-29 Multiply Auto Grade Change Overview

Multiply Auto Grade Change Overview

Individual ply information is displayed here. This section allows to operator to divide the total target
weight/stockflow between the individual plys. There are two main entries which can be modified by
the operator as follows:

New Grade Ply Weight Targets – This parameter will either come from the grade codes (for liner
furnish types) or will be system calculated (fillers). The operator can redistribute the ply controls here
before running a grade change.

New Target Stock Bias - Enter the setpoint bias for the controller targets to add or take away from
the calculated new level 1 stock controller setpoints.

Both of these entries also appear in the ‘Grade Change New Targets’ section of the Ply Loading
Summary display (see Figure 4-23).

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Dryline Control Overview (Optional)

This section will only be present if dryline control is configured in the system. Dryline is usually
controlled by slice but may be steam flow. You may change the set point and mode for the dryline
actuator (slice or stream flow). You may also set the step change value, which is a percentage of the
actuator range. In order to use the step change, the dryline actuator (slice or stream flow) must be in
E1. The dryline step change is used to move the dryline while maintaining the rush/drag
measurement. Making an appropriate change to the rush/drag level 1 controller when a dryline step
change is made does this.

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4.4.3 Consistency Compensation Summary

The Consistency Compensation Summary display provides access to the Consistency Compensation
entries listed below. You can make changes to the instrument status and control mode and to the
constant reference and bias. See Figure 4-30 for an example of the Consistency Compensation
Summary display.

Figure 4-30 Consistency Compensation Summary Display

Instrument Number - It is used as a reference number on the Ply Loading Summary display to
associate the consistency measurement with a given stock flow. The operator cannot change this
number.

Instrument Name - It is a customer name for the analog input or the consistency controller. The
operator cannot change this number.

Instrument Status - You may change this status by selecting it from a drop down list as shown in
Figure 4-31. The following four status values can be selected by the operator:

1. Normal - This status uses the filtered (smoothed) analog input for the corrected value.

2. Bias - This status uses the filtered (analog input plus the bias) for the corrected value.

3. Constant - This status uses the filtered reference value for the corrected value

4. OutSvc - This status uses the last valid value, marks the consistency as invalid

There is also a fifth status (Failure) which cannot be selected by the operator. This status uses the
filtered reference value for the corrected value and marks the consistency as invalid. Failure may be
caused by the measurement going invalid, an excessive change in the consistency, or the consistency
measurement not changing for a specified period of time.

Figure 4-31 Consistency Status Selection

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Reference Value - You may change this value by selecting it, entering the new value, and pressing
<CR>. This value is an absolute consistency value used for the constant and failure state.

Bias Value - You may change this value by selecting it, entering the new value, and pressing <CR>.
This value corrects the measured consistency to absolute consistency and is usually based on
laboratory tests. The date/time is updated when a new bias is entered.

Corrected Value - This value is the filtered value used for dry fiber calculations for Multi-Ply
control, Multi Dry Stock Control, Refiner Network per ton control, etc.

Date/Time - This column shows the date and time when the last bias was entered or when the
measurement failed.

Filter Time Constant - You may change this value only from the Consistency Compensation
Tuning display. The filter time constant is shown in seconds of the corrected value. The larger the
time constant the more the corrected value is smoothed.

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Chapter 5 Cross Direction Control Displays

5.1 CD Control Overview

The CD Control Overview display provides detailed measurement, actuator status and dialog for CD
control operation. The CD Overview display is divided into multiple interface sections. Figure 5-1
gives a typical appearance of the CD Control Overview display.

Figure 5-1 CD Control Overview

5.1.1 Plot Windows

The plot window shows the high-resolution error profile, mapped (mapped to the actuator zones) error
profile, actuator setpoint, actuator measured values, and actuator statuses. Three sub-windows are
created to organize the profile views. The sub-windows are shown in Figure 5-2.

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Figure 5-2 CD overview plot window

5.1.2 High-Resolution Profile Sub-Window

The high-resolution profile shows an error (deviation) profile of the sensor measurement profile as
deviation from a target profile (sensor measurement profile minus target profile). Setup of the target
profile is performed on a dedicated display. Operation of this target profile display will be discussed
in its dedicated section.

The CD control allows for the high-resolution profile to be built from the combination of two profile
measurements. Ratio factors are applied to the individual profile measurements to produce the high-
resolution profile. If only one profile measurement is controlled, the error profile is made up of 100%
of that profile measurement. Refer to the Table Window section on how to enter the ratio factor. The
combination of the profile measurements is displayed in the high-resolution profile sub-window.

In this window, the edges of the window are aligned with the scanner’s home (profile data point 1)
and far (highest profile data point) limits. The profile is plotted in the data point resolution defined by
the scanner-sensor system. Orientation of the profile can be from left-to-right or right-to-left. Figure
5-3 visually defines the physical significance of the plot edges.

Figure 5-3 Physical references of the high-resolution profile plot

High-Resolution Profile Alignment With Actuators

The high-resolution profile region that is aligned (mapped) to an actuator is highlighted with a
rectangle drawn around the profile and the actuator. To identify the actuator zone that is mapped to a
profile region, the following steps are performed:

 With the mouse, move the cursor over the profile point of interest (Figure 5-5).

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 Click the left-mouse button.

System Response: A white rectangle outlines the actuator and the profile region of interest.

To identify the profile region that is mapped or aligned to an actuator (which is the converse of the
above paragraph), the following steps are performed:

 With the mouse, move the cursor over the actuator to be selected (Figure 5-4).

 Click the left-mouse button to select the actuator.

System Response: A white rectangle outlines the actuator and the profile region of interest.

Figure 5-4 Left click to find alignment between an actuator and a profile region

Tool Tips

High-resolution profile tool tip is a pop-up message box that presents information about the displayed
profile. Information displayed in the message box include profile name, data point number and value
for the data point number. The tool tip box becomes visible when the cursor is positioned directly
over a data point in the plot as illustrated in Figure 5-5.

Figure 5-5 High resolution profile tool tip

Depending on the individual preference, tool tips can be turned on or off. The steps for enabling and
disabling tool tips are as follows:

 With the mouse, right click anywhere on the plot window.

 Right click on the “Show Tool Tips” text to toggle the option on and off. If a check mark appears
to the left of the “Show Tool Tips” text then the option is on (Figure 5-6).

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Figure 5-6 Show tool tips

Data Change Time-Stamp

The time-stamp displayed in the upper left corner of the high-resolution profile indicates data change
time for the profile displayed in the window.

5.1.3 Mapped Profile Sub-Window

The mapped error profile represents the combined high-resolution profile mapped to the control zones
of the profiler unit. The mapped profile is referenced to the width of the CD profiler unit. It is aligned
with the control zones in the actuator window.

In this window, the edges of the window are referenced to the first and last actuators. The profile is
plotted in the actuator resolution defined by the actuator system. Orientation of the profile can be from
left-to-right or right-to-left. Figure 5-7 visually defines the physical significance of the plot edges.

Figure 5-7 Physical references of the mapped profile plot

Tool Tips

Mapped profile Tool Tip is a message pop-up box that displays information about the mapped profile.
Information displayed in the message box includes profile name, data point number and value for the
data point (Figure 5-8). The tool tip can be toggled on and off as described previously.

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Figure 5-8 Mapped profile tool tip

Data Change Time-Stamp

The time-stamp displayed in the upper left corner of the mapped profile indicates data change time for
the profile displayed in the window.

5.1.4 Actuator Sub-Window

The actuator sub-window plots the setpoint array as a bar graph, feedback value as line graph, and
actuator zone status by the color of the setpoint bar (Figure 5-9). The actuator window allows
selection of actuator(s), viewing of zone status, changing of manual/auto mode, and changing setpoint
values.

Figure 5-9 Actuator setpoint, feedback and status representation

Control Width

The system calculates the control width based on the mapping. The control width starts and stops at
the first and last actuators that contain valid measured profile data. If the edge actuators are outside of
the control width, the actuators will be displayed with crosshatch (Figure 5-10).

Figure 5-10 Control width indicators

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Selecting Single Actuator

A single actuator can be selected in the actuator window. The steps to perform this operation are
described in the following.

 Move cursor over the actuator to be selected.

 Click the left-mouse button.

System Response: A white rectangle outline appears around the actuator selected.

Selecting Multiple Actuators

Multiple actuators can be selected in the actuator window. Different methods of selecting multiple
actuators are available. The steps to perform this operation are described in the following.

The “ctrl” key is used to select multiple actuators that are not necessarily next to each other. This
method may be useful for selecting actuators that are at opposite edges of the profiler unit (Figure
5-11).

 Move the cursor over the first actuator to be selected and click the left-mouse button.
System Response: A white rectangle outline appears around the actuator selected.

 Move the cursor over the next actuator to be selected.

 Press and hold the “ctrl” key down and click the left-mouse button.
System Response: A white rectangle outline appears around the actuator selected.

 Repeat steps 2 and 3 to select other actuators.

Figure 5-11 Selecting actuators with “Ctrl” key

The “shift” key is used to select multiple actuators that are next to each other. This method may be
useful for selecting a range of actuators (Figure 5-12).

 Move the cursor over the first actuator of a range of actuators to be selected and click the left-
mouse button.
System Response: A white rectangle outline appears around the actuator selected.

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 Move the cursor over the last actuator of a range of actuators to be selected.

 Push and hold the “shift” key down and click the left-mouse button.
System Response: A white rectangle outline appears around the actuator selected with the cursor
and the actuators that are between the first actuator and last actuator selected.

Figure 5-12 Selecting actuators with “Shift” key

To select all actuators, the “ctrl” and “shift” key methods described above can be used. Alternatively,
a right-mouse pop-up menu method can be used (Figure 5-13).

 Move the cursor into the actuator window frame and click the right-mouse button.
System Response: A pop-up window appears with a list of options that includes “Select All”.

 Move the cursor over the text “Select All”.

System Response: The text “Select All” is highlighted.

 Click the left-mouse button.

System Response: A white rectangle outline appears around every actuator.

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Figure 5-13 Selecting all actuators

Actuator Dialog Window

The actuator dialog window is used to change mode and make manual setpoint changes on the
actuators. The appearance of the actuator dialog window is given in Figure 5-14. The detail steps to
change mode and make manual setpoint changes will be described in further detail in following
sections. In this section, indicators and viewing options available in the actuator dialog window are
discussed. The topics for discussion are highlighted by area 1 and 2, in the figure.

Data Table

 Sel Column
“Sel” column is interactive. By moving the cursor to any cell under the “Sel” column, that
actuator can be selected or deselected with the click of the left-mouse button. The symbol “>>”
identifies actuators that have been selected in the actuator sub-window. Cells of unselected
actuators appear empty.

 Act Column
“Act” column identifies the actuator number in the data table.

 Status Column
“Status” column indicates whether the actuator appearing the data table has an active status of
auto or manual.

 Man Column
“Man” column is interactive. By moving the cursor to any checkbox under the “Man” column,
that actuator can be marked for an intended mode change to auto or manual with the click of the
left-mouse button. A mode change to manual is indicated by a check in the box. A mode change
to auto is simply an empty box. For the mode change to be completed, the checking and
unchecking of the mode must be applied. More details on changing an actuator status will be
provided in the coming sections.

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 SP Column
“SP” column indicates the active actuator setpoint feedback for actuators appearing the data table.

 New SP Column
“New SP” column is interactive. By moving the cursor to any cell under the “New SP” column, a
new setpoint value can be specified for that actuator by numerically entering the new value. For
the manual setpoint change to be completed, the new setpoint value must be applied. More details
on changing the setpoint of a manual actuator will be provided in the coming sections.

 MV Column
“MV” column indicates the active actuator measurement feedback for actuators appearing the data
table.

Data Table View Options

 Show Selected Actuators

“Show Selected Actuators” button is used to display only those actuators selected from the
actuator sub-window in the data table. Selected actuators are those actuators appearing with a
white rectangle outline in the actuator sub-window. In the actuator dialog window, selected
actuators are identified by the symbol “>>” in the “Sel” column.

 Show All Actuators

“Show All Actuators” button is used to display all actuators in the data table. With all the
actuators displayed, selected actuators are identified by the symbol “>>” in the “Sel” column.
Unselected actuators have empty “Sel” cells.

Select All Button

The “Select All” button is used to select all the actuators. If the “Selected All” button is pressed, the
data table will update displaying all actuators with the “>>” symbol appearing in the “Sel” column.

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Figure 5-14 Actuator dialog window

The actuator dialog window can be opened with two methods. The dialog window will pop-up if the
left mouse button is used to click on the actuator dialog icon located in the lower left corner of the
plot window. The dialog window appears if the left mouse button is used to double-click on any of the
actuators. Figure 5-15 identifies the two methods for opening the actuator dialog window

Figure 5-15 Method to open actuator dialog window

Changing Actuator Status between Auto and Manual

Actuator status is indicated by the color of the actuator bar graph. The color-code representation is
documented in Table 5-1.

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Table 5-1 Actuator status color indication

Color Description

Blue AUTO mode. Setpoints for these actuators are generated by the CD
control.

Green MAN mode. Setpoints for these actuators are changeable by the user.

Yellow NOT MOVEABLE status. An actuator with this status is not moveable by
the user or the CD control. Its setpoint is updated to track the feedback
value. The condition resulting in this status for an actuator is failure to a
feedback device on an adjacent actuator. When the condition that results
in this status is cleared, the actuator is restored to its prior mode of
AUTO or MANUAL.

Red BAD status. An actuator with this status is not moveable by the user or
the CD control. Its setpoint is updated to track the feedback value. The
conditions resulting in this status for an actuator includes mechanical
failure to the actuator, failure to the feedback device for the actuator, and
out-of-service mode selected (from the actuator interface system) for the
actuator. When the condition that results in this status is cleared, the
actuator is restored to its prior mode of AUTO or MANUAL.

The “Auto” and “Manual” modes are changeable by the user. The “Bad” and “Not Moveable” status
are determined by the actuator system.

It is necessary to change the mode between Auto and Manual to give to and take away from the CD
control command of the actuator setpoint. When an actuator is in Auto, the CD control determines the
setpoint value for that actuator zone. When an actuator is in Manual, the user determines the setpoint
value for that actuator zone. Under special circumstances, actuator zones that are in Manual may be
interlocked from user intervention or may be moved without user intervention. If any of these
conditions are present, indication will be presented in the message box. These conditions include:

1. Actuator system in Local

2. Actuator system request abort and interlock of CD control

3. Actuator system request suspend of CD control

4. Communication (watchdog or transporter) failure between CD control and the actuator system

The steps for changing the actuator mode between Auto and Manual (Figure 5-16) are described in the
following.

 Select the actuator(s) that needs to be changed. Refer to section on “Selecting Actuators”.

 Move the cursor over the actuator dialog window icon and click the left-mouse button. This icon
is located in the lower left corner of the actuator window.
System Response: An actuator dialog window pops open. The selected actuators are displayed in
the table along with the actuator status and its current setpoint and feedback values. Alternatively,
the actuator dialog window will open if the last actuator selected is double clicked with the left-
mouse button.

 Move the cursor over the “Manual” mode button and click the left-mouse button to change the
mode to manual (1).
System Response: A check appears in the checkboxes under the “Man” column.

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Alternatively, the left-mouse click can be used to individually check each checkboxes under the
“Man” column.

Move the cursor over the “Auto” mode button and click the left-mouse button to change the mode
to auto (1).
System Response: The checks in the checkboxes under the “Man” column are cleared.
(Alternatively, the left-mouse click can be used to individually uncheck each checkboxes under
the “Man” column.).

 Move the cursor over the “Apply” or “Ok” button and click with the left-mouse button (2).
System Response: The “Apply” button will accept the mode changes and leave the dialog window
open. The “Ok” button will accept the mode changes and close dialog window. The actuator bars
in the actuator window turn green indicating that the actuator mode is Manual. The actuator bars
in the actuator window turn blue indicating that the actuator mode is Auto.
NOTE: To cancel the operation of changing actuator modes to Manual, move the cursor over the
“Cancel” (instead of “Apply” or “Ok”) button and click with the left-mouse button. Pressing the
“Cancel” button discards all operations performed up to that point and closes the dialog window.

Figure 5-16 Changing actuator mode in the dialog window

Making Manual Setpoint Changes

Once an actuator is put in Manual mode, the user can enter a setpoint value for that actuator. Unless
one of the special circumstances discussed in the section “Changing Actuator Status between Auto
and Manual” occurs, this setpoint value is maintained until the user changes it. To change the setpoint
of an actuator, the desired actuators must be in manual mode and must be selected. The actuator
dialog window is used to apply a manual setpoint. Three methods are discussed below.

To change all of the selected actuators to the same setpoint (“Set” command), the steps for making the
manual changes are described in the following.

 Move the cursor over the “Setpoint” textbox and click the left-mouse button. This selects the
textbox.

 Enter the setpoint value that should be applied to all the selected actuators (1). See Figure 5-17.

 Move the cursor over the “Set” button and click the left-mouse button (2). See Figure 5-17.
System Response: The setpoint value entered in the “Setpoint” textbox appears in the “New SP”
column for all the selected actuators.

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 Move the cursor over the “Apply” or “Ok” button and click the left-mouse button (5).See Figure
5-17.
System Response: The “Apply” button accepts the changes and leaves the dialog window open.
The “Ok” button accepts the changes and closes the dialog window. The setpoint values in the
“New SP” column that can be applied to the actuator without limitation are displayed in the “SP”
column. Those “New SP” values that cannot be applied without limitation remain displayed in the
“New SP” column, while those that can be applied in its entirety are cleared from the “New SP”
cell.
NOTE: To cancel the operation of making manual setpoint changes, move the cursor over the
“Cancel” (instead of “Apply” or “Ok”) button and click the left-mouse button. Pressing the
“Cancel” button discards all operations and closes the dialog window.

To change all of the selected actuators by the same amount (“Offset” command), the steps for making
the manual changes are described in the following.

 Move the cursor over the “Setpoint” textbox and click the left-mouse button. This selects the
textbox.

 Enter the value that should be added to or subtracted from the current setpoint values of all the
selected actuators (1). To add to the current setpoint values, a positive entry is made. To subtract
from the current setpoint values, a negative entry is made. See Figure 5-17.

 Move the cursor over the “Offset” button and click the left-mouse button (3).See Figure 5-17.
System Response: The setpoint value entered in the “Setpoint” textbox is either added or
subtracted from the current setpoint values and displayed in the “New SP” column for all the
selected actuators.

 Move the cursor over the “Apply” or “Ok” button and click the left-mouse button (5).See Figure
5-17.
System Response: The “Apply” button accepts the changes and leaves the dialog window open.
The “Ok” button accepts the changes and closes the dialog window. The setpoint values in the
“New SP” column that can be applied to the actuator without limitation are displayed in the “SP”
column. Those “New SP” values that cannot be applied without limitation remain displayed in the
“New SP” column, while those that can be applied in its entirety are cleared from the “New SP”
cell.
NOTE: To cancel the operation of making manual setpoint changes, move the cursor over the
“Cancel” (instead of “Apply” or “Ok”) button and click the left-mouse button. Pressing the
“Cancel” button discards all operations and closes the dialog window.

To change the selected actuators individually (“New SP” data table column), the steps for making the
manual changes are described in the following.

 Move the cursor over the “New SP” cell for actuator that needs to be changed and click the left-
mouse button (4). This selects the cell.

 Enter the setpoint value for the actuator and press the “Enter” key.
System Response: The entered setpoint appears in “New SP” cell for the actuator being changed.

 Repeat the previous two steps for all the selected actuators that need to be changed.

 Move the cursor over the “Apply” (5) or “Ok” (6) button and click the left-mouse button. See
Figure 5-17.
System Response: The “Apply” button accepts the changes and leaves the dialog window open.
The “Ok” button accepts the changes and closes the dialog window. The setpoint values in the

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“New SP” column that can be applied to the actuator without limitation are displayed in the “SP”
column. Those “New SP” values that cannot be applied without limitation remain displayed in the
“New SP” column, while those that can be applied in its entirety are cleared from the “New SP”
cell
NOTE: To cancel the operation of making manual setpoint changes, move the cursor over the
“Cancel” (instead of “Apply” or “Ok”) button and click the left-mouse button. Pressing the
“Cancel” button discards all operations and closes the dialog window..

Figure 5-17 Changing manual actuator setpoint in dialog window

Tool Tips

Any actuator information may be viewed by positioning the cursor over the desired actuator. A tool
tip will pop up showing the actuator name, number, status, setpoint and feedback value. See Figure
5-18. The tool tip can be toggled on and off as described previously.

Figure 5-18 Actuator tool tip

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Data Change Time-Stamp

The time-stamp displayed in the upper left corner of the actuator window indicates data change time
for any of the actuators status, setpoint or feedback value.

5.1.5 Statistics Window

The statistics window shows the variability (default is 2-Sigma), high value and low value for the
mapped profile, high resolution profile and the profiler setpoint (see Figure 5-19).

Figure 5-19 Statistics window

5.1.6 Profile Combination and Control Counter Window

The measurement averages and ratio factors for combining multiple profile inputs for determination of
the error profile are displayed in the data table. The measurement averages are received directly from
the measurement system. The ratio is interactive for the primary measurement. The ratio for the
secondary measurement, in the same column, is automatically determined to maintain a total of 100
(percent). If only one measurement profile is configured as the input, then the secondary measurement
will not be displayed in the data table. By moving the cursor and selecting the interactive ratio cell, a
new combination factor can be entered. If the entered ratio is 100 (percent), the error profile is made
up entirely of the primary profile measurement. If the entered ratio is 0 (percent), the error profile is
made up entirely of the secondary profile measurement. If the entered ratio is 75 (percent), the error
profile is 75 percent of the primary measurement and 25 percent of the secondary measurement. See
Figure 5-20.

The control counter is displayed in the data table under the heading “Scans till control action”. The
count value indicates the number of scans remaining before the next control action is taken. See
Figure 5-20.

Figure 5-20 MD measurement and control counter

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5.1.7 Message Window

The message window displays conditions that affect operations of the CD control. If there are no
existing conditions, the message window displays the text “Control Status Normal” as shown in
Figure 5-21. The following are conditions that may appear in the message window:

1. Profile Response Simulation Active

The CD control is receiving profile measurement and scanner information from a simulator.

2. Actuator Interface Simulation Active

The CD control is exchanging actuator setpoint and status with a simulator.

3. Actuator Data Bridge Error

The data bridge that is used to transport OPC tag data between CD control and the actuator
interface has stopped. An actuator data bridge error aborts the CD control.

4. Actuator Watchdog Error

The execution indicator (heartbeat) of the actuator interface has stopped. An actuator watchdog
error aborts the CD control.

5. Profile Measurement Data Bridge Error

The data bridge that is used to transport OPC tag data from the profile measurement system has
stopped. A profile measurement data bridge error suspends the CD control.

6. Profile Measurement Watchdog Error

The execution indicator (heartbeat) of the profile measurement system has stopped. A profile
measurement watchdog error suspends the CD control.

7. Actuator in Local
The actuator system is operating in a local mode and has blocked setpoint updating in the CD
control.

8. Actuator Request Control Abort

CD control has been aborted due to an abort request from the actuator system.

9. Too Few Actuators In Auto

CD control has been suspended because there are insufficient number of actuators in the Auto
mode for the CD control to operate effectively.

10. Excessive CD Variation

CD control has been suspended because the error profile variability was in excess of a permitted
limit.

11. Excessive MD Variation

CD control has been suspended because the profile average has changed by more than a permitted
limit from one profile update to the next.

12. Excessive Auto Setpoint Change

CD control has been aborted because a requested automatic setpoint change was in excess of a
permitted maximum change limit.

13. Constraint Prevents Auto Control

The automatic setpoint change was blocked from being sent to the actuator system because the
requested new setpoint is in excess of the high limit, low limit, 1st difference limit or 2nd
difference limit.

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14. Bump Test In Progress

CD control has been suspended because an on-line bump test is being performed.

15. Profile Target On

CD control operation is configured correct the measurement profile to a target shape.

16. Break Recovery - Fast Response Actions

CD control has been suspended because the actuator setpoints are being dynamically restored
following a sheet break event.

17. Break Recovery - Scanner Operations

CD control has been suspended because the process and scanner measurements being allowed to
re-condition following a sheet break event.

18. Grade change should be in progress.

Figure 5-21 CD control overview message window with normal status

5.1.8 CD Control Mode

The control status contains the interface object for activating CD control and for running CD Control
in a test mode (Figure 5-22).

Figure 5-22 CD control modes

To turn CD control on or off, the following steps are performed:

 With the mouse, move the cursor to the “On” button

 Click the left-mouse button to toggle the CD control on or off.

System Response: A confirmation message box pops up (Figure 5-23).

 In the pop-up message box, confirm the action by left-mouse clicking the “Yes” option to accept
the action or the “No” option to cancel the action.
System Response: When the “On” button is green and appears pressed down, the control is turned
on. When the “On” button is gray and appears raised, the control is turned off.

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Figure 5-23 CD control mode change confirmation window

The CD control can be used in a test (on line simulation) mode. When the test mode is turned on (the
Test button is pushed in), any control actions applied in the actuator setpoint window is blocked from
being sent to the actuator system. The test mode is useful for visually examining CD tuning setup and
diagnosis. To enable the test mode, the following steps are performed:

 With the mouse, move the cursor to the “Test” button

 Click the left-mouse button to toggle the test mode on or off.

System Response: A confirmation message box pops up (Figure 5-24).

 In the pop-up message box, confirm the action by left-mouse clicking the “Yes” option to accept
the action or the “No” option to cancel the action.
System Response: When the “Test” button is green and appears pressed down, the test mode is
turned on. When the “Test” button is gray and appears raised, the test mode is turned off.

Figure 5-24 CD control test mode change confirmation window

5.2 CD Target Profile Setup Display

The CD Target Profile Setup display is used to specify a target profile. If the target option is enabled
(target command button is active), the control will make the necessary actuator adjustments to drive
the sensor profile to the shape of the target profile. The result of operating CD control with the target
option enabled is illustrated in Figure 5-25.

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Figure 5-25 CD control operation with target profile mode active

Each CD control has its own target setup display. For each CD control, its target setup display
includes setup parameters and indicators for profile measurements that have been configured as input
profiles. Figure 5-26 gives a typical appearance of the CD Target Profile Setup display for a control
configured with two profile measurement inputs. Regardless of the number profile measurement
inputs, target profile setup for the 1st (primary) and 2nd (secondary) profiles are the same. For this
reason, the following discussions will be applicable for setting up the 1st or the 2nd target profiles.

Figure 5-26 CD target profile setup display

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5.2.1 Target Profiles

For each profile measurement configured, the following four sub plots are displayed in Figure 5-27.

1. Sensor profile measurement: High-resolution profile measurement received from the sensor.

2. Target profile: Target profile used by CD control when the target mode is active. The resolution
of the active target profile is the same as the sensor profile measurement.

3. Editing target profile: Target profile with editing handles for building the target shape. The
resolution of the editing target profile is the same as the number of actuator zones to allow
building a target shape that is as narrow as the actuator width.

4. Smooth target profile: Target profile generated from the editing target profile with smooth settings
applied. The resolution of the smooth target profile is the same as the sensor profile measurement.
The smooth target is a preview of the target profile to aide with the shape building.

Figure 5-27 Profile types on the target setup display

5.2.2 Editing Target Profile

The window edges for all four target profiles (sensor measurement, target, smooth target and editing
profile) are aligned with the scanner’s home limit (profile data point 1) and far limit (highest profile
data point). Orientation of the profile within the window can be from left-to-right or right-to-left.
Since the sensor measurement, target and smooth target profiles all have resolution matching the
sensor measurement their indices are databox numbers.

The number of handles on the editing target profile is equal to the number of actuators. Orientation of
the editing target profile bare the same impact on the high resolution target profile as the actuator
control zones have on the sensor profile. In other words, if actuator zone 1 affects the lower databox
numbers then editing target handle 1 will change the shape of the target profile in the lower databox
numbers. If actuator zone 1 affects the higher databox numbers then editing handle 1 will change the
shape of the target profile in the higher databox numbers. The window edge references are identified
in Figure 5-28.

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Figure 5-28 Physical reference of target profile plot

Selecting Single Target Profile Handle

A single target profile handle can be selected in the target profile window. The steps for selecting a
single handle are described in the following.

 Move the cursor over the handle to be selected.

 Click the left-mouse button.

System Response: A white outline appears around the selected handle.

Selecting Multiple Target Profile Handles

Multiple target profile handles can be selected in the target profile window. Different methods of
selecting multiple handles are available to satisfy different needs. The steps for selecting multiple
handles are described in the following paragraphs.

The “ctrl” key is used to select multiple handles that are not necessarily next to each other. This
method may be useful for selecting handles that are at opposite edges of the window (Figure 5-29).

 Move the cursor over the first handle to be selected and click with the left-mouse button.
System Response: A white outline appears around the selected handle.

 Press and hold the “ctrl” key down.

 Move the cursor over the next handle to be selected and click with the left-mouse button.
System Response: A white outline appears around the selected handle.

 Repeat steps 2 and 3 to select other handles.

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Figure 5-29 Selecting multiple target profile handles with “Ctrl” key

The “shift” key is used to select multiple handles that are next to each other. This method may be
useful for selecting a range of handles (Figure 5-30).

1. Move cursor over the first handle in the range of handles to be selected and click with the left-
mouse button.
System Response: A white outline appears around the selected handle.

2. Press and hold the “shift” key down.

3. Move cursor over the last handle in the range of handles to be selected and click with the left-
mouse button.
System Response: A white outline appears around the handle selected with the cursor and the
handles that are between the first handle and last handle in the range.

Figure 5-30 Select multiple target profile handles with “Shift” key

To select all handles, the “ctrl” and “shift” key methods described above can be used. Alternatively, a
right-mouse pop-up menu method can be used (Figure 5-31).

1. Move the cursor into the editing target profile window frame and click the right-mouse button.
System Response: A pop-up window appears with a list of options that includes “Select All”.

2. Move the cursor over the “Select All” text.

System Response: The “Select All” text is high-lighted.

3. Click “Select All” with the left-mouse button.

System Response: A white outline appears around every handle.

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Figure 5-31 Selecting all target profile handles

Target Dialog Window

The target dialog window is used to create or change the editing target profile. The appearance of the
target dialog window is given in Figure 5-32. The detail steps for creating or changing the editing
target profile will be described in following sections. In this section, indicators and viewing options
available in the target dialog window are discussed. The topics for discussion are highlighted by area
1 and 2, in the figure.

Data Table

 Sel Column
“Sel” column is interactive. By moving the cursor to any cell under the “Sel” column, that editing
handle can be selected or deselected with the click of the left-mouse button. The symbol “>>”
identifies editing handles that have been selected in the target window. Cells of unselected editing
handles appear empty.

 Point Column
“Point” column identifies the editing handle number in the data table.

 Fixed Column
“Fixed” column is interactive. The “Fixed” checkbox forces the smooth target profile curve to
come close to the value associated with the fixed handle. By moving the cursor to any checkbox
under the “Fixed” column, that editing handle can be marked as an intended fixed or non-fixed
value with the click of the left-mouse button. A fixed value is indicated by a check in the box. A
non-fixed value is simply an empty box. For fixed/non-fixed selection to be completed, the
checking and unchecking of the selection must be applied. More details on applying this option
will be provided in the coming sections.

 Value Column
“Value” column indicates the active value of the editing target profile handle appearing the data
table.

 New Value Column

“New Value” column is interactive. By moving the cursor to any cell under the “New Value”
column, a target value can be specified for that editing handle by numerically entering the new
value. For the target value change to be completed, the new handle value must be applied. More
details on changing the editing target value will be provided in the coming sections.

Data Table View Options

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 Show Selected Points

“Show Selected Points” button is used to display only those editing target handles selected from
the target profile window in the data table. Selected handles are those appearing with a white
outline the target profile window. In the target dialog window, selected handles are identified by
the symbol “>>” in the “Sel” column.

 Show All Points

“Show All Points” button is used to display all target handles in the data table. With all the
handles displayed, selected handles are identified by the symbol “>>” in the “Sel” column.
Unselected handles have empty “Sel” cells.

Select All Button

The “Select All” button is used to select all the target handles. When the “Select All” button is
pressed, the data table will update displaying all handles with the “>>” symbol appearing in the “Sel”
column.

Figure 5-32 Target profile dialog window

The target dialog window can be opened with two methods. The dialog window will pop-up if the left
mouse button is used to click on the target dialog icon located in the lower left corner of the plot
window. The dialog window appears when double clicking the left mouse button any of the editing
target handles. Figure 5-33 identifies the two methods for opening the target profile dialog window.

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Figure 5-33 Method to open target profile dialog window

Changing Fixed Mode of a Target Profile Handle

The fixed mode of the target profile handle forces the smooth target profile curve to be created close
to the value associated with the handle location. It is used to define breakpoints or crossing points in
the smooth target profile. By using the target handle fixed mode, a target profile can be produced with
minimal handles specified. Figure 5-34 illustrates creation of a “smile” shape target profile by
specifying only 8 handles.

Figure 5-34 Target profile created by setting a few target handles

A target handle that is fixed is represented by a diamond icon and a non-fixed handle is represented
by a square icon. The visual difference between the two modes is shown in Figure 5-35.

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Figure 5-35 Fixed and non-fixed target profile handles

The fixed and non-fixed modes are changeable by the user. The steps for changing the fixed mode are
described in the following.

 Select the handle(s) that you want to change. Refer to section on “Selecting Handles”.

 Move the cursor over the “Open Dialog” icon and click with the left-mouse button.
System Response: A target dialog window pops open. The selected handles are displayed in the
table along. (Alternatively, the target dialog window will open if the last handle selected is double
clicked with the left-mouse button.)

 Move the cursor over the “Fixed” mode checkbox for the required handles and click the left-
mouse button to toggle between the fixed and not fixed modes (1). See Figure 5-36.
System Response: A check appears in the checkbox for fixed mode and the checkbox is empty
for non-fixed mode.

 Move the cursor over the “Apply” or “OK” button and click with the left-mouse button (2). See
Figure 5-36.
System Response: Clicking the “Apply” button applies the changes without closing the target
dialog window. Clicking the “OK” button applies the changes and closes the target dialog
window.
NOTE: To cancel the operation of changing the fixed mode, move the cursor to the “Cancel”
(instead of “Apply”) button and click with the left-mouse button. Pressing the “Cancel” button
discards all changes performed and closes the target dialog window.

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Figure 5-36 Changing target handle fixed mode with dialog window

Building a Target Profile

The target profile is built by setting the editing handles to desired values. When the editing handles
are changed and applied, the smooth target profile updates as this is the sensor resolution target profile
that is used if the target option is enabled.

Depending on the level of precision required to specify the target profile values, two basic methods
can be used to set the editing handle values. Both methods require opening the target dialog window
to apply the modified editing target profile. One method uses a mouse drag-drop operation while the
second is direct typing of handle values in the target dialog window. While a drag-drop operation is
faster for creating a relative target profile shape, it lacks the exactness of direct data entry. With the
understanding of the two basic methods, the task of building the target profile can be refined further
by combining steps from the two methods.

To change and apply the editing handles using the mouse drag-drop method (Figure 5-37), the
following steps are performed:

 Move the mouse over the editing target handle that needs to be changed.

 While on a handle, press and hold the left mouse button down. This selects the handle.
System Response: A white outline appears around the selected handle.

 With the left mouse button still pressed down, drag the handle up or down to a position in the
editing target profile sub-window that represents a suitable target magnitude. With tool tips turned
on, the target value can be seen when the handle is dragged.
System Response: A white trace line is drawn to show the intended target value and target shape.
The trace line is not the editing target profile. If additional changes are required, the handle of the
editing target profile is manipulated. The trace line is cleared only after the intended changes are
applied or cancelled.

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 Repeat steps 1 through 3 on other editing target handle.

 Move the mouse over the target dialog window icon and open the dialog window by pressing the
left mouse button.

 In the target dialog window, click on the “Apply” or “OK” button with the left mouse button to
apply changes made on the target handles.
System Response: Clicking the “Apply” button applies the changes without closing the target
dialog window. Clicking the “OK” button applies the changes and closes the target dialog
window. The editing target profile snaps to the white trace line. The trace line disappears.
NOTE: To cancel the operation of changing the fixed mode, move the cursor to the “Cancel”
(instead of “Apply”) button and click with the left-mouse button. Pressing the “Cancel” button
discards all changes performed and closes the target dialog window.

Figure 5-37 Building a target profile with the drag-and-drop operation

To change and apply the editing handle values using direct data entry in the target dialog window, the
following steps are performed (Figure 5-38):

 Select the editing target handles that need to be changed.

 Move the mouse over the target dialog window icon and click with the left-mouse button to open
the dialog window.

 To change the value of the selected target handles to the same value, enter the desired target value
in the “Point Value” (1) box and click the “Set” (2) button with the mouse.
System Response: The entered value appears in the “New Value” column for all the selected
target handles. A white trace line is drawn to show the intended target value for all the selected
target handles.

 To change the value of the selected target handles by the same magnitude, enter the desired
change value in the “Point Value” (1) box and click the “Offset” (3) button with the mouse.
System Response: The entered value is added to the value appearing in the “Value” column of
the selected target handles. The sum appears in the “New Value” column. A white trace line is
drawn to show the intended target value for all the selected target handles.

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 To individually change the value of the selected target handles to a desired value, enter the desired
target value in the “New Value” (4) cell corresponding to the desired target handle.
System Response: A white trace line is drawn to show the intended target value at the target
handle that has been changed.

 In the target dialog window, click on the “Apply” (5) or “OK” (6) button with the left mouse
button to apply changes made on the target handles.
System Response: Clicking the “Apply” button applies the changes without closing the target
dialog window. Clicking the “OK” button applies the changes and closes the target dialog
window. The editing target profile snaps to the white trace line. The trace line disappears.
NOTE: To cancel the operation of changing the fixed mode, move the cursor to the “Cancel”
(instead of “Apply”) button and click with the left-mouse button. Pressing the “Cancel” button
discards all changes performed and closes the target dialog window.

Figure 5-38 Building target profile with dialog window

5.3 Smooth Target Profile

The value and fix mode of a target handle will influence how the smooth target profile will appear.
Additionally, the “Smoothness” option can be used to broaden or localize impact of the target handle
value and fix mode. The smoothness option is specified with relative consequences. The option is
adjusted for the desired target shape appearance.

Disabling the smoothness option (unchecked) will localize the smooth target profile while enabling
the option (checked) will broaden the smooth target profile. Figure 5-39 presents the difference
between smooth target profiles generated by having the smoothness option enabled and disabled. The
target handle value and fix mode are the same in both cases.

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Smooth target with “Smooth” option enabled

Smooth target with “Smooth” option disabled

Figure 5-39 Impact of “Smoothness” option on the smooth target profile

To impact the smooth target profile with the “Smooth” option, the following steps are performed:

 Move the cursor to the “Smooth” checkbox.

 Click the left-mouse button to toggle the option on or off.

System Response: The checkbox will be empty if the option is off and filled with a check if the
option is on. The smooth target profile will update to reflect the change associated with the option
value.

 Alternate the smooth option state between on and off while observing the smooth target profile
difference. Choose the state that corresponds to the desired smooth target profile (Figure 5-40).

Figure 5-40 Target profile smoothing

5.3.1 Target Indices

A target profile is associated to an index. The association allows the storage of multiple target shapes,
recall of the shapes for further editing and selecting of the target profile as the active target.

Ten indices are available. For each index, the following parameters are stored:

 Target handle values

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 Target handle fixed mode

 Global smoothness option

From these stored parameters, the high resolution target profile (smooth or active) can be recreated.

Saving Target Profile

The editing target profile that is currently in the target plot window can be saved to an index (Figure
5-41). To store the parameters used to create the current editing target profile, the following steps are
performed:

 Enter an index value between 1 and 10 under the “Save Index” column.

 Move the cursor over the “Save Target” button and click with the left-mouse button.

Figure 5-41 Save target profile to an index

Loading Target Profile

A saved target profile can be loaded from its storage index into the editing target profile (Figure 5-42).
By loading a target index, all the stored parameters are recalled, and the editing and smooth target
profiles are reconstructed from the stored parameters. To load a target profile from storage, the
following steps are performed:

 Enter an index value between 1 and 10 under the “Load Index” column.

 Move the cursor over the “Load Target” button and click with the left-mouse button.
System Response: The editing target profile will update with the handle values, handle fixed
mode and global smoothness option corresponding to the load index.

Figure 5-42 Load target profile from an index

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Specifying An Active Target Profile

A saved target profile can be used as the active target profile. By specifying an active target index, all
the stored parameters are recalled and the active target profile is reconstructed from the stored
parameters.

To select an active target profile, perform the following steps:

 Enter an index value between 1 and 10 under the “Active Target” column (Figure 5-43).
System Response: The active target profile will update the curve defined by the handle values,
handle fixed mode and global smoothness option corresponding to the active target index.

 NOTE: If during the process of saving a target profile to an index that is currently specified as the
“Active Target”, the save operation will automatically update the active target profile.

Figure 5-43 Specifying an active target profile index

5.3.2 Target Profile Mode

The target profile option is enabled and disabled with a button. When the target profile button is
disabled, the target profile is automatically set to a flat profile shape. Since this target selection is
automatically performed, it is not necessary to associate a flat target profile shape to any of the ten
target indices. When the target profile button is enabled, the target profile corresponding to the
“Active Index” is used by the CD control (Figure 5-44).

Figure 5-44 Target profile option button

To turn target profile option on or off, the following steps are performed:

 With the mouse, move the cursor to the “Target On” button

 Click the left-mouse button to toggle the target option on or off.

System Response: A confirmation message box pops up (Figure 5-45).

 In the pop-up message box, confirm the action by left-mouse clicking the “Yes” option to accept
the action or the “No” option to cancel the action.
System Response: Once the action has been confirmed, the “Target On” button will display the
state of the control. When the “Target On” button is green and appears pressed down, the target
profile option is turned on. When the “Target On” button is gray and appears raised, the target
profile option is turned off.

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Figure 5-45 Target profile mode change confirmation window

5.4 CD Control Coater Operations

When CD control is applied to a coat weight measurement, supplemental features are included to
support operations typical of the coating process. These features are specific to the coater blade type,
blade change event and splice event. In addition to specific functions tied to the blade change and
splice events, several preset setpoint options are also provided. Execution of all features pertaining to
coater operations is performed from the overview display illustrated in Figure 5-46. The regions of
this display corresponding to blade logic, splice event, preset setpoint options and coater operations
messages are outlined.

Figure 5-46 CD control coater operations overview display

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5.4.1 Blade Logic

Two coater blade types, bent and rigid, are supported in the CD control coater application. The blade
type is used strictly for updating the appropriate blade dependent control model and storing the CD
actuator setpoint values to the correct preset setpoint. Regardless of the blade type, all features
implemented in the blade logic are executed in the same fashion.

Selecting Blade Type

The selection of bent or rigid blade type can be performed for the current blade or for the next blade.
The latter is performed to set up for a blade change event.

To select or deselect bent blade to be the current blade type, the following steps are performed:

 With the mouse, move the cursor to the “Current Blade Type - Bent” checkbox.

 Click the left-mouse button to toggle the checkbox on or off. If a check appears in the box, then
bent blade is selected. If the checkbox is empty, then bent blade is deselected.
System Response: If the “Current Blade Type – Rigid” is selected and bent blade is selected, then
the system will deselect the rigid blade.

To select or deselect rigid blade to be the current blade type, the following steps are performed:

 With the mouse, move the cursor to the “Current Blade Type - Rigid” checkbox.

 Click the left-mouse button to toggle the checkbox on or off. If a check appears in the box, then
rigid blade is selected. If the checkbox is empty, then rigid blade is deselected.
System Response: If the “Current Blade Type – Bent” is selected and rigid blade is selected, then
the system will deselect the bent blade.

If the current blade type is neither bent blade nor rigid blade, then updating of the blade dependent
control model and storing of the CD actuator setpoint values to the preset setpoint will both cease.

To select or deselect the next blade type, the above two bulleted procedures are applied to the
checkboxes labeled “Next Blade Type – Bent” and “Next Blade Type – Rigid”.

Blade Change Setup

A coater blade has a finite operating life. When a blade is replaced, some setup is required to ensure
that the blade dependent control model is correctly reflected and that setpoint values are stored to the
right preset setpoint. During a blade change sequence, a request is submitted to suspend CD control
execution. The setup and execution of blade change event are as follows:

 Select Next Blade Type. Select either “Next Blade Type - Bent” or “Next Blade Type – Rigid”.

 Blade Retract. Retract the coater blade. If a blade retracted process input is provided, then the
state of the retract signal will be reflected by the checkbox labeled “Blade Retract Input” (checked
box = retracted, empty box = not retracted). If a process input is not provided, then a simulated
retract signal is provided as the pushbutton labeled “Auxiliary Blade Retract” (pressed down =
retracted, popped up = not retracted).

 (Optional) Blade Wear-In. Provisions are built into the blade logic to extend suspension of CD
control execution beyond the blade change event for conditioning of the new blade. The
additional CD control suspend duration is specified as the “Wear-In Time” for the new blade.

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This duration is entered in minutes. The “Blade Wear-In Suspend” checkbox is checked to apply
the additional CD control suspend duration (unchecked to release CD control suspension upon
completion of the blade change sequence). The additional suspend duration is initiated only after
the blade change sequence is completed.

 Blade Change Marker. Since a coater blade can be retracted for reasons other then to change the
blade, a “Blade Change Marker” pushbutton is provided to tag a coater head retract as a blade
change. When the button is transitioned to the down position, the blade change sequence is
initiated. This button can only be pressed down if the blade is retracted, as indicated by the
process input or the simulated signal.
System Response: CD control suspension is requested. Blade change in progress is indicated in
the message box. Next blade type is transferred to the current blade type.

 (Optional) Apply Preset Setpoint. While the blade change sequence is in progress, different preset
setpoints can be applied to the CD actuators.

 Ending Blade Change Sequence. To end the blade change sequence, extinguish both the blade
retract process input (“Blade Retract Input” checkbox is empty) and simulated retract signal
(“Auxiliary Blade Retract” button in the up position).
System Response: The “Blade Change Marker” pushbutton will automatically reset to the up
position when both of the retract signals are extinguished. The blade change in progress indicator
is no longer displayed in the message box. Blade wear-in suspend indication will commence if
this option is selected. CD control suspension will be released if blade wear-in suspend is not
selected.

 (Optional) Blade Wear-In Reset. If the blade wear-in suspend feature is used, the “State” timer
for the “Wear-In Time” is set to the specified duration. This timer counts down to zero. When the
timer reaches zero, suspension of CD control execution is released. If it is necessary to reset the
wear-in time, the “Reset Wear-In Time” pushbutton is pressed.

5.4.2 Splice Event

The splice event is typically associated with operations on an off-machine coater. Since the splice
operation may result from piecing a sheet together from different paper machines and may render the
sheet travel through the scanner unstable, a request is submitted to suspend CD control execution.
During a splice event, the preset setpoint option is available for setting up the CD actuators for the
next production run. Some setup is required to inform the CD control coater application of an
upcoming splice event and to activate features afforded during this event. The setup and execution of
the splice event are as follows:

 Splice Signal. If a splice process input is provided, then the state of the splice signal will be
reflected by the checkbox labeled “Sheet Splice Input” (checked box = splice active, empty box =
splice not active). If a process input is not provided, then a simulated sheet splice signal is
provided as the pushbutton labeled “Auxiliary Sheet Splice” (pressed down = splice active,
popped up = splice not active). By setting either of these signals initiates the splice event.
System Response: CD control suspension is requested. Splice event in progress is indicated in the
message box.

 (Optional) Extended Splice Time. Provisions are built into the splice logic to extend suspension
of CD control execution beyond the splice event. The additional CD control suspend duration is
specified as the “Splice Suspend Time”. If addition suspend time is not desired, the “Splice
Suspend Time” is set to zero. This duration is entered in minutes. The additional suspend duration
is initiated only after the splice signals are cleared.

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 (Optional) Apply Preset Setpoint. While the splice event is in progress, different preset setpoints
can be applied to the CD actuators.

 Ending Splice Sequence. To end the splice sequence, extinguish both the splice process input
(“Sheet Splice Input” checkbox is empty) and simulated splice signal (“Auxiliary Sheet Splice”
button in the up position).
System Response: The splice event in progress indicator is removed from the message box if
there is no additional splice suspend time specified. CD control suspension is released if there is
no additional splice suspend time specified.

 (Optional) Extended Splice Time Reset. If the extended splice time feature is used, the “State”
timer for the “Splice Suspend Time” is set to the specified duration. This timer counts down to
zero. When the timer reaches zero, suspension of CD control execution is released. If it is
necessary to reset the extended splice suspend time, the “Reset Splice Time” pushbutton is
pressed.

5.4.3 Preset Setpoint Options

Three preset setpoint options are stored and are available to be applied to the CD control during a
blade change event or splice event. The three options are as follows:

 Last Auto Setpoint. This is the last actuator setpoint computed by CD control. The stored setpoint
values corresponding to this option are displayed in the plot as the “Last Auto SP”. The date and
time stamp for the stored setpoint values is displayed in the table under the column heading “SP
Time-Stamp” for the row labeled “Last Auto SP”.

 Bent Blade Setpoint. This is the actuator setpoint corresponding to when a bent blade type was
last selected and when the profile performance measure was at its minimum value during
operation on that bent blade. The stored setpoint values corresponding to this option are displayed
in the plot as the “Bent Blade SP”. The date and time stamp for the stored setpoint values is
displayed in the table under the column heading “SP Time-Stamp” for the row labeled “Bent
Blade SP”. The profile performance value corresponding to the stored setpoint values is displayed
in the table under the column heading “Performance” for the row labeled “Bent Blade SP”. The
profile performance value is reset to a large value when a new instance of a bent blade is used, to
allow for storage of setpoint values to reflect performance on the new bent blade.

 Rigid Blade Setpoint. This is the actuator setpoint corresponding to when a rigid blade type was
last selected and when the profile performance measure was at its minimum value during
operation on that rigid blade. The stored setpoint values corresponding to this option are displayed
in the plot as the “Rigid Blade SP”. The date and time stamp for the stored setpoint values is
displayed in the table under the column heading “SP Time-Stamp” for the row labeled “Rigid
Blade SP”. The profile performance value corresponding to the stored setpoint values is displayed
in the table under the column heading “Performance” for the row labeled “Rigid Blade SP”. The
profile performance value is reset to a large value when a new instance of a rigid blade is used, to
allow for storage of setpoint values to reflect performance on the new rigid blade.

These options are transferred to an output buffer before setpoint values are applied to the CD control.
In addition to the three stored options, the output buffer can be edited to take on a global value or an
offset to the current values in the output buffer before the setpoints are applied to the CD control.

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Selection of Preset Setpoint

Any of the three stored setpoint options can be transferred to the output buffer. This transferred can be
performed at any time. To transfer the preset setpoints, the following steps are performed:

 With the mouse, move the cursor to the pushbutton “Load Last Auto SP”, “Load Bent Blade SP”,
or “Load Rigid Blade SP”.

 Click the left-mouse button to load the desired stored setpoint option.
System Response: The stored setpoint values corresponding the load button that is pressed is
copied to the “Output” buffer in the plot.

Output Buffer Editing

The setpoint values appearing in the “Output” buffer of the plot can be edited before it is applied to
the CD control. Using Figure 5-47 as a reference, the following steps are performed to edit the
setpoint output buffer:

Figure 5-47 Output buffer dialog window

 Open the output buffer dialog window by clicking on the output buffer dialog window icon.

 In the dialog window, select all the actuator setpoints in the output buffer by clicking on the
“Select All” pushbutton.
System Response: The table in the dialog window updates with setpoint values for all actuators.

 For a global setpoint value, enter the desired global setpoint value in the box labeled “Point
Value”. Click on the “Set” pushbutton to copy the global setpoint to the “New Value” of all
actuators.
System Response: The table in the dialog window updates with the global setpoint appearing in
the “New Value” column for all actuators.

For an offset value to be applied to the current output setpoint buffer, enter the desired setpoint
offset magnitude in the box labeled “Point Value”. If the offset is to increase the setpoint value,

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then a positive value is entered. If the offset is to decrease the setpoint value, then a negative
value is entered. Click on the “Offset” pushbutton to add the offset magnitude to the “Value” of
all actuators.
System Response: The table in the dialog window updates with the “New Value” equal to the
offset magnitude added to the “Value” entry.

 Click the “Apply” pushbutton to accept the “New Value”.

Click the “Cancel” pushbutton to reject the “New Value” and close the dialog window.
Click the “Ok” pushbutton to accept the “New Value” and close the dialog window.

Applying Output Setpoints

The setpoint values appearing in the output buffer can only be applied to the CD control when either a
blade change is in progress or a splice event is in progress. When neither of these conditions is true,
the “Apply SP” pushbutton is interlocked. To apply the output setpoints to CD control in the presence
of either conditions, the “Apply SP” pushbutton is pressed. This button will initially go to a press
down state and will pop back up.

Stored Setpoint Performance Measure

The decision to store actuator setpoints to either the bent or rigid blade setpoint buffers is based on a
profile performance measure. When the actuator setpoints are stored for a particular blade, a
corresponding performance measure is also stored. The stored performance measure is compared
against the current performance measure to determine of the current actuator setpoints yield
improvement in the profile control. If the current performance measure is less than the stored
performance measure by a specified improvement percentage, then stored actuator setpoints and
corresponding performance measure are updated.

The performance measure is defined as the variability of a filtered profile divided by the MD average.

Performance Measure = (2-sigma of filtered profile) / MD average

Two methods of filtering (MD and CD) can be applied to the CD control high-resolution (databox
resolution) error profile to produce the filtered profile. The related variables for setting up the
performance measure based storage are documented in Table 5-2.

Table 5-2 Performance measure based storage variables

Tag Label Description

MD Average Average value of the CD control profile.

(Information Only)

Current Current computed profile performance measure computed from

Performance
Measure Performance Measure = (2-sigma of filtered profile) / MD average

(Information Only)

MD Filter Factor for setting up filtering in the machine direction (direction of sheet
travel). The MD filter is an exponential filter applied on the individual
(Setup Variable) databoxes. The filter factor has a meaningful value between 0.0 and less than
1.0. When the filter factor is 0.0, no filtering is applied. When the filter factor is
set closer to 1.0, the resulting filtered profile contains more of the previous

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Tag Label Description

filtered profile and less of the current raw profile.

Since the MD filter is an exponential algorithm, residual of the filter will take
time to purge out. To reset the filtered profile to the current profile, three
actions can be taken:

 Click the “Reset MD Filter” pushbutton

 Set the “MD Filter” factor to 0.0 for at least one profile update

 Stop update of profile data (example, take the scanner off sheet) for a
duration longer than the “Profile Time-out (mins)” value

CD Filter Factor for setting up filtering in the cross direction (direction across the
sheet). The CD filter is a Blackman window applied over a specified number
(Setup Variable) of databoxes. The filter factor is an integer value. When the filter factor is 0,
no filtering is applied. The filter factor should be cautiously increased, using a
maximum step size of 2, and evaluated after each change. An excessively
large filter factor will increase the computation time of the filtering algorithm.

Profile Time-out The profile time-out is used to reset the MD filtering. The time-out value has
(mins) units of minutes. If the profile cease to update for a duration longer than the
profile time-out value, then the MD filter is automatically reset.
(Setup Variable)

Elapsed Profile The elapse time, in minutes, between profile updates.

Time-out (mins)

(Information Only)

Performance The performance improvement percentage sets the threshold on the current
Improvement performance measure to trigger updating of the stored actuator setpoints.
Percentage When the current performance value falls below the stored performance
value by the specified percentage, the stored actuator setpoints are updated.
(Setup Variable)
Current Performance < [00 – (Improvement %)] * Saved Performance

5.4.4 Coater Operation Messages

The following messages are displayed in the message box on the coater operations overview display:

CD Control Suspend Requested. This message is displayed as a result of the blade change event or
the splice event.

Blade Change In Progress. This message is displayed whenever the “Blade Change Marker” is set
along with the setting of either the “Blade Retract Input” or the “Auxiliary Blade Retract” signal.

Blade Retracted Input Set. This message is displayed if the blade retract process input is set to a true
state.

Blade Wear-In Active. This message is displayed during a blade wear-in period, following the blade
change in progress sequence.

Sheet Splice In Progress. This message is displayed if either the “Sheet Splice Input” or the
“Auxiliary Sheet Splice” signal is set.

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Sheet Splice Input Set. This message is displayed if the splice process input is set to a true state.

5.5 Local Variability (LV) Control Operations

The CD mapping of a paper machine is affected by a number of machine conditions. Uneven
distribution of materials in the cross direction, drying variation across the web, sheet wandering
perpendicular to the machine direction, machine speed changes, and variation of sheet draw tension
all contribute to both mapping non-linearity and frequent mapping variations. The nonlinear mapping
leads to a potential localized non-uniformity of profiles and the frequent mapping changes cause the
degradation of profile variation locally and globally. Therefore, one key challenge in commissioning a
CD control is how to accurately identify and continuously maintain a good CD mapping.

The primary symptom of a mapping misalignment is the presence of localized regions with very high
variability on the sheet. The purpose of Local Variability Control (LVC) is to identify these regions
and optimize the mapping alignment in the CD control to correct and remove these regions of high
variability.

LVC is designed to perform two distinct operations. These operations will be referred to as
monitoring and optimization. The first of these two operations, monitoring, deals with the process of
continually analyzing the measurements and actuator setpoints being generated in the CD control.
These two values are continuously analyzed for the presence of patterns that indicate that a mapping
misalignment is present. In the event that a mapping misalignment is detected, the monitoring portion
of LVC will indicate the region of the sheet that is suspected of having a mapping misalignment and
will request that the optimizing portion of the control optimize that section of the sheet.

The optimization portion of the control is responsible for updating parameters in the CD control in
order to eliminate the effects of a mapping misalignment. Regions of the sheet that require
optimization can be selected either manually or automatically by the monitoring portion of the
control. During an optimization, LVC will update parameters in the CD control and evaluate their
effect on the sheet. LVC will continue to do this until the proper parameter value is obtained.

LVC attempts to optimize two different parameters of the associated CD control. One parameter is the
mapping alignment of the control with the associated actuator system. This alignment is critical for
proper operation of the CD control. The second parameter optimized by the LV control is the
smoothness factor in the CD control. This factor is associated with the overall ‘smoothness’ of the
setpoint array and helps to improve control performance by finding an optimal value for this
parameter.

The LV control overview display, illustrated in Figure 5-48, is organized to promote process and CD
control troubleshooting. The various operations possible from this display are described in the
following sections.

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Figure 5-48 LV control operations overview display

5.5.1 Using LVC Monitoring

Enabling LVC Monitoring Operations

Two buttons control the LVC monitoring operations. One button is assigned to enabling LVC
monitoring while the second button is used to reset the analysis profiles used by LVC monitoring for
detecting CD actuators that need mapping adjustments. If LVC mapping optimization is enabled, the
detected CD actuators will be optimized. The LVC monitoring results are always available for
diagnostic purposes.

To enable LVC monitoring, the following steps are performed:

 With the mouse, move the cursor to the pushbutton “Monitor ON”.

 Click the left-mouse button to toggle between off (button in the up position) and on (button in the
down position).

To reset the LVC analysis profiles, the following steps are performed:

 With the mouse, move the cursor to the pushbutton “Reset Monitor”.

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 Click the left-mouse button to request a reset action of LVC monitoring.

System Response: The button will initially go to the depressed position and then back to the up
position once the application has acknowledge receiving the request.

LVC Monitoring Information

LVC monitoring maintains the following information to indicate regions of mapping problems:

Current Monitor Activity. This information is presented as a profile plot. Each data point in this
profile plot represents a CD control zone. The data points have an integer value with a lower limit
of zero(0). The magnitude of one data point holds relative meaning to all the rest. The higher the
value the higher the probability of mapping problem existing at that CD control zone. The
“Current Monitor Activity” is reset to zero when either the “Reset Monitor” button is click or the
LVC optimization operation completes an optimization sequence.

LV - Detected. This information is presented as a number list in a table format. A list of all zeros
indicates that LVC monitoring has not detected mapping problems at any of the CD control zones.
As mapping problems are detected, the CD control zone suspect of the problem is added to the
list. This list is reset to all zeros when either the “Reset Monitor” button is click or the LVC
optimization operation completes an optimization sequence.

5.5.2 Using LVC Optimization

Enabling LVC Optimization Operations

Two checkboxes and two buttons control the LVC optimization operations. The checkboxes are used
to choose the CD control parameters that get optimized. The buttons are used to manually start and
abort an optimization sequence. If either of the checkboxes for selecting the CD control parameters is
checked and the LVC monitoring operation detects a region requiring optimization, then LVC
optimization will begin performing optimization on the selected CD control parameters.

To select (or deselect) the CD control parameters that get optimized, the following steps are
performed:

 With the mouse, left mouse click the checkbox for “Smooth Optimization” to toggle between
selected (checkbox is checked) and deselected (checkbox is unchecked).

 With the mouse, left mouse click the checkbox for “Mapping Optimization” to toggle between
selected (checkbox is checked) and deselected (checkbox is unchecked).

To initiate a manual optimization sequence, one of the CD control parameter checkboxes must be
checked. A second requirement for manually starting optimization on the CD control mapping is the
manually specification of at least one CD actuator. The following steps are performed to initiate a
manual optimization sequence:

 With the mouse, move the cursor to the pushbutton “Manual Optimization”.

 Click the left-mouse button to toggle between off (button in the up position) and on (button in the
down position).

To manually abort an LVC optimization sequence that is currently in process, the following steps are
performed:

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 With the mouse, move the cursor to the pushbutton “Abort Optimization”.

 Click the left-mouse button to request an abort action.

System Response: The button will initially go to the depressed position and then back to the up
position once the application has acknowledge receiving the request.

The manual abort can be used to terminate an optimization sequence that was manually started or one
that was started by LVC monitoring detection of a CD actuator.

LVC Optimization Information

LVC optimization maintains the following information to indicate its operating state:

Optimization Status. This information is presented as a text message in a table format. Three text
messages are possible. “Not Active” indicates that there are no optimization sequences currently
active. “Mapping Search” indicates that an optimization sequence is currently being executed to
tune the CD mapping parameter. “Smoothness Search” indicates that an optimization sequence is
currently being executed to tune the CD control setpoint smoothness parameter.

Current Optimization Activity. This information is presented as a profile plot. Each data point in
this profile plot represents a CD control zone. The data points have an integer value of either 1 or
0. A value of 1 for any CD control zone indicates that the control zone is currently being
optimized to improve the local mapping alignment. A value of 0 for any CD control zone
indicates inactivity of mapping optimization on that control zone.

LV - Tuned. This information is presented as a number list in a table format. A list of all zeros
indicates that LVC optimization is neither performing mapping optimization currently nor has it
performed any mapping optimizations since the last restart of the LVC application. When
mapping optimization is performed on a CD control zone, the control zone number is added to the
list. The control zone number remains in the list until the next time that the LVC mapping
optimization sequence is executed. The list is refreshed to display only the control zones
associated with the current or most recent execution of the LVC optimization sequence.

Optimization History. This information is presented as a profile plot. Each data point in this profile
plot represents a CD control zone. The default interpretation of the data point value is the average
number of mapping optimizations performed on that control zone over an elapsed period of days.
The maximum number of elapsed days is 30.

Last Smooth Optimization. This information is presented as a text string in a table format. The text
string indicates the date-stamp and time-stamp of the last smooth optimization that ran to
completion.

Last Mapping Optimization. This information is presented as a text string in a table format. The text
string indicates the date-stamp and time-stamp of the last mapping optimization that ran to
completion.

5.5.3 CD Control Profile Information

For operational convenience, LVC maintains fundamental information about the CD control that it is
assigned to optimize. The CD control information on this overview display follows:

Current High Resolution Profile. This information is presented as a profile plot. The profile is the
CD control high-resolution (databox resolution) error profile (sensor profile minus target profile).

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CD Actuator Name. This information is presented as a profile plot. The label for this plot is the name
assigned to the CD actuator. The profile is the CD actuator setpoints.

5.5.4 LVC Messages

The following messages are displayed in the message box on the LVC operations overview display:

Optimization Active. This message is displayed when LVC optimization is actively executing an
optimization sequence (either smooth optimization or mapping optimization).

CD Process Monitor Locked Out by Optimization. This message is displayed as a result of LVC
optimization suspending operation of both LVC monitor and LVC optimization. The suspension
occurs immediately after LVC optimization completes its scheduled execution of smooth and/or
mapping optimizations. The suspend duration is specified when LVC is set up.

Bump Test In Progress. This message is displayed as a result of LVC being interlocked because a
CD control bump test is in progress.

CD Control Suspended. This message is displayed as a result of LVC being interlocked because CD
control is in a suspended state.

CD Control Off. This message is displayed as a result of LVC being interlocked because CD control
is turned off.

CD Excessive Profile Error. This message is displayed as a result of LVC being interlocked because
an excessive CD profile condition exists.

Grade Change Active. This message is displayed as a result of LVC being interlocked because a
grade change is in progress.

Profile Not Updating. This message is displayed as a result of LVC being interlocked because update
profile data from CD control has terminated for a long duration.

Sheet Break. This message is displayed as a result of LVC being interlocked because a sheet break
event is active.

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Chapter 6 Multivariable CD Control Displays

6.1 MCD Control Overview Display

The MCD Control Overview display provides detailed measurement, actuator, and control status
information for the MCD control operation. The MCD Control Overview display is divided into
multiple sections. Figure 6-1 shows a typical appearance of the MCD Control Overview display.

Figure 6-1 MCD Control Overview Display

The plot windows in the left part of the Control Overview display consist of a measurement plot
window for every measurement input and an actuator plot window for every actuator output of the
MCD controller. The right part of the display consists of several tables of active values, status and
dialog options, an operation section and the message window.

Each of the above-mentioned display sections is described in more detail below.

6.1.1 Measurement Plot Window

Depending on the MD participation status the measurement plot will show the high-resolution
absolute profile (MD participating) or zero-mean profile (MD not participating) along with the active
measurement target. The MD participation status is determined by the measurement target settings
(c.f. chapter 6.2.2).

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6.1.2 Actuator Plot Window

An actuator plot window plots the setpoint array as a bar graph, the feedback value as line graph, and
the actuator zone status by the color of the setpoint bar (Figure 6-2). The actuator window allows
selection of actuator(s), viewing of zone status, changing of manual/auto mode, and changing setpoint
values.

Figure 6-2 Actuator setpoint, feedback and status representation

Control Width

The system calculates the control width based on the profile to actuator mapping. The control width
starts and stops at the first and last zones that contain valid measured profile data. If the edge actuators
are outside of the control width, they will be displayed with crosshatch (Figure 6-3).

Figure 6-3 Control width indicators

Selecting Single Actuator Zone

A single actuator zone can be selected in the actuator window. The steps to perform this operation are
described in the following.

 Move cursor over the actuator zone to be selected.

 Click the left-mouse button.

System Response: A white rectangle outline appears around the actuator zone selected.

Selecting Multiple Actuator Zones

Multiple actuator zones can be selected in the actuator window. Different methods of selecting
multiple actuator zones are available. The steps to perform this operation are described in the
following.

The “Ctrl” key is used to select multiple actuator zones that are not necessarily next to each other.
This method may be useful for selecting multiple discontinuous zones of the profiler (Figure 6-4).

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 Move the cursor over the first actuator zone to be selected and click the left-mouse button.
System Response: A white rectangle outline appears around the actuator zone selected.

 Move the cursor over the next actuator zone to be selected.

 Press and hold the “Ctrl” key down and click the left-mouse button.
System Response: A white rectangle outline appears around the actuator zone selected.

 Repeat steps 2 and 3 to select other actuator zones.

Figure 6-4 Selecting actuators with “Ctrl” key

The “Shift” key is used to select multiple actuator zones that are adjacent to each other. This method
may be useful for selecting a range of continuous actuator zones (Figure 6-5).

 Move the cursor over the first zone of a range of actuator zones to be selected and click the left-
mouse button.
System Response: A white rectangle outline appears around the zone selected.

 Move the cursor over the last zone of a range of actuator zones to be selected.

 Push and hold the “Shift” key down and click the left-mouse button.
System Response: A white rectangle outline appears around the zone selected with the cursor and
the zones that are between the first and last zones selected.

Figure 6-5 Selecting actuators with “Shift” key

To select all actuator zones, either the “Ctrl” or the “Shift” key method described above can be used.
Alternatively, the right-mouse pop-up menu method can be used (Figure 6-6).

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 Move the cursor into the actuator window frame and click the right-mouse button.
System Response: A pop-up window appears with a list of options that includes “Select All”.

 Move the cursor over the text “Select All”.

System Response: The text “Select All” is highlighted.

 Click the left-mouse button.

System Response: A white rectangle outline appears around every actuator zone.

Figure 6-6 Selecting all actuators

Actuator Dialog Table

The actuator dialog table is used to change the actuator mode and make manual setpoint changes on
the actuator zones. The appearance of the actuator dialog table is shown in Figure 6-7. The detailed
steps to change actuator mode and make manual setpoint changes will be described in the following
sections. In this section, indicators and viewing options available in the actuator dialog table are
discussed. The topics for discussion are highlighted by area 1 and 2, in the figure.

Figure 6-7 Actuator dialog table

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Data Table

 “Sel” Column
“Sel” column is interactive. By moving the cursor to any cell under the “Sel” column, that
actuator zone can be selected or deselected with the click of the left-mouse button. The symbol
“>>” identifies zones that have been selected in the actuator sub-window. Cells of unselected
zones appear empty.

 “Act” Column
“Act” column identifies the actuator zone number in the data table.

 “Status” Column
“Status” column indicates whether the zone appears in the data table has an active status of auto
or manual.

 “Man” Column
“Man” column is interactive. By moving the cursor to any checkbox under the “Man” column,
that actuator zone can be marked for a mode change to auto or manual with the click of the left-
mouse button. A mode change to manual is indicated by a check mark in the box. A mode change
to auto is simply an empty box. For the mode change to be completed, the checking and
unchecking of the mode must be applied. More details on changing an actuator status will be
provided in the coming sections.

 “SP” Column
“SP” column indicates the active setpoint feedback for actuator zones appearing the data table.

 “New SP” Column

“New SP” column is interactive. By moving the cursor to any cell under the “New SP” column, a
new setpoint value can be specified for that zone by manually entering the new value. For the
manual setpoint change to be completed, the new setpoint value must be applied. More details on
changing the setpoint of a manual actuator will be provided in the coming sections.

 “MV” Column
“MV” column indicates the active actuator measurement feedback for actuator zones appearing
the data table.

Data Table View Options

 Show Selected Actuators

“Show Selected Actuators” button is used to display only those actuator zones selected from the
actuator sub-window in the data table. Selected actuators are those zones appearing with a white
rectangle outline in the actuator sub-window. In the actuator dialog window, selected actuator
zones are identified by the symbol “>>” in the “Sel” column.

 Show All Actuators

“Show All Actuators” button is used to display all actuator zones in the data table. With all the
actuator zones displayed, selected zones are identified by the symbol “>>” in the “Sel” column.
Unselected zones have empty “Sel” cells.

Select All Button

The “Select All” button is used to select all the actuators. If the “Selected All” button is pressed, the
data table will update displaying all actuators with the “>>” symbol appearing in the “Sel” column.

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The actuator dialog window can be opened with two methods. The dialog window will pop-up if the
left mouse button is used to click on the actuator dialog icon located in the lower left corner of the
plot window. The dialog window appears if the left mouse button is used to double-click on any of the
actuator zones. Figure 6-8 identifies the two methods for opening the actuator dialog window

Figure 6-8 Method to open actuator dialog window

Changing Actuator Status between Auto and Manual

The actuator zone status is indicated by the color of the zone bar graph. The color-code representation
is documented in Table 6-1.

Table 6-1 Actuator Status Color Indication

Color Description

Blue AUTO mode. Setpoints for these actuator zones are generated by the
MCD control.

Green MAN mode. Setpoints for these actuator zones are changeable by the
user.

Yellow NOT MOVEABLE status. An actuator zone with this status is not
moveable by the user or the MCD control. Its setpoint is updated to track
the feedback value. The condition resulting in this status for a zone is
failure to a feedback device on an adjacent actuator. When the condition
that results in this status is cleared, the zone is restored to its prior mode
of AUTO or MANUAL.

Red BAD status. A zone with this status is not moveable by the user or the
MCD control. Its setpoint is updated to track the feedback value. The
conditions resulting in this status for a zone includes mechanical failure
to the zone, failure to the feedback device for the zone, and out-of-
service mode selected (from the actuator interface system) for the zone.
When the condition that results in this status is cleared, the zone is
restored to its prior mode of AUTO or MANUAL.

The “Auto” and “Manual” modes are changeable by the user. The “Bad” and “Not Moveable” status
are determined by the actuator system.

It is necessary to change the mode between Auto and Manual to give to and take away from the MCD
control command of the actuator setpoint. When a zone is in Auto, the MCD control determines the
setpoint value for that actuator zone. When a zone is in Manual, the user determines the setpoint value
for that actuator zone. Under special circumstances, actuator zones that are in Manual may be

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interlocked from user intervention or may be moved without user intervention. If any of these
conditions are present, indication will be presented in the message box. These conditions include:

1. Actuator system in Local

2. Actuator system requests abort and interlock of MCD control

3. Actuator system requests suspend of MCD control

4. Communication (watchdog or transporter) failure between MCD control and the actuator system

The steps for changing the actuator zone mode between Auto and Manual are described in the
following with the illustration in Figure 6-9.

Figure 6-9 Changing actuator mode in the dialog window

 Select the zone(s) that needs to be changed. Refer to section on “Selecting Actuator Zones”.

 Move the cursor over the actuator dialog table icon and click the left-mouse button. This icon is
located in the lower left corner of the actuator window.
System Response: An actuator dialog table pops open. The selected actuator zones are displayed
in the table along with the zone status, the current setpoints and feedback values. Alternatively,
the actuator dialog table will open if the last actuator zone selected is double clicked with the left-
mouse button.

 Move the cursor over the “Manual” mode button and click the left-mouse button to change the
mode to manual (1).
System Response: A check mark appears in the checkboxes under the “Man” column.
Alternatively, the left-mouse click can be used to individually check each checkboxes under the
“Man” column.

Move the cursor over the “Auto” mode button and click the left-mouse button to change the mode
to auto (1).
System Response: The checks in the checkboxes under the “Man” column are cleared.
(Alternatively, the left-mouse click can be used to individually uncheck each checkboxes under
the “Man” column.).

 Move the cursor over the “Apply” or “Ok” button and click with the left-mouse button (2).
System Response: The “Apply” button will accept the mode changes and leave the dialog table
open. The “Ok” button will accept the mode changes and close dialog table. The actuator bars in
the actuator window turn green indicating that the actuator zone mode is Manual. The actuator

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zone bars in the actuator window turn blue indicating that the zone mode is Auto.
NOTE: To cancel the operation of changing zone modes to Manual, move the cursor over the
“Cancel” (instead of “Apply” or “Ok”) button and click with the left-mouse button. Pressing the
“Cancel” button discards all operations performed up to that point and closes the dialog table.

6.1.3 Measurement CD Information Table

The measurement CD information table shown in Figure 6-10 contains one column for every
measurement input of the controller. It can be used to set parameters for the CD part of the controller
and also shows statistical information about each input profile of the MCD controller.

Figure 6-10 Measurement CD Information Table

The following table describes the elements of the CD Information Table.

Table 6-2 Measurement CD Information

Tag Label Description

Participate This checkbox can be used to enable and disable the participation of a
measurement input profile for MCD control.

Priority Each input can have a dedicated priority setting for the MCD optimization.
Thus it is possible to weight different inputs differently. Inputs that have a
higher priority will be more tightly controlled.

The following priority levels can be selected:

 High (High)
 Medium High (MH)
 Medium (Med)
 Medium Low (ML)
 Low (Low)
Note: This priority only applied to CD portion of the profiles if MD/CD
separation is enabled on MCD Control Tuning Display. If MD/CD separation
is not enabled, this priority is applied to the absolute profile including the MD
average.

Diff 2-Sigma This cell shows the 2-Sigma of the high-resolution error profile.

MV 2-Sigma This cell shows the 2-Sigma of the high-resolution zero-mean profile.

High This cell shows the highest value of the high-resolution error profile.

Low This cell shows the lowest value of the high-resolution error profile.

Peak-Peak This cell shows the spread of the high-resolution error profile, i.e. the
difference between its highest and lowest value.

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6.1.4 Measurement MD Information Table

The measurement MD information table shown in Figure 6-11 contains one column for every
measurement input of the controller. It can be used to set parameters for the MD part of the controller
and also shows statistical information about each input profile of the MCD controller.

Figure 6-11 Measurement MD Information Table

The following table describes the elements of the MD Information Table.

Table 6-3 Measurement MD Information

Tag Label Description

Participate This indicator is used to show the participation of a measurement input profile
for MD control. For a measurement to participate in MD control, it must also
participate in CD control.

Priority Each input can have a dedicated priority setting for the MD optimization. Thus
it is possible to weight different inputs differently. Inputs that have a higher
priority will be more tightly controlled.

The following priority levels can be selected:

 High (High)
 Medium High (MH)
 Medium (Med)
 Medium Low (ML)
 Low (Low)
Note: MD Priority will be actively used only if the MD/CD separation is
enabled in the MCD Control Tuning Display. If MD/CD separation is not
enabled, only the priority setting in CD information table is applied.

Target This textbox can be used to set the MD target. It will only be available for
input if the target type allows an MD target.

Average This cell shows the average value of the high-resolution absolute profile if the
MD target option is active. Otherwise it shows the average value of the high-
resolution zero-mean profile.

6.1.5 Actuator Information Table

The actuator information table shown in Figure 6-12 contains one column for every actuator output of
the controller. It shows statistical data about each actuator output setpoint array of the MCD
controller. Figure 6-12 shows two different configurations of actuator information table. The left one
is for supercalender applications and the right one is for paper machine applications.

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Figure 6-12 Actuator Status Information Table (SC left, PM right)

The following table describes the elements of the Actuator Information Table.

Table 6-4 Actuator Information Table

Tag Label Description

Participate This checkbox allows operator to pick actuators for participating in the MCD
control. The marked checkbox indicates the participating actuator.

High This cell shows the highest value of the actuator setpoint array.

Average This cell shows the average value of the actuator setpoint array.

Low This cell shows the lowest value of the actuator setpoint array.

Retracted This cell shows whether the actuator is retracted or not. It will only be
displayed for those actuator types that support retraction.

High Limit This entry specifies an external high limit that can be used to temporarily
constrain the actuator setpoints. This entry is only available on
supercalenders and not on paper machines.

Low Limit This entry specifies an external low limit that can be used to temporarily
constrain the actuator setpoints. This entry is only available on
supercalenders and not on paper machines.

6.1.6 Control Status Table

The control status table shown in Figure 6-13 is used to switch the MCD control on and off. It also
shows some status information about the machine and MCD control. Figure 6-13 shows two different
configurations of control status table. The left one is for supercalender applications and the right one
is for paper machine applications.

Figure 6-13 Control Status Table (SC left, PM right)

The following table describes the elements of the Control Status Table.

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Table 6-5 Control Status Table

Tag Label Description

Control On This button is used to switch the MCD controller on and off.

Next Control Action (sec) This cell shows the time in seconds remaining until the next control
action of the MCD controller if the MCD controller is switched on. If the
MCD controller is switched off, it shows the delay time in seconds until
the first control action once the controller is switched on.

Machine Speed Target This cell shows the target for the machine speed.

Machine Speed This cell shows the current machine speed.

Sheetbreak This indicator turns red in case of a sheetbreak. It stays grey if there is
no sheetbreak.

Current Phase This cell is only available on supercalenders and not on paper
machines. It displays the phase the machine is currently in. The
following phases can be shown:

 Stop
The machine is stopped.
 Thread
Paper is threaded or in the process of threading through the
machine.
 Startup
Actuator setpoints are initialized to predefined values if the
startup feature is activated.
 Transition
The machine is in transition from startup to cruise phase, which
will be activated after a configurable transition period.
 Cruise
The machine is in normal operation mode. MCD feedback
control is active.
 Shutdown
Actuator setpoints are set to zero if the shutdown feature is
activated.

Actual Footage This cell shows the footage that has been accumulated on the current
reel. Depending on the speed units the footage is shown in feet
(feet/minute) or m (m/min). This cell is only available on
supercalenders and not on paper machines.

Enable External Limits Enables the external limits to temporarily constrain the actuator
setpoints within the limits specified as High Limit and Low Limit. This
entry is only available on supercalenders and not on paper machines.

6.1.7 Message Window

The message window, Figure 6-14, displays conditions that affect the operation of the MCD
controller.

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Figure 6-14 Message Window

If the message window has only green messages, the MCD controller is working in normal condition.
Yellow and red messages are indications of different severities of conditions that may prevent MCD
control from being active.

The following conditions may appear in the message window:

 Measurement Simulation Active

MCD control is receiving profile measurement and scanner information from a simulator.

 Actuator Simulation Active

MCD control is exchanging actuator setpoint and status with a simulator.

 MC<K> Control Active

MCD control K is active.

 MC<K> Control Aborted

MCD control K has been aborted.

 Abort: Act<N> Feedback Invalid

MCD control has an active abort condition due to invalid feedback data from profiler N.

 Abort: Act<N> Request Control Abort

MCD control has an active abort condition due to an abort request from profiler N.

 Abort: Act<N> Too Few Zones

MCD control has an active abort condition because there is an insufficient number of zones in
Auto mode on profiler N for MCD control to operate effectively and this condition has been
configured to abort control (default setting).

 Abort: MC<K> Actuator Not Available

MCD control K has an active abort condition because there is no actuator available or one of the
configured actuators is not available.

 Abort: MC<K> No Available Measurement

MCD control K has an active abort condition because there is no measurement available.

 Abort: MC<K> Interlock (<Description>)

MCD control K has an active abort condition because an interlock that is configured to abort
control is active.

 MC<K> Control Suspended

MCD control K has been suspended.

 Suspend: Act<N> Too Few Zones

MCD control has an active suspend condition because there is an insufficient number of zones in

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Auto mode on profiler N for MCD control to operate effectively and this condition has been
configured to suspend control (configurable setting).

 Suspend: Act<N> Request Control Suspend

MCD control has an active suspend condition due to a suspend request from profiler N.

 Suspend: Act<N> Request Bumpless Transfer

MCD control has an active suspend condition because profiler N requested a bumpless transfer of
its setpoints to the control.

 Suspend: Act<N> Not Ready for Feedback Control

MCD control has an active suspend condition because the actuator is not ready for feedback
control since some other function (such as bumptest or startup feedforward) is driving the
actuator. This could be due to an active bump test or an ongoing setpoint transition.

 Suspend: Meas<M> CD Variations

MCD control has an active suspend condition because the error profile variability of measurement
M was in excess of a permitted limit.

 Suspend: Meas<M> MD Variations

MCD control has an active suspend condition because the profile average of measurement M has
changed by more than a permitted limit from one profile update to the next.

 Suspend: Meas<M> Invalid

MCD control has an active suspend condition because the profile measurement M is invalid.

 Suspend: Meas<M> Timeout

MCD control has an active suspend condition because the profile measurement M has timed out.

 Suspend: MC<K> Sheetbreak

MCD control K has an active suspend condition because of a sheetbreak.

 Suspend: MC<K> Off-sheet

MCD control K has an active suspend condition because a frame is off-sheet.

 Suspend: MC<K> Waiting for Measurement

MCD control K has an active suspend condition because it is waiting for valid measurements.

 Suspend: MC<K> Interlock (<Description>)

MCD control K has an active suspend condition because an interlock that is configured to suspend
control is active.

 Suspend: MC<K> Finishing Control Calculation

MCD control K has an active suspend condition because it is currently finishing a control
calculation. This happens if the controller was switched off while it was still calculating new
setpoints.

 Act<N> in Local
The actuator N is operating in local mode and is not accepting setpoints from MCD control.

 Act<N> Startup Active

The startup feature has control over profiler N. This message only appears on supercalenders.

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 Act<N> Shutdown Active

The shutdown feature has control over profiler N. This message only appears on supercalenders.

 Act<N> Sheetbreak Reduction Active

The sheetbreak reduction feature is controlling profiler N. This message only appears on paper
machines.

 Act<N> Manual Reset Active

The actuator setpoints on profiler N are currently being manually reset.

 MC<K> Constraints Prevent Control

The last calculated setpoint change exceeds the high limit, low limit, 1st difference limit and/or
2nd difference limit. Hence the calculated setpoint changes are not applied.

 MC<K> Excessive Actuator Change

The last calculated setpoint change exceeds the permitted maximum change limit. Hence the
calculated setpoint changes are not applied.

6.2 MCD Measurement Target Display

The measurement target display shown in Figure 6-15 allows operators to set up the average and
shape targets for a measured profile. It allows the operator to enter a target shape by drag-and-drop
editing of a profile with a selected number of handles. The target average is entered as a value by the
operator or taken from MD controls (or other sources) as an external reference.

Figure 6-15 MCD Measurement Target Display

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The operator can also capture the current measurement and use it as a base for editing a new target
shape. The active target profile shows up on all overview displays just as it appears on the
Measurement Target display. This way the operator can see the active target and the actual deviation
between target and measurement.

6.2.1 Measurement Target Plots

The plot area of Figure 6-15 is divided in two parts. The upper plot shows the active target for the
measurement and the current profile.

The lower plot shows the preliminary target in high and low resolutions as well as the zero-mean
target. The low-resolution preliminary target can be edited in the plot in order to specify the desired
target shape.

6.2.2 Measurement CD Target Table

The measurement CD target table as shown in Figure 6-16 allows users to change the CD target type.
The supported type is explained in Table 6-6. When the CD Target Type is either “Operator Entry” or
“MD setpoint”, the MD control of the corresponding measurement is activated, i.e. it participates in
MD control. For a measurement to participate (or to be active) in MD control, it must also participate
in CD control.

Figure 6-16 CD Target Table

Table 6-6 Measurement CD Target

Tag Label Description

Target Type Zero Target – Use a flat zero profile as target.

Zero Mean – Use a zero mean shape specified by the operator.

Operator Entry – Use a shape with arbitrary mean value.

MD Setpoint – Use a shape with the MD setpoint as mean value.

Note: For a measurement to participate (or be active) in MD control, it

must also participate in CD control.

Non Zero Target Indicator that shows that a non-zero target is used.

6.2.3 Measurement MD Target Table

Figure 6-17 illustrates the measurement MD target table that shows the target for the mean of the
measured profile. When CD Target Type is either “Operator Entry” or “MD setpoint”, then MD
control of the corresponding measurement is activated, i.e. it participates in MD control. For a
measurement to participate (or to be active) in MD control, it must also participate in CD control.

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Figure 6-17 MD Target Table

Table 6-7 Measurement MD Target

Tag Label Description

MD Target Shows the preliminary and active targets for the average of the
measured profile. If Operator Entry is selected, this is where the target
is entered.

MD Measurement Displays the current measurement average.

MD Setpoint Displays the current MD setpoint (from MD control or grade data).

MD External Displays an additional external MD reference (normally not used).

6.2.4 Measurement Target Handling Table

The measurement target handling table as shown in Figure 6-18 allows operators to specify the
measurement target shape with various options. The usage of each option is explained in Table 6-8.

Figure 6-18 Target Handling Table

Table 6-8 Measurement Target Handling

Tag Label Description

Capture Target Copy a snapshot of the current measurement to the low resolution
Preliminary shape and make it the preliminary target shape.

Target Onsheet On – distribute the target shape over the databoxes that are currently
on-sheet. If the sheet width changes the target shape will be stretched
to fit the new width.

Off – distribute the target shape over all databoxes (typically 600). This
creates a static target shape.

Flip Target Flips the target shape. Useful if the target needs to be associated with
actuators that are not aligned with the databoxes (i.e. actuator #1
corresponds to databox #600).

Num Handles Sets the number of handles in the editable low resolution Preliminary
shape. Can be changed at any time.

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Tag Label Description

Global Smoothing On – create a target profile from all non-zero handles in the low
resolution Preliminary profile. Allows the operator to create a target by
only changing a few handles.

Off – create a target profile using all handles in the low resolution
Preliminary profile. Allows the user to create a target profile with local
detailed shape.

Smoothness Factor [%] Smoothing factor in percent to specify the smoothness of the target
profile.

6.2.5 Measurement Target Operation Buttons

Figure 6-19 shows the buttons and entries for operators to move the target shape between preliminary
and active or save and retrieve targets through data file. Table 6-9 explains the usage of each button
and entry.

Figure 6-19 Target Operation Buttons

Table 6-9 Measurement Target Operation Buttons

Tag Label Description

Save To Grade group number for saving a target profile.

Retrieve From Grade group number for retrieving a target profile. The value on the
right shows the currently active grade group (0 if unknown) that may
have been activated by a grade change.

Prelim To Active Copy the preliminary target profile to the active target profile.

Active To Prelim Copy the active target profile to both high and low resolution
preliminary profiles. This button allows the user to remove any
unwanted preliminary target and start over with the active target profile.

6.2.6 Display Links

The display links can be used to quickly navigate to the Measurement Target displays of the other
measurements.

Figure 6-20 Display Links

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6.2.7 Editing Measurement Target Profiles

The following steps describe how to set up a target profile. These steps should be performed before
starting the control.

 Select the appropriate Target Type. This depends on the type of application. Either Zero
Target or Zero Mean should be used when the average of the measurement is not affected by
the average setpoints of the used actuator(s). An example of this would be the control of a
weight profile with headbox slice screw actuators or a dilution profiler. Operator Entry or MD
Setpoint may be used if the average of the measurement is affected by the average of the used
actuator(s). An example of this is a supercalender where a gloss average is strongly affected
by the average setpoint of an induction profiler.

 If Operator Entry is selected, the target average can be entered in the MD Target field. This
immediately affects the top plot where the active target is shown.

 Check “Target Onsheet” if the target should be applied to the databoxes currently on sheet.
Typically this option is switched on. With Target Onsheet checked, the target shape is
distributed over the current sheet width. If the width should change, the target shape will be
stretched to fit the new width.

 Check “Flip Target” if the target should be flipped. This depends on the numbering direction
between the low-res target profile and profile databoxes. If, for example, the target should be
associated with a certain number of actuators and the actuators and databoxes are not aligned
(i.e. actuator #1 corresponds to databox #600) then the target should be flipped. If Flip Target
is checked the display direction of the Lo-Res Prelim Target should also be changed in order
to align the low-res and the high-res targets.

 Set the number of handles for the low resolution Preliminary profile. Typically, it is set equal
to the number of zones of one set of actuators.

 Set the Global option. If set, all non-zero handles in the low-resolution preliminary profile
will be used to create the high-resolution preliminary profile by connecting the specified
points with straight-line before the smoothing factor is applied. This makes it possible to
create a target profile with just a few handle points.

 Set the smoothing factor. Smoothing is entered as percentage. The number can be changed at
any time and immediately affects the high-resolution preliminary profile.

 Edit the low-resolution preliminary profile by dragging-and-dropping the handles or by

bringing up the profile dialog box. Click the green checkbox after dragging the handles to
accept the new shape. Alternatively, click Capture Target to copy the current measurement in
to the low-resolution preliminary profile and start from there. Changes to Global Smoothing
and Smoothness Factor can be made at any time.

Figure 6-21 Edit Dialog

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 Click Prelim to Active to transfer the high-resolution preliminary profile to the active target
profile.

6.3 MCD Actuator Target Display

The actuator target display, Figure 6-22, allows the operator to enter a desired actuator setpoint shape
and average. This display consists of following areas:

 Plot area of actuator target profiles

 Target setup table

 Edge option selection tables

 Edge parameters table

 Width status table

 Actuator target operation buttons

Figure 6-22 MCD Actuator Target Display

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6.3.1 Actuator Target Profiles

The actuator target plot area shown in Figure 6-22 is divided in three parts. The upper part shows the
current actuator setpoints. Below that is one plot that shows the active and preliminary targets. The
lower plot visualizes the control width contributions from the different measurement profiles.

Table 6-10 Actuator Target Plots

Tag Label Description

Actuator Plot Shows actuator information similar to what is shown on MCD control
overview displays.

Active Target Shows the currently active target.

Prelim Target Shows the preliminary target. Use Prelim to Active to transfer the
preliminary target to the active target.

Width Count Shows the width counters for all zones of all profilers. The width
counters for a zone will decrement at every scan if the zone is inside
the control width. The lowest value will be zero. The width counters for
a zone will increment if the zone is outside the control width. The
highest value will be the configured confirmation duration.

6.3.2 Target Setup Table

The target setup table (Figure 6-23) allows the operator to choose target type, target value and target
tracking gain.

Figure 6-23 Target Setup Table

Table 6-11 Actuator Target Setup

Tag Label Description

Target Type Midrange – sets the target for all zones to the center of the operating
range (i.e. 50 for a 0 – 100 % control output)

Manual – allows the operator to enter an average target. This target is

then used for all zones.

Manual Target Displays the current target. Is used if the Target Option is set to
Manual.

Tracking Gain A gain (0 – 1) that decides how fast the target should move towards a
new entered target.

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6.3.3 Edge Mode Selection Tables

Figure 6-24 shows the tables that allow the operator to choose different modes of operation for edge
zones at both the beginning and the ending edges.

Figure 6-24 Edge Selection Tables

Table 6-12 Actuator Target Edge Mode Selection

Tag Label Description

Mode Off – no edge handling. Setpoints of edge zones are calculated by

MCD control similar to that of all other zones.

Flat Fixed – sets all zones outside the control width to a fixed value
specified by Manual Target.

Flat Offset – sets the zones outside the control width to the same value
as the first zone inside the control width but with an offset specified by
Offset Value.

Shape Offset – takes a user entered shape and applies an offset to it

(relative to the first actuator inside the control width).

Offset Value Entry for beginning and ending offsets for Flat Offset mode.

Manual Target Entry for beginning and ending fixed values for Flat Fixed mode.

6.3.4 Edge Parameters Table

Figure 6-25 shows the parameters associated with how the sheet edges and the edge setpoints are
changed.

Figure 6-25 Edge Parameters Table

Table 6-13 Actuator Target Edge Parameters

Tag Label Description

Coverage Fraction (0~1) This fraction indicates how much of a zone must be covered with
profile measurement to count it as on-sheet.

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Tag Label Description

Confirmation Duration Number of consecutive scans needed for confirming a change in

control width. Typically set to 2 or more.

Use Min Width Option to enable or disable the usage of the minimum width from all
active measurements for the control width calculation. If this option is
active, the narrowest profile will determine the control width. If it is not
active, the widest profile will determine the control width.

Step Size Step size specifies the setpoint increment or decrement of edge
setpoint transition when edge mode is active. If the step size is 0 then
the edge zones are not moved at all.

6.3.5 Control Width Status Table

Figure 6-26 shows the control widths associated with each measured profile, the active control width
and indicates the profiles that are actively used to determine the active control width.

Figure 6-26 Control Width Status Table

Table 6-14 Actuator Target Width Status

Tag Label Description

Active Width Shows the beginning and ending zones of the current control width.

<Measurement> Width Shows the beginning and ending zones of the potential control width
based on the information from the displayed measurement. The
indicator on the left side shows whether the measurement is used for
control and the determination of the active control width.

6.3.6 Actuator Target Operation Buttons

Figure 6-27 shows the collection of buttons used to operate actuator target.

Figure 6-27 Actuator Target Operation Buttons

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Table 6-15 Actuator Target Operation Buttons

Tag Label Description

Save To Grade group number for saving a target profile.

Retrieve From Grade group number for retrieving a target profile. The retrieved target
is displayed as a preliminary target. The right value shows the group
number of the active target if is is known, otherwise it shows 0.

Prelim to Active Copy the preliminary target to the active target.

Active to Prelim Copy the active target to the preliminary target.

6.3.7 Display Links

The display links Figure 6-28 can be used to quickly navigate to the Actuator Target displays of the
other actuators.

Figure 6-28 Display Links

6.3.8 Editing Actuator Target Profiles

The following steps describe how to create and activate an actuator target.

 Select the appropriate Target Option. This depends on the type of application. Some actuators
(like headboxes) should be kept close to the center of their control range; others need to be
kept at an arbitrary average.

 Depending on the Target Option, enter a user target or change the manual target.

 Select proper modes for edge handling. Set appropriate values for offset and fixed value if the
respective mode is selected. Perform “Prelim to Active” when the edge handling values are
changed.

 Set the desired confirmation interval. The recommended value is at least two scans, this will
prohibit any temporary process upsets to change the control width.

 Change the coverage percentage if needed.

 To change the active target, click “Prelim to Active” button. This copies the Prelim Target to
the Active Target profile. Always select Prelim to Active when the target or the target options
have changed.

 The tracking gain decides how fast the actual target is moving toward the selected target.
Setting a tracking gain of 1 will make the actual target move to the active target in one step.

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6.4 MCD Actuator Overview Display

The MCD Actuator Overview display provides information about the relationship of an actuator to
each measurement of the MCD application. It shows information that typically is also available on
other displays, but gives operators the option to display only the setpoints of one set of actuators and
all measurement profiles with a higher resolution than for instance on the MCD Control Overview
display.

The display is divided into multiple sections. Figure 6-29 shows a typical appearance of the MCD
Actuator Overview display.

Figure 6-29 MCD Actuator Overview Display

6.4.1 Measurement Plot Window

The measurement plot window shows the high-resolution error profiles of all measurement inputs that
are configured in the MCD application. The profiles can be displayed in a set of stacked plots or
together in the same plot. Each profile plot can be independently hidden. Thus it is possible to view
the profile next to the actuator setpoints for detailed analysis.

6.4.2 Actuator Plot Window

Only a single actuator plot window is displayed on the Actuator Overview display. The actuator plot
can be operated the same way as the actuator plots on the MCD Control Overview display (c.f.
chapter 6.1.2).

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6.4.3 Measurement Information Table

The measurement information table contains one column for every measurement input of the
controller.

Figure 6-30 Measurement Information Table

The following table describes the elements of the Measurement Information table.

Table 6-16 Measurement Information Table

Tag Label Description

Average This entry shows the average value of the high-resolution error profile.

Diff 2-Sigma This entry shows the 2-Sigma of the high-resolution error profile.

Peak-Peak This entry shows the spread of the high-resolution error profile, i.e. the
difference between its highest and lowest value.

High This entry shows the highest value of the high-resolution error profile.

Low This entry shows the lowest value of the high-resolution error profile.

6.4.4 Control Status Table

The control status table, Figure 6-31, shows which of the measurements participates in CD and MD
control. It has one column for each measurement that is configured in the MCD application.

Figure 6-31 Control Status Information Table

The following table describes the elements of the Control Status Information table.

Table 6-17 Control Status Information

Tag Label Description

CD Ctrl The indicators show whether the measurement is currently participating in CD

control through any of the MCD controllers.

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Tag Label Description

MD Ctrl The indicators show whether the measurement is currently participating in

MD control through any of the MCD controllers. For a measurement to
participate in MD control, it must also participate in CD control. (c.f. Chapter
6.2.2)

6.4.5 Actuator Information Table

The actuator status table, Figure 6-32, contains a single column for the actuator. It shows statistical
data about the actuator.

Figure 6-32 Actuator Status Information Table

The following table describes the elements of the table.

Table 6-18 Actuator Status Information

Tag Label Description

High This entry shows the highest value of the actuator setpoint array.

Average This entry shows the average value of the actuator setpoint array.

Low This entry shows the lowest value of the actuator setpoint array.

6.4.6 Message Window

The message window, Figure 6-33, displays conditions that affect the operation of the MCD
controller.

Figure 6-33 Message Window

If there are no existing conditions, the message window will be empty. The conditions that may
appear in the message window are the same ones as on a MCD Control Overview display (c.f. chapter
6.1.7).

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6.4.7 Display Links

The display links can be used to quickly navigate to the Actuator Overview displays of the other
actuators.

Figure 6-34 Display Links

6.5 MCD Control Messages

The following messages show up on the MCD Overview display in case of an abnormal state such as
communication errors or control being suspended or aborted. The messages of normal operations or
information only are shown in green. The warning messages are either in yellow or red depending the
severity of the conditions.

6.5.1 General Messages

Measurement Simulation Active

MCD control is receiving profile measurement and scanner information from a simulator.

Actuator Simulation Active

MCD control is exchanging actuator setpoint and status with a simulator.

MC<K> Control Active

MCD control K is active.

MC<K> Control Aborted

MCD control K has been aborted.

MC<K> Control Suspended

MCD control K has been suspended.

Act<N> in Local

The actuator N is operating in local mode and is not accepting setpoints from MCD control.

Act<N> Startup Active

The startup feature has control over profiler N. This message only appears on supercalenders.

Act<N> Shutdown Active

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The shutdown feature has control over profiler N. This message only appears on supercalenders.

Act<N> Sheetbreak Reduction Active

The sheetbreak reduction feature is controlling profiler N. This message only appears on paper
machines.

Act<N> Manual Reset Active

The actuator setpoints on profiler N are currently being manually reset.

MC<K> Constraints Prevent Control

The last calculated setpoint changes exceed the high limit, low limit, 1st difference limit and/or 2nd
difference limit. Therefore it has not been applied.

This may require manual intervention. Make sure that no actuators have exceeded any
maximum/minimum setpoint limits or bend limits.

MC<K> Excessive Actuator Change

The last calculated setpoint changes exceed the permitted maximum change limit. Therefore it has not
been applied.

Check the change limits for the configured actuators and make sure that they are wide enough for the
control to operate. Alternatively, move some actuators manually to reduce the change that would be
made by the controller.

6.5.2 Abort Conditions

Abort: Act<N>Feedback Invalid

MCD control has an active abort condition due to invalid feedback data from profiler N.

The cause of this could be invalid data from the actuator itself or problems with the communication
between actuator and controller. Check the communication status overview and any status overview
for the actuator.

Abort: Act<N> Request Control Abort

MCD control has an active abort condition due to an abort request from profiler N.

This indicates that the actuator system has requested the controller to abort. This may be because the
actuator was taken out of service. Check the status of the actuator system.

Abort: Act<N> Too Few Zones

MCD control has an active abort condition because there is an insufficient number of zones in Auto
mode on profiler N for the MCD control to operate effectively and this condition has been configured
to abort control (Default Setting).

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This indicates that too few of the actuator zones of the given actuator system are available for control.
Check the number of available zones and make sure that it is larger than the limit (setup parameter on
the Control Tuning display).

Abort: MC<K> Actuator Not Available

MCD control K has an active abort condition because there was no actuator available or one of the
configured actuators was not available.

This indicates that no actuators are configured or available for the given controller or that one of the
configured actuators is not available. Change the configuration on the supervisor page and make sure
that at least one actuator system is available. Make sure that all configured actuators are available, i.e.
not in local mode.

Abort: MC<K> No Available Measurement

MCD control K has an active abort condition because there was no measurement available.

This indicates that no measurements are configured for the given controller. Change the configuration
on the supervisor page and make sure that at least one configured measurement is valid.

Abort: MC<K> Interlock (<Description>)

MCD control K has an active abort condition because of an interlock that is configured to abort
control.

Make sure that the interlock condition is no longer active before switching MCD control on.

6.5.3 Suspend Conditions

Suspend: Act<N> Too Few Zones

MCD control has an active suspend condition because there is an insufficient number of zones in Auto
mode on profiler N for the MCD control to operate effectively and this condition has been configured
to suspend control (Configurable Setting).

Suspend: Act<N> Request Control Suspend

MCD control has an active suspend condition due to a suspend request from profiler N.

This indicates that the actuator system has requested the controller to suspend. This may be because
the actuator system is not ready for control. Check the status of the actuator system.

Suspend: Act<N> Request Bumpless Transfer

MCD control has an active suspend condition because profiler N requested a bumpless transfer of its
setpoints to the control.

Suspend: Act<N> Not Ready for Feedback Control

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MCD control has an active suspend condition because the actuator is not ready for feedback control
since some other function is driving the actuator.

This could be due to an active bump test or an ongoing setpoint transition.

Suspend: Meas<M> CD Variations

MCD control has an active suspend condition because the error profile variability of measurement M
was in excess of a permitted limit.

Suspend: Meas<M> MD Variations

MCD control has an active suspend condition because the profile average of measurement M has
changed by more than a permitted limit from one profile update to the next.

Suspend: Meas<M> Invalid

MCD control has an active suspend condition because the profile measurement M is invalid.

Suspend: Meas<M> Timeout

MCD control has an active suspend condition because the profile measurement M has timed out.

Suspend: MC<K> Sheetbreak

MCD control K has an active suspend condition because of a sheetbreak.

Suspend: MC<K> Off-sheet

MCD control K has an active suspend condition because a frame is off-sheet.

Suspend: MC<K> Waiting for Measurement

MCD control K has an active suspend condition because it is waiting for valid measurements.

This indicates that the controller is currently waiting for a measurement update. The controller waits
for a measurement update after any abnormal conditions such as a sheetbreak.

Suspend: MC<K> Interlock (<Description>)

MCD control K has an active suspend condition because of an interlock that is configured to suspend
control. Control will resume once the interlock condition is no longer active.

Suspend: MC<K> Finishing Control Calculation

MCD control K has an active suspend condition because it is currently finishing a control calculation.

This happens if the controller was switched off while it was still calculating new setpoints.

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Chapter 7 CD Actuator Interface Displays

7.1 General Information

For details and troubleshooting information on actuator alarms, refer to the following manuals:

ProfileIT Slice/CoatWeight Profiler Installation and Service Manual, part number 103072-002.

ProfileIT Weight Profiler Installation and Maintenance Manual, part number 101794-003.

ProfileIT CoatWeight Profiler Installation and Maintenance Manual, part number 103007-003.

ProfileIT Dilution Profiler Installation and Service Manual, part number 103072-005.

ProfileIT Consistency Profiler Installation and Maintenance Manual, part number 103046-002.

ProfileIT Calender Profiler Service Manual, part number 103020-003.

ProfileIT Calender Profiler with Remote Electronics Service Manual, part number 3BUS 208 037
R0101.

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7.2 CD Actuator Interface Overview

The CD Actuator Interface Overview display provides detailed measurement, actuator status and
dialog for CD Actuator Interface operation. The CD Overview display is divided into multiple
interface sections. Figure 7-1 gives a typical appearance of the CD Actuator Interface Overview
display.

Figure 7-1 CD Actuator Interface Overview

7.2.1 Actuator Plot Window

The actuator sub-window plots the numeric equivalents of the setpoints as a bar graph, feedback value
as line graph, and actuator zone status by the color of the setpoint bar if available (see Figure 7-2).
The actuator window allows selection of actuator(s), viewing of zone status, changing of manual/auto
mode, and changing setpoint values.

Some actuator systems do not provide feedback. If it is not present, only the bar graph will show in
the actuator plot window.

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Figure 7-2 Actuator setpoint, feedback and status representation

Selecting A Single Actuator

A single actuator can be selected in the actuator window. The steps to perform this operation are
described in the following.

1. Move cursor over the actuator to be selected.

2. Click the left-mouse button.

System Response: A white rectangle outline appears around the actuator selected.

Selecting Multiple Actuators

Multiple actuators can be selected in the actuator window. Different methods of selecting multiple
actuators are available. The steps to perform this operation are described in the following.

The “ctrl” key is used to select multiple actuators that are not necessarily next to each other. This
method may be useful for selecting actuators that are at opposite edges of the profiler unit (see Figure
7-3).

Move the cursor over the first actuator to be selected and click the left-mouse button.
System Response: A white rectangle outline appears around the actuator selected.

Move the cursor over the next actuator to be selected.

Press and hold the “ctrl” key down and click the left-mouse button.
System Response: A white rectangle outline appears around the actuator selected.

Repeat steps 2 and 3 to select other actuators.

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Figure 7-3 Selecting actuators with “Ctrl” key

The “shift” key is used to select multiple actuators that are next to each other. This method may be
useful for selecting a range of actuators (see Figure 7-4).

Move the cursor over the first actuator of a range of actuators to be selected and click the left-mouse
button.
System Response: A white rectangle outline appears around the actuator selected.

Move the cursor over the last actuator of a range of actuators to be selected.

Push and hold the “shift” key down and click the left-mouse button.
System Response: A white rectangle outline appears around the actuator selected with the cursor
and the actuators that are between the first actuator and last actuator selected.

Figure 7-4 Selecting actuators with “Shift” key

To select all actuators, the “ctrl” and “shift” key methods described above can be used. Alternatively,
a right-mouse pop-up menu method can be used (see Figure 7-5).

1. Move the cursor into the actuator window frame and click the right-mouse button.
System Response: A pop-up window appears with a list of options that includes “Select All”.

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2. Move the cursor over the text “Select All”.

System Response: The text “Select All” is highlighted.

3. Click the left-mouse button.

System Response: A white rectangle outline appears around every actuator.

Figure 7-5 Selecting all actuators

Actuator Dialog Window

The actuator dialog window is used to change mode and make manual setpoint changes on the
actuators. The appearance of the actuator dialog window is given in Figure 7-6. The detail steps to
change mode and make manual setpoint changes will be described in further detail in following
sections. In this section, indicators and viewing options available in the actuator dialog window are
discussed. The topics for discussion are highlighted by area 1 and 2, in the figure.

Data Table

1. Sel Column
Sel” column is interactive. By moving the cursor to any cell under the “Sel” column, that actuator
can be selected or deselected with the click of the left-mouse button. The symbol “>>” identifies
actuators that have been selected in the actuator sub-window. Cells of unselected actuators appear
empty.

2. Act Column
”Act” column identifies the actuator number in the data table.

3. Status Column
”Status” column indicates whether the actuator appearing the data table has an active status of
auto or manual.

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4. Man Column
“Man” column is interactive. By moving the cursor to any checkbox under the “Man” column,
that actuator can be marked for an intended mode change to auto or manual with the click of the
left-mouse button. A mode change to manual is indicated by a check in the box. A mode change
to auto is simply an empty box. For the mode change to be completed, the checking and
unchecking of the mode must be applied. More details on changing an actuator status will be
provided in the coming sections.

5. SP Column
“SP” column indicates the active actuator setpoint feedback for actuators appearing the data table.

6. New SP Column
“New SP” column is interactive. By moving the cursor to any cell under the “New SP” column, a
new setpoint value can be specified for that actuator by numerically entering the new value. For
the manual setpoint change to be completed, the new setpoint value must be applied. More details
on changing the setpoint of a manual actuator will be provided in the coming sections.

7. MV Column
“MV” column indicates the active actuator measurement feedback for actuators appearing the data
table.

Data Table View Options

1. Show Selected Actuators

“Show Selected Actuators” button is used to display only those actuators selected from the
actuator sub-window in the data table. Selected actuators are those actuators appearing with a
white rectangle outline in the actuator sub-window. In the actuator dialog window, selected
actuators are identified by the symbol “>>” in the “Sel” column.

2. Show All Actuators

“Show All Actuators” button is used to display all actuators in the data table. With all the
actuators displayed, selected actuators are identified by the symbol “>>” in the “Sel” column.
Unselected actuators have empty “Sel” cells.

Select All Button

The “Select All” button is used to select all the actuators. If the “Selected All” button is pressed, the
data table will update displaying all actuators with the “>>” symbol appearing in the “Sel” column
(Figure 7-6).

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Figure 7-6 Actuator dialog window

The actuator dialog window can be opened with two methods. The dialog window will pop-up if the
left mouse button is used to click on the actuator dialog icon located in the lower left corner of the
plot window. The dialog window will also pop-up if the left mouse button is used to double-click on
any of the actuators. Figure 7-7 identifies the two methods for opening the actuator dialog window

Figure 7-7 Method to open actuator dialog window

Actuator Status Display

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Actuator status is indicated by the color of the actuator bar graph. The color-code representation is
documented in Table 7-1.

Table 7-1 Actuator status color indication

Color Description

Blue AUTO mode. Setpoints for these actuators are generated by the CD
control.

Green MAN mode. Setpoints for these actuators are changeable by the user.

Yellow NOT MOVEABLE status. An actuator with this status is not moveable by
the user or the CD control. Its setpoint is updated to track the feedback
value. The condition resulting in this status for an actuator is failure to a
feedback device on an adjacent actuator. When the condition that results
in this status is cleared, the actuator is restored to its prior mode of
AUTO or MANUAL.

Red BAD status. An actuator with this status is not moveable by the user or
the CD control. Its setpoint is updated to track the feedback value. The
conditions resulting in this status for an actuator includes mechanical
failure to the actuator, failure to the feedback device for the actuator, and
out-of-service mode selected (from the actuator interface system) for the
actuator. When the condition that results in this status is cleared, the
actuator is restored to its prior mode of AUTO or MANUAL.

Under special circumstances, actuator may be interlocked from user intervention or may be moved
without user intervention. If any of these conditions are present, indication will be presented in the
message box. These conditions include:

1. Actuator system in Local

2. Actuator system request abort and interlock of CD control

3. Actuator system request suspend of CD control

4. Communication (watchdog or transporter) failure between CD control and the actuator system

Making Setpoint Changes

Once an actuator is put in Manual mode, the user can enter a setpoint value for that actuator. Unless
one of the special circumstances discussed in the section “Changing Actuator Status between Auto
and Manual” occurs, this setpoint value is maintained until the user changes it. To change the setpoint
of an actuator, the desired actuators must be in manual mode and must be selected. The actuator
dialog window is used to apply a manual setpoint. Three methods are discussed below.

To change all of the selected actuators to the same setpoint (“Set” command), the steps for making the
setpoint changes are described in the following.

1. Move the cursor over the “Setpoint” textbox and click the left-mouse button. This selects the
textbox.

2. Enter the setpoint value that should be applied to all the selected actuators (1). See Figure 7-8.

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3. Move the cursor over the “Set” button and click the left-mouse button (2). See Figure 7-8.
System Response: The setpoint value entered in the “Setpoint” textbox appears in the “New SP”
column for all the selected actuators.

4. Move the cursor over the “Apply” or “Ok” button and click the left-mouse button (5).See Figure
7-8.
System Response: The “Apply” button accepts the changes and leaves the dialog window open.
The “Ok” button accepts the changes and closes the dialog window. The setpoint values in the
“New SP” column that can be applied to the actuator without limitation are displayed in the “SP”
column. Those “New SP” values that cannot be applied without limitation remain displayed in the
“New SP” column, while those that can be applied in its entirety are cleared from the “New SP”
cell.
NOTE: To cancel the operation of making manual setpoint changes, move the cursor over the
“Cancel” (instead of “Apply” or “Ok”) button and click the left-mouse button. Pressing the
“Cancel” button discards all operations and closes the dialog window.

To change all of the selected actuators by the same amount (“Offset” command), the steps for making
the setpoint changes are described in the following.

1. Move the cursor over the “Setpoint” textbox and click the left-mouse button. This selects the
textbox.

2. Enter the value that should be added to or subtracted from the current setpoint values of all the
selected actuators (1). To add to the current setpoint values, a positive entry is made. To subtract
from the current setpoint values, a negative entry is made. See Figure 7-8.

3. Move the cursor over the “Offset” button and click the left-mouse button (3).See Figure 7-8.
System Response: The setpoint value entered in the “Setpoint” textbox is either added or
subtracted from the current setpoint values and displayed in the “New SP” column for all the
selected actuators.

4. Move the cursor over the “Apply” or “Ok” button and click the left-mouse button (5).See Figure
7-8.
System Response: The “Apply” button accepts the changes and leaves the dialog window open.
The “Ok” button accepts the changes and closes the dialog window. The setpoint values in the
“New SP” column that can be applied to the actuator without limitation are displayed in the “SP”
column. Those “New SP” values that cannot be applied without limitation remain displayed in the
“New SP” column, while those that can be applied in its entirety are cleared from the “New SP”
cell.
NOTE: To cancel the operation of making setpoint changes, move the cursor over the “Cancel”
(instead of “Apply” or “Ok”) button and click the left-mouse button. Pressing the “Cancel” button
discards all operations and closes the dialog window.

To change the selected actuators individually (“New SP” data table column), the steps for making the
manual changes are described in the following.

1. Move the cursor over the “New SP” cell for actuator that needs to be changed and click the left-
mouse button (4). This selects the cell.

2. Enter the setpoint value for the actuator and press the “Enter” key.
System Response: The entered setpoint appears in “New SP” cell for the actuator being changed.

3. Repeat the previous two steps for all the selected actuators that need to be changed.

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4. Move the cursor over the “Apply” (5) or “Ok” (6) button and click the left-mouse button. See
Figure 7-8.
System Response: The “Apply” button accepts the changes and leaves the dialog window open.
The “Ok” button accepts the changes and closes the dialog window. The setpoint values in the
“New SP” column that can be applied to the actuator without limitation are displayed in the “SP”
column. Those “New SP” values that cannot be applied without limitation remain displayed in the
“New SP” column, while those that can be applied in its entirety are cleared from the “New SP”
cell
NOTE: To cancel the operation of making manual setpoint changes, move the cursor over the
“Cancel” (instead of “Apply” or “Ok”) button and click the left-mouse button. Pressing the
“Cancel” button discards all operations and closes the dialog window..

Figure 7-8 Changing actuator setpoint in dialog window

Tool Tips

Any actuator information may be viewed by positioning the cursor over the desired actuator. A tool
tip will pop up showing the actuator name, number, status, setpoint and feedback value. See Figure
7-9. The tool tip can be toggled on and off as described previously.

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Figure 7-9 Actuator tool tip

Data Change Time-Stamp

The time-stamp displayed in the upper left corner of the actuator window indicates data change time
for any of the actuators status, setpoint or feedback value.

7.2.2 Actuator data grid window

The actuator data grid window shows actuator data for the Actuator Interface (see Figure 7-10).

Figure 7-10 Actuator data grid window

The following sections list data that can appear in the actuator data grid window.

AccuRay Serial Protocol/VIB Steambox ASCII Serial Protocol

Table 7-2 AccuRay Serial Protocol/VIB Steambox ASCII Serial Protocol Actuator Status
Actuator Status Description

Actuator OK The actuator is capable of movement.

Zone Not In Auto The zone is not in auto. Setpoints will be rejected.

Short Circuit There is a short circuit in the actuator. Setpoints will be

rejected.

Open Circuit There is an open circuit in the actuator. Setpoints will be

rejected.

Zone Removed from Service The zone is removed from service. Setpoints will be
rejected.

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Zone In Limited Service The zone is in limited service. Setpoints will be rejected.

Table 7-3 AccuRay Serial Protocol/VIB Steambox ASCII Serial Protocol Feedback Status
Feedback Status Description

Feedback OK The position feedback reading of the actuator is valid.

Feedback Invalid The position feedback reading of the actuator is invalid.

Setpoints will be rejected.

Upper Hard Limit Reached The position feedback reading of the actuator has
reached the upper hard limit.

Lower Hard Limit Reached The position feedback reading of the actuator has
reached the lower hard limit.

Upper Soft Limit Reached The position feedback reading of the actuator has
reached the upper soft limit.

Lower Soft Limit Reached The position feedback reading of the actuator has
reached the lower soft limit.

First Order Bend Limit Reached The position feedback reading of the actuator has
reached the first order bend limit.

Second Order Bend Limit Reached The position feedback reading of the actuator has
reached the second order bend limit.

MX 200/100 Serial Protocol

Table 7-4 MX 200/100 Serial Protocol Actuator Status

Table 7-5 Actuator Status Description

Actuator OK The actuator is capable of movement.

Actuator Failure The actuator has failed. Setpoints will be rejected.

Actuator Disabled The actuator is disabled. Setpoints will be rejected.

Actuator Locked The actuator is locked. Setpoints will be rejected.

Actuator Runaway Position feedback has detected actuator movement

even though there was no setpoint request. Setpoints
will be rejected.

Wrong Direction Position feedback has detected movement in the

wrong direction in response to a setpoint request.
Setpoints will be rejected.

Actuator Moving Too Slow Position feedback has detected that the actuator has
failed to move sufficiently in response to a setpoint
request. Setpoints will be rejected.

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Table 7-6 MX 200/100 Serial Protocol Feedback Statuses

Feedback Status Description

Feedback OK The position feedback reading of the actuator is valid.

AI Recalibration Failed The position feedback reading of the actuator is invalid.

Setpoints will be rejected.

LVDT Undervoltage The LVDT voltage reading of the actuator has reached
the lower limit. Setpoints will be rejected.

LVDT Overvoltage The LVDT voltage reading of the actuator has reached
the upper limit. Setpoints will be rejected.

At Hard Bend Limit The position feedback reading of the actuator is at a

first or second order bend limit.

Upper Soft Limit Reached The position feedback reading of the actuator has
reached the upper soft limit.

Lower Soft Limit Reached The position feedback reading of the actuator has
reached the lower soft limit.

Slice Profiler/CoatWeight Profiler/Dilution Profiler

For details and troubleshooting information on actuator alarms, refer to the following manuals:

ProfileIT Slice/CoatWeight Profiler Installation and Service Manual, part number 103072-002.

ProfileIT Dilution Profiler Installation and Service Manual, part number 103072-005.

Table 7-7 Slice Profiler/CoatWeight Profiler/Dilution Profiler Actuator Status

Actuator Status Description

Actuator OK The actuator is ok and capable of movement.

Power On Error A power on error is detected in the actuator. Setpoints

will be rejected.

High Torque Error A high torque error is detected in the actuator.

Setpoints will be rejected.

Wrong Direction Position feedback has detected movement in the

wrong direction in response to a setpoint request.
Setpoints will be rejected.

Insufficient Movement Position feedback has detected that the actuator has
failed to move sufficiently in response to one setpoint
request. Setpoints will be rejected.

Invalid Feedback The position feedback reading of the actuator is invalid.

Setpoints will be rejected.

Manual Disable The actuator is manually disabled. Setpoints will be

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rejected.

Over Temperature An over temperature condition is detected in the

actuator. Setpoints will be rejected.

Invalid Temperature An invalid temperature condition is detected in the

actuator. Setpoints will be rejected.

Sister Power On Error A sister power on error is detected in the actuator.

Setpoints will be rejected.

Adjacent Feedback Invalid An adjacent actuator has an invalid feedback condition.

Setpoints will be rejected.

CIO Offline The CIO that the actuator is plugged into is off-line.
Setpoints will be rejected.

CIO Offline Soft Alarm The CIO that the actuator is plugged into is off-line.
Setpoints will be rejected.

Long Term Insufficient Movement Position feedback has detected that the actuator has
failed to move sufficiently in response to multiple
setpoint requests. Setpoints will be rejected.

Actuator Not Configured The actuator is not configured in the actuator system.
Setpoints will be rejected.

Table 7-8 Slice Profiler/CoatWeight Profiler/Dilution Profiler Feedback Status

Feedback Status Description

Feedback OK The position feedback reading of the actuator is valid.

Invalid Feedback The position feedback reading of the actuator is invalid.

Setpoints will be rejected

AI Reference Error The position feedback reading of the actuator has

failed. Setpoints will be rejected.

Unexpected Change The position feedback reading of the actuator has

changed even though there was no setpoint request.
Setpoints will be rejected.

Manual Disable The actuator is manually disabled. Setpoints will be

rejected.

Lower Hard Limit Reached The position feedback reading of the actuator has
reached the lower hard limit. Setpoints will be rejected.

Upper Hard Limit Reached The position feedback reading of the actuator has
reached the upper hard limit. Setpoints will be rejected.

At Hard Bend Limit The position feedback reading of the actuator has
reached the hard bend limit. Setpoints will be rejected.

AI Recalibration Failed Recalibration of the position feedback analog input has

failed. Setpoints will be rejected.

CIO Offline The CIO that the actuator is plugged into is off-line.

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Setpoints will be rejected.

Actuator Not Configured The actuator is not configured in the actuator system.
Setpoints will be rejected.

At Soft Bend Limit The position feedback reading of the actuator has
reached the second order bend limit.

Adjacent Feedback Invalid An adjacent actuator has an invalid feedback condition.

Setpoints will be rejected.

Lower Soft Limit Reached The position feedback reading of the actuator has
reached the lower soft limit.

Upper Soft Limit Reached The position feedback reading of the actuator has
reached the upper soft limit.

Transient Change A transient change in the position feedback has been

detected.

CIO Offline Soft Alarm The CIO that the actuator is plugged into is off-line.
Setpoints will be rejected.

Smart Weight Profiler/Smart CoatWeight Profiler/Smart Consistency Profiler

For details and troubleshooting information on actuator alarms, refer to the following manuals:

ProfileIT Weight Profiler Installation and Maintenance Manual, part number 101794-003.

ProfileIT CoatWeight Profiler Installation and Maintenance Manual, part number 103007-003.

ProfileIT Consistency Profiler Installation and Maintenance Manual, part number 103046-002.

Table 7-9 Smart Weight Profiler/Smart CoatWeight Profiler/Smart Consistency Actuator

Status
Actuator Status Description

Actuator OK The actuator is ok and capable of movement.

Digital Feedback Error Motor digital output and digital feedback do not match.
Setpoints will be rejected.

Bus Feedback Error A high torque error in the actuator is detected. Setpoints
will be rejected.

Wrong Direction Position feedback has detected movement in the wrong

direction in response to a setpoint request. Setpoints will
be rejected.

Insufficient Movement Position feedback has detected that the actuator has
failed to move sufficiently in response to one setpoint
request. Setpoints will be rejected.

Invalid Feedback The position feedback reading of the actuator is invalid.

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Setpoints will be rejected.

Manual Disable The actuator is manually disabled. Setpoints will be

rejected.

Open Solenoid An open circuit was detected in an actuator solenoid.

Setpoints will be rejected.

Shorted Solenoid A short circuit was detected in an actuator solenoid.

Setpoints will be rejected.

SIO Offline The SIO that the actuator is plugged into is off-line.
Setpoints will be rejected.

Select Line Shorted A short circuit was detected in the actuator select line.
Setpoints will be rejected.

Sequence Line Shorted A short circuit was detected in the actuator sequence line.
Setpoints will be rejected.

Adjacent Feedback Invalid An adjacent actuator has an invalid feedback condition.

Setpoints will be rejected.

Actuator Not Configured The actuator is not configured in the actuator system.
Setpoints will be rejected.

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Table 7-10 Smart Weight Profiler/Smart CoatWeight Profiler/Smart Consistency Profiler

Feedback Status
Feedback Status Description

Feedback OK The position feedback reading of the actuator is valid.

Feedback Invalid The position feedback reading of the actuator is invalid.

Setpoints will be rejected.

AI Reference Error The position feedback reading of the actuator has reached
the upper hard limit.

Unexpected Change The position feedback reading of the actuator has reached
the lower hard limit.

Manual Disable The position feedback reading of the actuator has reached
the upper soft limit.

Lower Hard Limit Reached The position feedback reading of the actuator has reached
the lower hard limit.

Upper Hard Limit Reached The position feedback reading of the actuator has reached
the upper hard limit.

SIO Offline The SIO that the actuator is plugged into is off-line.
Setpoints will be rejected.

Actuator Not Configured The actuator is not configured in the actuator system.
Setpoints will be rejected.

At Soft Bend Limit The position feedback reading of the actuator has reached
the second order bend limit.

Adjacent Feedback Invalid The position feedback reading of the actuator has reached
the second order bend limit.

Lower Soft Limit Reached The position feedback reading of the actuator has reached
the lower soft limit.

Upper Soft Limit Reached The position feedback reading of the actuator has reached
the upper soft limit.

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Calender Profiler/Smart Calender Profiler

For details and troubleshooting information on actuator alarms, refer to the following manuals:

ProfileIT Calender Profiler Service Manual, part number 103020-003.

ProfileIT Calender Profiler with Remote Electronics Service Manual, part number 3BUS 208 037
R0101.

Table 7-11 Calender Profiler/Smart Calender Profiler actuator status

Actuator Status Description

Actuator OK The actuator is ok and capable of movement.

Heater Unplugged An actuator heater is unplugged. Setpoints will be

rejected.

1 Heater Coil Open An actuator heater coil is open. Setpoints will be rejected.

2 Heater Coils Open Two actuator heater coils are open. Setpoints will be
rejected.

Heater Broken An actuator heater has failed. Setpoints will be rejected.

Current Sensor Failed An actuator heater current sensor has failed. Setpoints will
be rejected.

Manual Disable The actuator is manually disabled. Setpoints will be

rejected.

480 Power Lost 480 volt actuator heater power has been lost. Setpoints
will be rejected.

SIOC Offline The SIOC that the actuator is plugged into is off-line.
Setpoints will be rejected.

2 Phases Shorted To Ground Two 480 volt actuator heater power phases are shorted to
ground. Setpoints will be rejected.

1 Phase Open Or Fuse Blown One 480 volt actuator heater power phase is open.
Setpoints will be rejected.

Shorted SIOC DO The digital output from the SIOC to the actuator heater is
shorted. Setpoints will be rejected.

Actuator Not Configured The actuator is not configured in the actuator system.
Setpoints will be rejected.

Heater Stuck On Or Off The actuator heater cannot be turned on or turned off
when commanded. Setpoints will be rejected.

Unknown Heater Error Heater diagnostics have detected but cannot identify an
abnormal heater operation. Setpoints will be rejected.

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SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution/Induction Profiler

Table 7-12 SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution/Induction

Profiler Actuator Status
Actuator Status Description

Actuator OK The actuator is capable of movement.

Zone Not In Auto The zone is not in auto. Setpoints will be rejected.

Short Circuit There is a short circuit in the actuator. Setpoints will be

rejected.

Open Circuit There is an open circuit in the actuator. Setpoints will be

rejected.

Zone Removed from Service The zone is removed from service. Setpoints will be
rejected.

Zone In Limited Service The zone is in limited service. Setpoints will be rejected.

Table 7-13 SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution/Induction

Profiler Feedback Status
Feedback Status Description

Feedback OK The position feedback reading of the actuator is valid.

Feedback Invalid The position feedback reading of the actuator is invalid.

Setpoints will be rejected.

Upper Hard Limit Reached The position feedback reading of the actuator has
reached the upper hard limit.

Lower Hard Limit Reached The position feedback reading of the actuator has
reached the lower hard limit.

Upper Soft Limit Reached The position feedback reading of the actuator has
reached the upper soft limit.

Lower Soft Limit Reached The position feedback reading of the actuator has
reached the lower soft limit.

First Order Bend Limit Reached The position feedback reading of the actuator has
reached the first order bend limit.

Second Order Bend Limit Reached The position feedback reading of the actuator has
reached the second order bend limit.

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7.2.3 Scalar data grid window

The scalar data grid window shows scalar variables for the Actuator Interface (see Figure 7-11).

Figure 7-11 Scalar data grid window

The following tables list data that can appear in the scalar data grid window.

AccuRay Serial Protocol/VIB Steambox ASCII Serial Protocol/MX 200/100 Serial

Protocol

Table 7-14 AccuRay Serial Protocol/VIB Steambox ASCII Serial Protocol/MX 200/100 Serial
Protocol data
Variable Description Default
Value

Setpoint High Limit Setpoint high limit 100.0

Setpoint Low Limit Setpoint low limit -100.0

Feedback High Limit Feedback high limit 100.0

Feedback Low Limit Feedback low limit -100.0

Setpoint Slope Setpoint slope 1.0

Setpoint Offset Setpoint offset 0.0

Actuators Connected Timeout (Secs) Actuators connected timeout in seconds 30

Setpoint When Retracted Setpoint when retracted 0.0

Setpoint Retrieval Time (Secs) Setpoint retrieval time in seconds 30

Serial Port Number Serial port number 1

Serial Port Number Baud Rate Serial port baud rate 9600

Serial Port Number Of Bits Serial port number of bits 8

Serial Port Number Parity Serial port parity Even

Serial Port Number Of Stop Bits Serial port number of stop bits 1

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Serial Port Poll Time (Secs) Serial port poll time in seconds 30

Multiple Actuator Device Serial Port Checkbox that indicates multiple actuator Off
devices are on this serial port

System Status Off Checkbox for disabling the system status Off
message.

Feedback Off Checkbox for disabling the feedback Off

message.

Zone Status Off Checkbox for disabling the zone status Off
message.

Profiler Retracted Logic Off Checkbox for disabling the profiler Off
retracted logic.

Slice Profiler/CoatWeight Profiler/Smart Weight Profiler/Smart CoatWeight Profiler

Table 7-15 Slice Profiler/CoatWeight Profiler/Smart Weight Profiler/Smart CoatWeight

Profiler data
Variable Description Default
Value

Setpoint High Limit Setpoint high limit 100.0

Setpoint Low Limit Setpoint low limit -100.0

Feedback High Limit Feedback high limit 100.0

Feedback Low Limit Feedback low limit -100.0

Setpoint Slope Setpoint slope 1.0

Setpoint Offset Setpoint offset 0.0

Actuators Connected Timeout (Secs) Actuators connected timeout in seconds 30

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Dilution Profiler/Smart Consistency Profiler

Table 7-16 Dilution Profiler/Smart Consistency Profiler data

Variable Description Default
Value

Setpoint High Limit Setpoint high limit 100.0

Setpoint Low Limit Setpoint low limit -100.0

Feedback High Limit Feedback high limit 100.0

Feedback Low Limit Feedback low limit -100.0

Setpoint Slope Setpoint slope 1.0

Setpoint Offset Setpoint offset 0.0

Actuators Connected Timeout (Secs) Actuators connected timeout in seconds 30

Edge Flow 1 Setpoint Current setpoint for edge flow valve #1 N/A

New Edge Flow 1 Setpoint New setpoint for edge flow valve #1 N/A

Edge Flow 1 Feedback Current feedback for edge flow valve #1 N/A

Edge Flow 1 Actuator Status Current actuator status for edge flow N/A
valve #1

Edge Flow 1 Feedback Status Current feedback status for edge flow N/A
valve #1

Edge Flow 2 Setpoint Current setpoint for edge flow valve #2 N/A

New Edge Flow 2 Setpoint New setpoint for edge flow valve #2 N/A

Edge Flow 2 Feedback Current feedback for edge flow valve #2 N/A

Edge Flow 2 Actuator Status Current actuator status for edge flow N/A
valve #2

Edge Flow 2 Feedback Status Current feedback status for edge flow N/A
valve #2

Flush Edge Flow Actuators Checkbox that indicates whether edge Off
flow valves are to be flushed during flush
cycle.

Flush Cycle Settle Time (Secs) # of seconds that the actuator interface 15
will wait for actuators to get to setpoint
during flush cycle.

Flush Cycle Flush Time (Secs) # of seconds each value will be flushed 1
during flush cycle.

Flush Cycle Number of Flushes Number of times each value will be 3

flushed during flush cycle.

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Flush Cycle Select 00 Number of actuators in a group that will 8

be flushed during flush cycle if Flush
Cycle Select 1 = false and Flush Cycle
Select 2 = false.

Flush Cycle Select 01 Number of actuators in a group that will 8

be flushed during flush cycle if Flush
Cycle Select 1 = false and Flush Cycle
Select 2 = true.

Flush Cycle Select 10 Number of actuators in a group that will 8

be flushed during flush cycle if Flush
Cycle Select 1 = true and Flush Cycle
Select 2 = false.

Flush Cycle Select 11 Number of actuators in a group that will 8

be flushed during flush cycle if Flush
Cycle Select 1 = true and Flush Cycle
Select 2 = true.

Two Actuator Devices Exist Checkbox that indicates whether a Off

second actuator device exists.

Calender Profiler/Smart Calender Profiler

Table 7-17 Calender Profiler/Smart Calender Profiler data

Table 7-18 Variable Description Default
Value

Setpoint High Limit Setpoint high limit 100.0

Setpoint Low Limit Setpoint low limit -100.0

Feedback High Limit Feedback high limit 100.0

Feedback Low Limit Feedback low limit -100.0

Setpoint Slope Setpoint slope 1.0

Setpoint Offset Setpoint offset 0.0

Actuators Connected Timeout (Secs) Actuators connected timeout in seconds 30

SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution Data

Table 7-19 SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution Data

Variable Description Default
Value

Setpoint High Limit Setpoint high limit 100.0

Setpoint Low Limit Setpoint low limit -100.0

Feedback High Limit Feedback high limit 100.0

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Feedback Low Limit Feedback low limit -100.0

Setpoint Slope Setpoint slope 1.0

Setpoint Offset Setpoint offset 0.0

Actuators Connected Timeout (Secs) Actuators connected timeout in seconds 30

Setpoint When Retracted Setpoint when retracted 0.0

Setpoint Retrieval Time (Secs) Setpoint retrieval time in seconds 30

System Status Off Checkbox for disabling the system status Off
message.

Feedback Off Checkbox for disabling the feedback Off

message.

Zone Status Off Checkbox for disabling the zone status Off
message.

Profiler Retracted Logic Off Checkbox for disabling the profiler Off
retracted logic.

Induction Profiler Data

Table 7-20 Induction Profiler Data

Variable Description Default
Value

Setpoint High Limit Setpoint high limit 100.0

Setpoint Low Limit Setpoint low limit -100.0

Feedback High Limit Feedback high limit 100.0

Feedback Low Limit Feedback low limit -100.0

Setpoint Slope Setpoint slope 1.0

Setpoint Offset Setpoint offset 0.0

Actuators Connected Timeout (Secs) Actuators connected timeout in seconds 30

Setpoint When Retracted Setpoint when retracted 0.0

Setpoint Retrieval Time (Secs) Setpoint retrieval time in seconds 30

System Status Off Checkbox for disabling the system status Off
message.

Feedback Off Checkbox for disabling the feedback Off

message.

Zone Status Off Checkbox for disabling the zone status Off
message.

Profiler Retracted Logic Off Checkbox for disabling the profiler Off
retracted logic.

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Cabinet Air Temperature (Celsius) Cabinet air temperature display in N/A

Celsius.

Cabinet Air Temperature High Limit Cabinet air temperature high limit in 40.0
(Celsius) Celsius.

Cabinet High Air Pressure (IN H2O) Cabinet High Air Pressure display in IN N/A
H2O.

Cabinet Low Air Pressure (IN H2O) Cabinet Low Air Pressure display in IN N/A
H2O.

Cabinet Air Flow (CFM) Cabinet Air Flow display in CFM. N/A

Cabinet Air Flow Low Limit (CFM) Cabinet Air Flow low limit in CFM. 30

Cabinet Air Flow Lost Limit (CFM) Cabinet Air Flow lost limit in CFM. 20

Cabinet Air Cabinet Air Flow Constant for converting air pressure 26.3
Constant differential into CFM.

Power Contactor On Checkbox for displaying power contactor Off/On

on status.

Frontside Proximeter Switch Checkbox for displaying frontside Off/On

proximeter switch status.

Driveside Proximeter Switch Checkbox for displaying driveside Off/On

proximeter switch status

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7.2.4 Message Window

The message window displays conditions that affect operations of the CD Actuator Interface (Figure
7-12)

Figure 7-12 CD Actuator Interface Overview message window

The following tables list conditions that can appear in the message window.

ABB Serial Protocol

Table 7-21 ABB Serial Protocol messages

Message Description

Actuators Not Connected There is a communications error between the actuator

interface and the actuators. This can be caused by an
transporter or serial communications error. Any setpoints
sent to the actuator system will be ignored.

Actuators Unavailable There is a condition in the actuator system that prevents

it from moving actuators. Any setpoints sent to the
actuator system will be ignored.

Actuators In Local An operator has put the actuator system in local. Any
setpoints sent to the actuator system will be ignored

Abort CD Control The actuator system has requested that CD control be

aborted. Any setpoints sent to the actuator system will be
ignored.

Suspend CD Control The actuator system has requested that CD control be

suspended. Any setpoints sent to the actuator system will
be ignored.

Put CD Control In Local The actuator system has requested that CD control be
put in local. Any setpoints sent to the actuator system will
be ignored.

Actuator Overview Selected If the Actuator Interface Overview page is selected,

setpoints can be entered from the Actuator Overview
page. If the Actuator Overview page is not selected,
setpoints must come from the host computer. Pressing

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the “Select” command button on the Actuator Overview

page toggles the selected/not-selected status.

Actuator System Alarm There is an alarm condition in the actuator system. To

get the exact alarm, you must look on the actuator
system diagnostic page.

Actuator Interface Startup Error This indicates that there was a problem when the
actuator interface system tried to start up. The specific
error will be logged in the error log file on the hard drive
and the debug window.

Actuator Stopped An actuator is not available to respond to setpoint

changes.

Actuators Moving to Target Actuators are moving in response to a setpoint change.

Air Pressure Lost Air pressure is lost in the actuator system.

Diagnostic Failure The actuator system has run diagnostics and detected a
failure. This error is for Impact actuators only. Any
setpoints sent to the actuator system will be ignored.

DAC Failure The actuator system has detected a failure in the DAC.
This error is for Impact actuators only. Any setpoints sent
to the actuator system will be ignored.

Profiler Retracted The actuator system profiler has retracted. Any setpoints
sent to the actuator system will be ignored.

Computer Restarted The actuator system computer has been restarted.

Last Setpoint Update Rejected The actuator system has rejected setpoints sent to it for
one of the following reasons:

Actuator system in local

Invalid type code in setpoint message

Invalid access code in setpoint message

Invalid setpoints in setpoint message

Invalid zone in setpoint message

Excessive setpoint message length

Main Breaker Tripped The main power breaker has tripped in the actuator
system.

Cooling Air Failure Cooling air has failed in the actuator system.

Over Temperature An over-temperature condition exists in the actuator

system.

Purge Cycle Active Purge cycle is active in the actuator system.

Ramping To Setpoints The actuator system is ramping to new setpoints.

Water Pressure Failure Water pressure has failed in the actuator system.

Water Temperature Off Spec Water temperature is off spec in the actuator system.

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Power Supply Failure The power supply has failed in the actuator system

Actuators In Startup Mode The actuators in the actuator system are in startup mode

Tank Level Low The tank level is low in the actuator system.

Sheet Break A sheet break is detected by the actuator system.

DC Power Off Spec The dc power is off spec in the actuator system.

Power Supply Over Temperature The power supply is over-temperature in the actuator
system.

Power Supply Breaker Tripped The power supply circuit breaker has tripped in the
actuator system.

Serial Port Setup Error This indicates that there was a problem when the
actuator interface system tried to set up the serial port.
This could be caused by trying to setup to a serial port
that is already being used, for example. The specific error
will be logged in the error log file on the hard drive and
the debug window.

VIB Steambox ASCII Serial Protocol

Table 7-22 VIB Steambox ASCII Serial Protocol messages

Message Description

Actuators Not Connected There is a communications error between the actuator

interface and the actuators. This can be caused by an
transporter or serial communications error. Any setpoints
sent to the actuator system will be ignored.

Actuators Unavailable There is a condition in the actuator system that prevents

it from moving actuators. Any setpoints sent to the
actuator system will be ignored.

Actuators In Local An operator has put the actuator system in local. Any
setpoints sent to the actuator system will be ignored

Abort CD Control The actuator system has requested that CD control be

aborted. Any setpoints sent to the actuator system will be
ignored.

Suspend CD Control The actuator system has requested that CD control be

suspended. Any setpoints sent to the actuator system will
be ignored.

Put CD Control In Local The actuator system has requested that CD control be
put in local. Any setpoints sent to the actuator system will
be ignored.

Actuator Overview Selected If the Actuator Interface Overview page is selected,

setpoints can be entered from the Actuator Overview
page. If the Actuator Overview page is not selected,
setpoints must come from the host computer. Pressing
the “Select” command button on the Actuator Overview

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page toggles the selected/not-selected status.

Actuator System Alarm There is an alarm condition in the actuator system. To

get the exact alarm, you must look on the actuator
system diagnostic page.

Actuator Interface Startup Error This indicates that there was a problem when the
actuator interface system tried to start up. The specific
error will be logged in the error log file on the hard drive
and the debug window.

Actuator Stopped An actuator is not available to respond to setpoint

changes.

Actuators Moving to Target Actuators are moving in response to a setpoint change.

Serial Port Setup Error This indicates that there was a problem when the
actuator interface system tried to set up the serial port.
This could be caused by trying to setup to a serial port
that is already being used, for example. The specific error
will be logged in the error log file on the hard drive and
the debug window.

MX 200/100 Serial Protocol

Table 7-23 MX 200/100 Serial Protocol messages

Message Description

Actuators Not Connected There is a communications error between the actuator

interface and the actuators. This can be caused by an
transporter or serial communications error. Any setpoints
sent to the actuator system will be ignored.

Actuators Unavailable There is a condition in the actuator system that prevents it

from moving actuators. Any setpoints sent to the actuator
system will be ignored.

Actuators In Local An operator has put the actuator system in local. Any
setpoints sent to the actuator system will be ignored.

Abort CD Control The actuator system has requested that CD control be

aborted. Any setpoints sent to the actuator system will be
ignored.

Suspend CD Control The actuator system has requested that CD control be

suspended. Any setpoints sent to the actuator system will
be ignored.

Put CD Control In Local The actuator system has requested that CD control be put
in local. Any setpoints sent to the actuator system will be
ignored.

Actuator Overview Selected If the Actuator Interface Overview page is selected,

setpoints can be entered from the Actuator Overview page.
If the Actuator Overview page is not selected, setpoints
must come from the host computer. Pressing the “Select”
command button on the Actuator Overview page toggles

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the selected/not-selected status.

Actuator System Alarm There is an alarm condition in the actuator system. To get
the exact alarm, you must look on the actuator system
diagnostic page.

Actuator Interface Startup This indicates that there was a problem when the actuator
Error interface system tried to start up. The specific error will be
logged in the error log file on the hard drive and the debug
window.

Actuator Stopped An actuator is not available to respond to setpoint changes.

Actuators Moving to Target Actuators are moving in response to a setpoint change.

Machine Interlock A machine interlock condition exists in the actuator system.

Actuator Interlock An actuator interlock condition exists in the actuator

system.

Maintenance Mode A maintenance mode condition exists in the actuator

system.

UniLogic Hardware Fault A UniLogic PLC hardware fault condition exists.

UniLogic Software Fault A UniLogic PLC software fault condition exists.

Profiler Retracted The actuator system profiler has retracted. Any setpoints
sent to the actuator system will be ignored.

Power Supply Failure The power supply has failed in the actuator system.

Sheet Break A sheet break is detected by the actuator system.

Serial Port Setup Error This indicates that there was a problem when the actuator
interface system tried to set up the serial port. This could
be caused by trying to setup to a serial port that is already
being used, for example. The specific error will be logged in
the error log file on the hard drive and the debug window.

Slice Profiler/CoatWeight Profiler/Smart Weight Profiler/Smart CoatWeight Profiler

For details and troubleshooting information on actuator alarms, refer to the following manuals:

ProfileIT Slice/CoatWeight Profiler Installation and Service Manual, part number 103072-002.

ProfileIT Weight Profiler Installation and Maintenance Manual, part number 101794-003.

ProfileIT CoatWeight Profiler Installation and Maintenance Manual, part number 103007-003.

Table 7-24 Slice Profiler/CoatWeight Profiler/Smart Weight Profiler/Smart CoatWeight

Profiler
Message Description

Actuators Not Connected There is a communications error between the actuator

interface and the actuators. This can be caused by an
transporter or serial communications error. Any setpoints

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sent to the actuator system will be ignored.

Actuators Unavailable There is a condition in the actuator system that prevents it

from moving actuators. Any setpoints sent to the actuator
system will be ignored.

Actuators In Local An operator has put the actuator system in local. Any
setpoints sent to the actuator system will be ignored

Abort CD Control The actuator system has requested that CD control be

aborted. Any setpoints sent to the actuator system will be
ignored.

Suspend CD Control The actuator system has requested that CD control be

suspended. Any setpoints sent to the actuator system will
be ignored.

Put CD Control In Local The actuator system has requested that CD control be put
in local. Any setpoints sent to the actuator system will be
ignored.

Actuators Moving to Target Actuators are moving in response to a setpoint change.

Actuator Overview Selected If the Actuator Interface Overview page is selected,

setpoints can be entered from the Actuator Overview
page. If the Actuator Overview page is not selected,
setpoints must come from the host computer. Pressing the
“Select” command button on the Actuator Overview page
toggles the selected/not-selected status.

Actuator System Alarm There is an alarm condition in the actuator system. To get
the exact alarm, you must look on the actuator system
diagnostic page.

Actuator Interface Startup Error This indicates that there was a problem when the actuator
interface system tried to start up. The specific error will be
logged in the error log file on the hard drive and the debug
window.

Air Pressure Lost Air pressure is too low to move any actuators.

Dilution Profiler/Smart Consistency Profiler

For details and troubleshooting information on actuator alarms, refer to the following manuals:

ProfileIT Dilution Profiler Installation and Service Manual, part number 103072-005.

ProfileIT Consistency Profiler Installation and Maintenance Manual, part number 103046-002.

Table 7-25 Dilution Profiler/Smart Consistency Profiler

Message Description

Actuators Not Connected There is a communications error between the actuator

interface and the actuators. This can be caused by an
transporter or serial communications error. Any setpoints
sent to the actuator system will be ignored.

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Actuators Unavailable There is a condition in the actuator system that prevents it

from moving actuators. Any setpoints sent to the actuator
system will be ignored.

Actuators In Local An operator has put the actuator system in local. Any
setpoints sent to the actuator system will be ignored

Abort CD Control The actuator system has requested that CD control be

aborted. Any setpoints sent to the actuator system will be
ignored.

Suspend CD Control The actuator system has requested that CD control be

suspended. Any setpoints sent to the actuator system will
be ignored.

Put CD Control In Local The actuator system has requested that CD control be put
in local. Any setpoints sent to the actuator system will be
ignored.

Actuators Moving to Target Actuators are moving in response to a setpoint change.

Actuator Overview Selected If the Actuator Interface Overview page is selected,

setpoints can be entered from the Actuator Overview
page. If the Actuator Overview page is not selected,
setpoints must come from the host computer. Pressing the
“Select” command button on the Actuator Overview page
toggles the selected/not-selected status.

Actuator System Alarm There is an alarm condition in the actuator system. To get
the exact alarm, you must look on the actuator system
diagnostic page.

Actuator Interface Startup Error This indicates that there was a problem when the actuator
interface system tried to start up. The specific error will be
logged in the error log file on the hard drive and the debug
window.

Air Pressure Lost Air pressure is too low to move any actuators.

Flush Cycle Active The actuator interface is indicating flush cycle active to the
DCS.

Flush Cycle Done The actuator interface is indicating flush cycle done to the
DCS.

Flush Cycle Sequence Active The DCS is indicating flush cycle sequence active.

Flush Cycle Stop Start The DCS has requested that flush cycle be stopped or
started.

Flush Cycle Select 1 The DCS has set flush cycle select 1.

Flush Cycle Select 2 The DCS has set flush cycle select 2.

Force Valves Open The DCS has requested that all valves be opened.

Force Valves Closed The DCS has requested that all valves be closed.

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Calender Profiler/Smart Calender Profiler

For details and troubleshooting information on actuator alarms, refer to the following manuals:

ProfileIT Calender Profiler Service Manual, part number 103020-003.

ProfileIT Calender Profiler with Remote Electronics Service Manual, part number 3BUS 208 037
R0101.

Table 7-26 Calender Profiler/Smart Calender Profiler

Message Description

Actuators Not Connected There is a communications error between the actuator

interface and the actuators. This can be caused by an
transporter or serial communications error. Any setpoints
sent to the actuator system will be ignored.

Actuators Unavailable There is a condition in the actuator system that prevents it

from moving actuators. Any setpoints sent to the actuator
system will be ignored.

Actuators In Local An operator has put the actuator system in local. Any
setpoints sent to the actuator system will be ignored

Abort CD Control The actuator system has requested that CD control be

aborted. Any setpoints sent to the actuator system will be
ignored.

Suspend CD Control The actuator system has requested that CD control be

suspended. Any setpoints sent to the actuator system will
be ignored.

Put CD Control In Local The actuator system has requested that CD control be put
in local. Any setpoints sent to the actuator system will be
ignored.

Actuators Moving to Target Actuators are moving in response to a setpoint change.

Actuator Overview Selected If the Actuator Interface Overview page is selected,

setpoints can be entered from the Actuator Overview
page. If the Actuator Overview page is not selected,
setpoints must come from the host computer. Pressing the
“Select” command button on the Actuator Overview page
toggles the selected/not-selected status.

Actuator System Alarm There is an alarm condition in the actuator system. To get
the exact alarm, you must look on the actuator system
diagnostic page.

Actuator Interface Startup Error This indicates that there was a problem when the actuator
interface system tried to start up. The specific error will be
logged in the error log file on the hard drive and the debug
window.

Emergency Stop An emergency stop has been requested by an operator.

Beam Retracted The profiler beam is retracted.

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Beam Extend Failure The profiler beam has failed to extend.

Beam Retract Failure The profiler beam has failed to retract.

Beam Retracted Too Long The profiler beam has been retracted too long

Stack Not Ready A condition exists in the calendar stack preventing the
beam from being extended.

Junction Box Interlock The junction box is not closed, preventing the beam from
being extended.

Plenum Air Pressure Lost Plenum air pressure is lost.

Wireway Air Pressure Lost Wireway air pressure is lost.

Actuator Heater Broken One or more actuator heaters are broken.

Setpoint Boost in Progress Setpoint boost is active in the actuator system.

Power Limiting in Progress Power limiting is active in the actuator system.

SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution

Table 7-27 SteamPlus Profiler/Generic AC800/Generic OPC/Voith OPC Dilution messages

Message Description

Actuators Not Connected There is a communications error between the actuator

interface and the actuators. This can be caused by an
transporter or serial communications error. Any setpoints
sent to the actuator system will be ignored.

Actuators Unavailable There is a condition in the actuator system that prevents

it from moving actuators. Any setpoints sent to the
actuator system will be ignored.

Actuators In Local An operator has put the actuator system in local. Any
setpoints sent to the actuator system will be ignored

Abort CD Control The actuator system has requested that CD control be

aborted. Any setpoints sent to the actuator system will be
ignored.

Suspend CD Control The actuator system has requested that CD control be

suspended. Any setpoints sent to the actuator system will
be ignored.

Put CD Control In Local The actuator system has requested that CD control be
put in local. Any setpoints sent to the actuator system will
be ignored.

Actuator Overview Selected If the Actuator Interface Overview page is selected,

setpoints can be entered from the Actuator Overview
page. If the Actuator Overview page is not selected,
setpoints must come from the host computer. Pressing
the “Select” command button on the Actuator Overview
page toggles the selected/not-selected status.

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Actuator System Alarm There is an alarm condition in the actuator system. To

get the exact alarm, you must look on the actuator
system diagnostic page.

Actuator Interface Startup Error This indicates that there was a problem when the
actuator interface system tried to start up. The specific
error will be logged in the error log file on the hard drive
and the debug window.

Actuator Stopped An actuator is not available to respond to setpoint

changes.

Actuators Moving to Target Actuators are moving in response to a setpoint change.

Induction Profiler Messages

Table 7-28 Induction Profiler Messages

Message Description

Actuators Not Connected There is a communications error between the actuator

interface and the actuators. This can be caused by an
transporter or serial communications error. Any setpoints
sent to the actuator system will be ignored.

Actuators Unavailable There is a condition in the actuator system that prevents

it from moving actuators. Any setpoints sent to the
actuator system will be ignored.

Actuators In Local An operator has put the actuator system in local. Any
setpoints sent to the actuator system will be ignored

Abort CD Control The actuator system has requested that CD control be

aborted. Any setpoints sent to the actuator system will be
ignored.

Suspend CD Control The actuator system has requested that CD control be

suspended. Any setpoints sent to the actuator system will
be ignored.

Put CD Control In Local The actuator system has requested that CD control be
put in local. Any setpoints sent to the actuator system will
be ignored.

Actuator Overview Selected If the Actuator Interface Overview page is selected,

setpoints can be entered from the Actuator Overview
page. If the Actuator Overview page is not selected,
setpoints must come from the host computer. Pressing
the “Select” command button on the Actuator Overview
page toggles the selected/not-selected status.

Actuator System Alarm There is an alarm condition in the actuator system. To

get the exact alarm, you must look on the actuator
system diagnostic page.

Actuator Interface Startup Error This indicates that there was a problem when the
actuator interface system tried to start up. The specific
error will be logged in the error log file on the hard drive

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and the debug window.

Actuator Stopped An actuator is not available to respond to setpoint

changes.

Actuators Moving to Target Actuators are moving in response to a setpoint change.

Emergency Stop An emergency stop has been requested by an operator.

Beam Extend Failure The profiler beam has failed to extend.

Beam Retract Failure The profiler beam has failed to retract.

Calender Stack Not Ready A condition exists in the calender stack preventing the
beam from being extended.

Cabinet Open The power module cabinet is open, preventing the beam
from being extended.

Cabinet Open Override The power module cabinet open beam extend interlock
has been overridden, allowing the beam to being
extended.

Extend Override All beam extend interlocks have been overridden except
for nip open, allowing the beam to being extended.

Power Contractor On Failure The power contractor is off when it should be on.

Power Contractor Off Failure The power contractor is on when it should be off.

Blower Off Failure The blower supplying air pressure is off.

Cabinet Air Flow Low The power module cabinet air flow is low.

Cabinet Air Flow Lost The power module cabinet air flow is lost.

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7.2.5 Command Buttons

Select: if the Actuator Interface Overview page is selected, setpoints can be entered from the Actuator
Interface Overview page. If the Actuator Overview page is not selected, setpoints must come from the
host computer. Pressing the “Select” command button on the Actuator Interface Overview page
toggles the selected/not-selected status.

Figure 7-13 Select mode off

Figure 7-14 Select mode on

To turn Select mode on or off, the following steps are performed:

With the mouse, move the cursor to the “Select” button

Click the left-mouse button to toggle the Select mode on or off.

System Response: A confirmation message box pops up (see Figure 7-15).

In the pop-up message box, confirm the action by left-mouse clicking the “Yes” option to accept the
action or the “No” option to cancel the action.
System Response: When the “Select” button is green and appears pressed down, the control is
turned on. When the “Select” button is gray and appears raised, the control is turned off.

Figure 7-15 Select mode change confirmation window

Clear Errors: This button allows the operator to clear actuator and feedback errors of all actuators in
the Slice Profiler/CoatWeight Profiler/Dilution Profiler/Smart Weight Profiler/Smart CoatWeight
Profiler /Smart Consistency Profiler systems. The Profiler must be in local in order to use this
command.

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Figure 7-16 Clear Errors

To clear actuator and feedback errors, the following steps are performed:
1. With the mouse, move the cursor to the “Clear Errors” button

2. Click the left-mouse button.

System Response: A confirmation message box pops up (see Figure 7-17).

3. In the pop-up message box, confirm the action by left-mouse clicking the “Yes” option to accept
the action or the “No” option to cancel the action.
System Response: Actuator and feedback errors for all actuators are cleared.

Figure 7-17 Clear Errors confirmation window

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7.3 SteamPlus Profiler Steambox Status Display

The SteamPlus Profiler steambox status display provides detailed measurement, actuator status and
dialog for SteamPlus Profiler steambox operation. This display is divided into multiple interface
sections. Figure 7-1 gives a typical appearance of the display.

Figure 7-18 SteamPlus Profiler Steambox Status Window

7.3.1 Steambox Control Setup Data Window

This window shows variables for steambox control setup (see Figure 7-11).

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Figure 7-19 SteamPlus Profiler Steambox Control Setup Data Window

The following table list data that can appear in this window:

Table 7-29 SteamPlus Profiler Steambox Control Setup Data Window

Variable Description Default
Value

Warmup Timer (secs) Counts off warmup time (seconds) N/A

Warmup Time (secs) Time for steambox to warmup (seconds) -100.0

Flush Timer (secs) Counts off flush time (seconds) N/A

Flush Time (secs) Time for steambox to flush (seconds) -100.0

Drain Timer (secs) Counts off drain time (seconds) N/A

Drain Time (secs) Time for steambox to drain (seconds) -100.0

Dry Timer (secs) Counts off dry time (seconds) N/A

Dry Time (secs) Time for steambox to dry (seconds) -100.0

Valve Warmup Setpoint (pct) Valve setpoint during warmup -100.0

Steam Pressure Warmup Setpoint Steam pressure setpoint during warmup -100.0

Steam Pressure Run Setpoint Steam pressure setpoint during run -100.0

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Steam Temperature Warmup Steam pressure setpoint during warmup -100.0

Setpoint

Steam Temperature Run Setpoint Steam pressure setpoint during run -100.0

Steam Flow 1 Warmup Setpoint Steam flow 1 setpoint during warmup -100.0

Steam Flow 1 Run Setpoint Steam flow 1 setpoint during run -100.0

Steam Flow 2 Warmup Setpoint Steam flow 2 setpoint during warmup -100.0

Steam Flow 2 Run Setpoint Steam flow 2 setpoint during run -100.0

Hard Buttons Enable Checkbox for enabling steambox control Off

hard buttons

7.3.2 Steam Pressure PID Data Window

This window shows variables for the steam pressure PID (see Figure 7-11).

Figure 7-20 SteamPlus Profiler Steam Pressure PID Data Window

The following table lists data that can appear in this window:

Table 7-30 SteamPlus Profiler Steam Pressure PID Data Window

Variable Description Default
Value

Setpoint Steam Pressure PID Setpoint N/A

Output Steam Pressure PID Output N/A

Measured Value Steam Pressure PID Measured Value N/A

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7.3.3 Steam Temperature PID Data Window

This window shows variables for the steam temperature PID (see Figure 7-11).

Figure 7-21 SteamPlus Profiler Steam Temperature PID Data Window

The following table lists data that can appear in this window:

Table 7-31 SteamPlus Profiler Steam Temperature PID Data Window

Variable Description Default
Value

Setpoint Steam Temperature PID Setpoint N/A

Output Steam Temperature PID Output N/A

Measured Value Steam Temperature PID Measured Value N/A

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7.3.4 Interlocks Window

This message window displays conditions that affect operations of the SteamPlus Profiler:

Figure 7-22 SteamPlus Profiler Message Window

The following tables list conditions that can appear in the message window.

Table 7-32 SteamPlus Profiler Messages

Message Description

Actuators Unavailable There is a condition in the actuator system that prevents

it from moving actuators. Any setpoints sent to the
actuator system will be ignored.

Actuators In Local An operator has put the actuator system in local. Any
setpoints sent to the actuator system will be ignored

Abort CD Control The actuator system has requested that CD control be

aborted. Any setpoints sent to the actuator system will be
ignored.

Suspend CD Control The actuator system has requested that CD control be

suspended. Any setpoints sent to the actuator system will
be ignored.

Put CD Control In Local The actuator system has requested that CD control be
put in local. Any setpoints sent to the actuator system will
be ignored.

Actuator Overview Selected If the Actuator Interface Overview page is selected,

setpoints can be entered from the Actuator Overview
page. If the Actuator Overview page is not selected,
setpoints must come from the host computer. Pressing
the “Select” command button on the Actuator Overview
page toggles the selected/not-selected status.

Actuator System Alarm There is an alarm condition in the actuator system. To

get the exact alarm, you must look on the actuator
system diagnostic page.

Actuator Interface Startup Error This indicates that there was a problem when the
actuator interface system tried to start up. The specific
error will be logged in the error log file on the hard drive

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and the debug window.

Actuator Stopped An actuator is not available to respond to setpoint

changes.

Actuators Moving to Target Actuators are moving in response to a setpoint change.

7.3.5 Steambox Control Window

Figure 7-23 Steambox Control Window

Steambox Off: This button allows the operator to request the steambox mode to be off: It also
displays whether the steambox is in ‘off’ mode.

Steambox Warmup: This button allows the operator to request the steambox mode to be in warmup
mode: It also displays whether the steambox is in ‘warmup’ mode.

Steambox Flush: This button allows the operator to request the steambox mode to be in flush mode:
It also displays whether the steambox is in ‘flush’ mode.

Steambox On: This button allows the operator to request the steambox mode to be in on mode: It also
displays whether the steambox is in ‘on’ mode.

To request a steambox mode, the following steps are performed:

1. With the mouse, move the cursor to the desired button

2. Click the left-mouse button.

System Response: A confirmation message box pops up (see Figure 7-17).

3. In the pop-up message box, confirm the action by left-mouse clicking the “Yes” option to
accept the action or the “No” option to cancel the action.
System Response: Steambox goes to the selected mode.

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Figure 7-24 Steambox Mode Confirmation Window

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Chapter 8 Grade Code Setup

8.1 On-line Grade Tool

There are two tools for setting up grade files, the off-line tool and the on-line tool. The off-line tool
allows changing the “model” for the grade files (the layout and data types). The off-line tool is
targeted towards engineers and ABB configuration / installation experts. The on-line tool is targeted
to operators.

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The on-line grade tool may be accessed by right clicking on the System Overview display. The menu
shown below appears, disclosing the Grade Setup selection (highlighted here).

Figure 8-1 System Overview Selection Menu

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Figure 8-2 On-line grade tool

The Figure above shows the on-line grade tool. The left panel works similar to Microsoft TM Explorer.
The tool allows the operator to view or change values in either the “Preliminary” or “Active” grade
files. When a entry is selected in the left panel an explanation of the highlighted entry including its
default value is shown in the “help” text box.

The Grade Selection panel on the upper right supports the “Next Grade” button which allows
selection of any configured grade code. Selection of a new grade code causes that grade to be read
from the permanent grade file and to appear in the preliminary part of this display. In this manner
changes can be made to any configured grade without activating it (i.e., without performing a grade
change).

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Figure 8-3 Selecting and changing a grade entry

In the above Figure the basis weight target has been selected and is highlighted. The current active
grade is “template” and the current preliminary grade is “1”. The value of both the active and
preliminary basis weight targets was “50.0”, but the value of the preliminary basis weight target has
just been changed to “51.2”. To activate this change the “Apply” button must be depressed. The
“Apply” and “Cancel” buttons are only active when a change is pending. No other selections may be
made until the change is either “Applied” or “Cancelled”.

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When a value change has been applied but has not been permanently saved to the grade file it will
retain a “change” highlight in red as well as its containing elements, SP1 and Basis Weight as in this
example.

Figure 8-4 A changed grade entry

To save changes the user may right click on the root icon and open a save dialog or more directly
simply push the ‘Save’ button and follow the instructions. The menu allows the user to either “Save”
the existing grade code or “Save As” which creates a new grade code. After saving changes to the
permanent grade file the “change” red highlighting is removed.

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