MACO Breeze IIc User Screens Manual

MACO Breeze II C
User Screen Manual
Table of Contents
Contents
1.
Introduction ................................................................................................. 6
1.1
Configurations ........................................................................................... 7
1.2
Main Menu ................................................................................................ 7
1.3
Recipe Storage ......................................................................................... 7
1.4
Parison Profile ........................................................................................... 8
1.5
Machine Monitor ........................................................................................ 8
1.6
Statisical Process Control (SPC) ............................................................... 8
2. Powerup ........................................................................................................ 9
2.1 Security........................................................................................................ 9
3.
Recipe Transfer......................................................................................... 11
4.
The Parison Profile Screen ........................................................................ 13
4.1
Setpoints ................................................................................................. 13
4.1.1
Profile Mode ......................................................................................... 13
4.1.2
Profile Graph Limits .............................................................................. 14
4.1.3
Profile Number ..................................................................................... 14
4.1.4
Weight (Head 1/Head 2) ....................................................................... 14
4.2
Values ..................................................................................................... 14
4.2.1
Current Point Size ................................................................................ 14
4.2.2
Active Cursor Position .......................................................................... 14
4.3
Commands.............................................................................................. 14
4.3.1
Read Profile ......................................................................................... 14
4.3.2
Send to Parison .................................................................................... 16
4.3.3
Toggle Lock Pt ..................................................................................... 16
4.3.4
Interpolate ............................................................................................ 16
4.3.5
Toggle Master ...................................................................................... 16
4.3.6
Cursor Mode ........................................................................................ 16
4.3.7
Shift Up (Increment Points) ................................................................... 16
4.3.8
Shift Down (Decrement Points) ............................................................. 16
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4.3.9
Shift Profile Left .................................................................................... 16
4.3.10
Shift Profile Right ................................................................................ 17
4.3.11
Spike Profile ....................................................................................... 17
4.3.12
Clear Profile ....................................................................................... 17
5.
Machine Monitors ...................................................................................... 18
5.1.1
Shotsize Time Setpoint ......................................................................... 18
5.1.2
Time Sync Delay Setpoint..................................................................... 19
5.1.3
Profile Delay Time Setpoint .................................................................. 19
5.1.4
Time Correction Limit Setpoint/Time Correction Enable ........................ 19
5.1.5
Actual Position Value............................................................................ 19
5.1.6
Percent Out Value ................................................................................ 19
5.1.7
Head Target Values.............................................................................. 19
5.1.8
Profile Point Values .............................................................................. 19
5.1.9
Cycle Counter Value............................................................................. 20
5.1.10
Sync Time Values............................................................................... 20
5.1.11
Machine Monitor Messages ................................................................ 20
5.2
Position Based Monitor ............................................................................ 22
5.2.1
Shotsize Setpoint ................................................................................. 22
5.2.2
Cushion Setpoint .................................................................................. 23
5.2.3
Actual Position Value............................................................................ 23
5.2.4
Percent Out Value ................................................................................ 23
5.2.5
Target Values ....................................................................................... 23
5.2.6
Accumulator Position Value .................................................................. 23
5.2.7
Cycle Time ........................................................................................... 23
5.2.8
Total Cycles ......................................................................................... 23
5.2.9
Machine Monitor Messages .................................................................. 23
5.3
Accumulator (A1) Calibration (Position Based only) ................................. 24
6.
Parison Setup ........................................................................................... 27
6.1
Time Based Parison Setup ...................................................................... 27
6.1.1
Control Span and Span 1-4 .................................................................. 28
6.2
Gain & Reset ........................................................................................... 28
6.3
Loop Config............................................................................................. 29
6.4
Position Based Parison Setup ................................................................. 30
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7.
Calibration................................................................................................. 31
7.1
Selection of Head Tooling Type (converging or diverging)........................ 31
7.2
Loops 1 – 4 Config. Setpoints .................................................................. 32
7.3
Open Loop Automatic Head Calibration ................................................... 32
7.4
Accumulator (A1) Calibration (Position Based only) ................................. 32
8.
Output Linearization Tables ....................................................................... 33
9. Option Setup Time Based ........................................................................... 35
9.1 Head Tooling Setup.................................................................................... 35
9.2 Time Correction.......................................................................................... 36
9.3 Comparator Setup ...................................................................................... 36
10. Option Setup 1- 2 Head Position Based, 1 Accumulator.............................. 37
10.1 Head Tooling Setup.................................................................................. 37
10.2 Parison Shot Start Type ........................................................................... 37
11. Option Setup 1- 2 Head Position Based, 2 Accumulator.............................. 38
11.1 Accumulator Selection .............................................................................. 38
11.2 Comparator Setup .................................................................................... 39
12. Option Setup 1- 4 Head Position Based, 1 Accumulator.............................. 40
12. 1 Head Tooling Selection ........................................................................... 40
13. Line graphs ................................................................................................ 42
14. Security Change......................................................................................... 45
14.1
Security Change Screen ........................................................................ 45
14.2
Setpoints ............................................................................................... 46
14.2.1
Password Change Pointer .................................................................. 46
14.2.2
New Password Change ...................................................................... 46
14.3
14.3.1
14.4
14.4.1
14.5
Values ................................................................................................... 46
Security Level Password Pointer......................................................... 46
System Commands ............................................................................... 46
Accept New Password ........................................................................ 46
New Module ASCII Strings .................................................................... 47
14.5.1
Current Password ............................................................................... 47
14.5.2
New Password ................................................................................... 47
14.6
14.6.1
Module Displayable Messages .............................................................. 47
Password Index Level 1-4................................................................... 47
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14.6.2
15
15.1
16
Password Index-complete................................................................... 47
SPC Introduction ...................................................................................... 49
Definitions ............................................................................................. 49
SPC Setup Setpoints ................................................................................ 50
16.1
Trig ....................................................................................................... 50
16.2
Sample Size .......................................................................................... 51
16.3
Sample Time ......................................................................................... 51
16.4
Group Period ......................................................................................... 51
16.5
LSL Spec limit ....................................................................................... 51
16.6
USL Spec limit ....................................................................................... 52
16.7
Recalc Limits ......................................................................................... 52
17
17.1
SPC Screens............................................................................................ 53
SPC X-BAR Values ............................................................................... 53
17.2 SPC Range Values .................................................................................. 54
17.3 SPC Graphs ............................................................................................ 55
17.4 SPC Table Data ...................................................................................... 56
17.4 SPC Distribution Curve............................................................................ 57
18
Parison Head 100 Setpoint Screens ......................................................... 58
19 Parison Head 100 Setpoint Screens .......................................................... 60
19.1 Flash Reload Count / Scroll Rates .......................................................... 60
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Figures
Figure 1 Security & Menu ........................................................................................................................ 9
Figure 2 Recipe Manager ...................................................................................................................... 11
Figure 3 Parison Profile Screen (Time Based)........................................................................................ 13
Figure 5 Interpolation Modes ................................................................................................................. 15
Figure 6 Machine Monitor (2 Head Time Based) .................................................................................... 18
Figure 7 Machine Monitor (4 Head Time Based) .................................................................................... 21
Figure 8 Machine Monitor (2 Head Position Based)................................................................................ 22
Figure 9 Machine Monitor (2 Head Position Based 2 Accum.) ................................................................ 25
Figure 10 Machine Monitor (4 Head Position Based) .............................................................................. 26
Figure 11 Profiler & StateSetup (Time Based) ........................................................................................ 27
Figure 12 Parison Setup (Position Based 2 Head 2 Accum.) .................................................................. 30
Figure 13 Tuning & Calibration .............................................................................................................. 31
Figure 14 Output Linearization ............................................................................................................... 33
Figure 15 Linearization example ............................................................................................................ 34
Figure 16 Option Setup (Time Based) .................................................................................................... 35
Figure 17 Option Setup (Position Based 1 Accum.) ................................................................................ 37
Figure 18 Option Setup (Position Based 2 Accum.) ................................................................................ 38
Figure 19 Option Setup (Position Based 4 Head) ................................................................................... 40
Figure 20 Parison Comp Help ................................................................................................................ 41
Figure 21 Line Graphs ........................................................................................................................... 42
Figure 22 Line Graph Help..................................................................................................................... 44
Figure 23 Security Change .................................................................................................................... 45
Figure 24 SPC Setup ............................................................................................................................. 50
Figure 25 Group Period diagram ............................................................................................................ 51
Figure 26 SPC X-Bar Data..................................................................................................................... 53
Figure 27 SPC Range Data ................................................................................................................... 54
Figure 28 SPC Graphs .......................................................................................................................... 55
Figure 29 SPC Table Data ..................................................................................................................... 56
Figure 30 SPC Distribution Curve .......................................................................................................... 57
Figure 31 Head 1 Setpoints ................................................................................................................... 58
Figure 32 Head 2 Setpoints ................................................................................................................... 59
Figure 33 Display Config........................................................................................................................ 60
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1. Introduction
The Breeze IIc parison-only controller is specifically designed for simple
installation and ease of use. It can be retrofitted on a wide variety of blow
molding machines to provide consistent wall thickness of blow-molded products
for improved quality, less material consumption and reduced scrap. It can also be
specified on new OEM blow molding machinery.
The Breeze IIc is factory configured for most blow molding applications. Specify
the machine type and the Breeze IIc will be factory programmed and wired for
that machine. Preconfigured applications are:
Continuous Extrusion, 1 Head
Continuous Extrusion, 2 Heads
Continuous Extrusion, 3 Heads
Continuous Extrusion, 4 Heads
Position Based 1 Accumulator, 1 Head Solenoid Valve
Position Based 1 Accumulator, 2 Heads Solenoid Valve
Position Based 2 Accumulators, 2 Heads Solenoid Valve
Position Based 1 Accumulator, 3 Heads Solenoid Valve
Position Based 1 Accumulator, 4 Heads Solenoid Valve
Wheel (Encoder), 1 Head, Incremental or Quadrature Encoders
Wheel (Encoder), 2 Heads, Incremental or Quadrature Encoders
The all-in-one package comes standard with a 120 VAC or 230 VAC Input 24
VDC, 5 amp output and a 4 Channel Servo Amplifier card. External machine
wiring is connected to connectors on the back of the unit. After connecting the
cables, the installer follows the labels diagram shipped with the Breeze IIc to
connect wires to the proper points on the machine. Once the unit is installed,
simply calibrate the head/accumulator and enter the desired parison profile.
The 100 point parison profile is displayed graphically on a large color display.
This enables the user to quickly modify the profile and compare it to the actual
process value. The entered profiles can then be stored either internally on
Compact Flash or in the internal NAND directory. It can also be saved externally
to USB cartridges.
The Breeze IIc uses the same cards as Barber-Colman’s MACO ® Compact total
machine controller. This allows users to stock fewer spare parts. It also provides
users with highly precise parison control. The Breeze IIc updates parison tooling
position every 0.1 milliseconds to minimize material usage and improve part
quality.
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1.1
Configurations
Based on the model number ordered, the Breeze IIc is shipped with either a time
based or position based (accumulator or reciprocating screw) or wheel (encoder)
configuration. Each configuration requires both a different program downloaded
into the Breeze and different internal/external wiring. All configurations share the
same internal cards and system screens.
Model Number
MCJx-11x21-1C0-0-L0
MCJx-12x21-1C0-0-L0
MCJx-17x21-1C0-0-M0
MCJx-18x21-1C0-0-M0
MCJx-14x21-1C0-0-L0
MCJx-15x21-1C0-0-L0
MCJx-16x21-1C0-A-L0
MCJx-1?x21-1C0-A-M0
MCJx-1?x21-1C0-0-L0
MCJx-1?x21-1CH-0-L0
1.2
Description
Continuous Extrusion, 1
Head
Continuous Extrusion, 2 Heads
Continuous Extrusion, 3 Heads
Continuous Extrusion, 4 Heads
Position Based 1 Accumulator, 1 Head
Position Based 1 Accumulator, 2 Heads
Position Based 2 Accumulator, 2 Heads
Position Based 1 Accumulator, 3-4 Heads
Wheel Based, 1-2 Heads Incremental Encoder
Wheel Based, 1-2 Heads Quadrature Encoder
Main Menu
The power up security code allows the Breeze IIc to be operated with only 4
screens. The main menu screen allows the user to choose one of four security
levels. Setup personnel can be given security codes that allow complete access
to setup information as well as to the normal operating screens. Operators can
be given security codes that provide access only to the operating screens.
The user can move through the screens either by pressing the path keys on the
bottom of each screen or by pressing the left most path key to return to the main
menu and then selecting the desired screen from the main menu.
Only screens that are at or below the entered security code will be accessible.
The screens are grouped according to the level of access:
Level 1
Level 2
Level 3
Level 4
1.3
Normal Operation without SPC access
Normal Operation with SPC access
Field Configuration and Tuning
Factory Configuration
User
User
Setup personnel
Factory personnel
Recipe Storage
Recipe storage can reduce startup time and allow easy job transfer between
different machines. All entered setpoints can be saved to either internal (NAND)
memory or to USB memory sticks. Approximately 200 different recipes can be
saved internally or to a single usb memory stick.
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1.4
Parison Profile
The parison profile screen is used to enter and view the parison profile. The
entire profile can be viewed on this screen. The user can enter any number of
master setpoints (two or more), and select any one of five modes of interpolation
(flat, linear, and three types of parabolic) to automatically interpolate the
remainder of the 100 profile points. To ease the entry of new parison profile you
can now specify a desired number of master points and auto populate the master
points. The generation of the profile setpoints and closed loop update of the
analog output takes place at a 1 millisecond rate for very precise control of the
tooling.
Separate profiles can be entered for Head 1, 2, 3, and 4. The parison process
value can be viewed on the parison profile screen. In multiple head applications
one profile can be sent to all heads as a base starting position. Then each profile
for up to 4 heads can then be adjusted individually for each mold.
An orientation mark can be placed on a part, with the parison “skip” point feature.
Specify any one of the 100 parison points as a “lock” point and interpolation will
not change the point. The time based profile screen is identical to the position
based screen except that several of the die-gap setpoints have been removed.
If the operator requires that more than one profile point be “skipped” then the
spike profile feature can be used to spike a group of profile points above and
below the active cursor.
1.5
Machine Monitor
The machine monitor screen provides an overview of the entire process.
Graphical sprites move with either one, two, three, or four heads and a bar graph
moves with the pushout motion. Both cycle time and total number of cycles are
tracked. A timer for Pushout and Fill are used to abort auto cycle if cushion or
shot-size are not reached before the timer expires. The time based machine
monitor screen functions identically to the position based screen except that the
setpoints and timers have been changed to reflect time based operation.
1.6
Statisical Process Control (SPC)
SPC provides for the simultaneous calculation of different process parameters.
Xbar, R and histogram charts can be displayed for each of the values. Calculated
X-bar, R, Cr, and CpK values are also available.
The last 100 calculated values for each of the parameters remain in memory and
are available for the operator to view and print on demand or automatically after
100 points have been collected. SPC alarms based on industry accepted
standards are available to make machine decisions based on part quality.
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Figure 1 Security & Menu
2. Powerup
As delivered, the controller will power up displaying a screen similar to Figure 1
(only security level 1 screens will be displayed).
2.1 Security
The setpoint entry area for the security code is located on the upper right of the
Header in the Security & Main Menu screen (in the user screen set). If it is
necessary to change the security level to go to one of those screens, use the
arrow keys to select the security setpoint entry area, and type in the code for the
security level desired (see appendixes). Observe the lower right of the screen.
An asterisk will appear for each character entered. Use the plus/minus key for
any dashes contained in the security code. Pressing Enter will cause the security
to change to the level indicated. Note that it will be necessary to refresh the Main
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Menu screen in order to display the available paths for the newly entered security
level (use the up and down page keys).
Level 1 is the lowest security level. Operating at Level 1 allows the least access
to the controller. Level 4 is the highest user security level. Operating at Level 4
allows the most access to the controller.
Only screens with a security level equal to or less than the operating security
level will be accessible.
If operating at Security Level 1, only Security Level 1 screens (or Paths) appear.
If at Security Level 2, only Security Level 1 & 2 screens (or Paths) appear.
If at Security Level 3, only Security Level 1, 2 & 3 screens (or Paths) appear.
If at Security Level 4, Security Level 1, 2, 3 & 4 screens (or Paths) appear.
Note that once a screen is displayed, only those setpoints can be changed which
have an assigned security level less than or equal to the operating security level.
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Figure 2 Recipe Manager
3. Recipe Transfer
The Powerup recipe is a special recipe located in recipe location ”0”. As the
name implies, this recipe is loaded into the system upon system power up. Any
recipe can be stored as the power up recipe.
All other recipes are stored in the locations indicated, 10 recipes per page.
(Recipes 1-10 are showing in this example.). A unique alpha-numeric name, up
to a maximum of 29 characters in length, can be entered for each recipe. All
setpoints within the system are stored or loaded to and from a recipe.
To save a recipe, enter an alpha-numeric name using the keyboard, enter the
desired recipe location setpoint and press “Save Recipe”.
To load a recipe, enter the desired recipe location setpoint and press “Load
Recipe”.
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To delete a recipe, enter the desired recipe location setpoint and press “Delete
Recipe”.
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Figure 3 Parison Profile Screen (Time Based)
4. The Parison Profile Screen
The parison profile screen for a time based system is shown in figure 3. The
screen will vary slightly depending on whether you have a time or position based
system.
If changes are made to setpoints on this screen, be sure to do a "save recipe"
(on the Recipe Storage screen).
4.1
Setpoints
4.1.1 Profile Mode
This setpoint determines how the profile will be interpolated (refer to Figure 5).
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4.1.2 Profile Graph Limits
These setpoints are shown beneath the profile graph on the left and right sides.
Typical entries are 00.00 (on the far left) to 100.00 (on the far right) for full
display. Note that these setpoints require an entry (and save) on initial powerup.
4.1.3 Profile Number
This setpoint determines which profile the system displays. The range is 1, 2, 3
or 4.
4.1.4 Weight (Head 1/Head 2)
This setpoint determines the minimum weight of all parison profile points. Weight
is an offset to the profile. The means that the actual Target = Weight + Profile
point.
4.2
Values
4.2.1 Current Point Size
This is the value of the profile point for the position (1-100) that the active cursor
is on.
4.2.2 Active Cursor Position
This value shows the position of the active cursor on the graph. To move the
active cursor, press the Up or Down Arrows that are above and below the Yellow
Cursor Key near the middle of the Parsion Profile screen. The cursor will then
move either “Point to Point” or “Master to Master” depending on which cursor
mode you are in.
4.3
Commands
4.3.1 Read Profile
This command causes the profile (as selected by the Profile Number Setpoint) to
be read from the module.
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Figure 4 Interpolation Modes
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4.3.2 Send to Parison
This command sends the displayed profile (as selected by the Profile Number
setpoint) to the parison module.
4.3.3 Toggle Lock Pt
Turns lock points on or off. A lock point is one which is not included in
interpolation. A lock point can be inserted by moving the active cursor to the
desired point on the profile and pressing "Toggle Lock Pt." Pressing "Toggle Lock
Pt" a second time will remove the lock point.
4.3.4 Interpolate
This command causes the profile to be interpolated in the selected mode.
4.3.5 Toggle Master
This command allows the insertion or removal of master points (1 to 100 master
points are available) at the position of the active cursor. A master point can be
inserted by moving the active cursor to the desired point on the profile and
pressing "Toggle Master." Pressing "Toggle Master" a second time removes the
point.
4.3.6 Cursor Mode
This changes how the cursor moves. It can either be “Point to Point” which
moves the cursor 1 profile point at a time or “Master to Master” in which the
cursor moves just between Master points. Master to Master is a faster way to
adjust the profile.
4.3.7 Shift Up (Increment Points)
Increases all profile points by the Step Size setpoint.
4.3.8 Shift Down (Decrement Points)
Decreases all profile points by the Step Size setpoint.
4.3.9 Shift Profile Left
Moves the profile toward the origin (point 1).
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4.3.10
Shift Profile Right
Moves the profile away from the origin (point 1).
4.3.11
Spike Profile
This is a feature that is similar to Skip (Lock) Points that allows a marking of the
profile either above or below the active cursor by a selected amount for a given
time period. Then after the time expires, the “mark” is automatically removed. So,
what is needed to make this work is an amount (of Spike) entered, the number of
points to Spike above and below the active cursor, and a Spike Time. Then you
can energize this command and the Profile will Spike. NOTE: Remember to set
the Spike timer longer than your Cycle Time. Otherwise you may never see the
Spike appear in the bottle.
4.3.12
Clear Profile
Clears the presently displayed profile from the screen. If the profile had been
sent to the module, it is not lost (perform a "read profile to recall it).
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Figure 5 Machine Monitor (2 Head Time Based)
5. Machine Monitors
The machine monitor screens will vary slightly depending on whether a time
based or position based system has been ordered Time Based Monitor
Refer to Figure 6. The time based machine monitor screen displays monitor
information for two die heads. If only one is used, it should be Head 1. If any
changes are made to the setpoints on this screen, be sure to do a "save recipe"
(on the Recipe Storage screen).
5.1.1 Shotsize Time Setpoint
This setpoint determines the total time over which profiling will be performed.
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5.1.2 Time Sync Delay Setpoint
This setpoint determines the time at which profiling is to begin after receiving a
sync pulse (from DC Input 1).
5.1.3 Profile Delay Time Setpoint
This setpoint determines the amount of time that the profiled value is held at the
segment 1 target. This time is subtracted from the shotsize time setpoint.
5.1.4 Time Correction Limit Setpoint/Time Correction Enable
This setpoint imposes a limit on the amount of correction that can be applied to
shotsize time after a machine cycle. It is used only in time based profiling and
both Time Correction and Alternating Time Correction (if desired) must be
enabled on the “Option Setup Screen”. “Time correction” is used in application in
which there is variation in the Sync to Sync time. Time Correction examines the
variation and adjust the shotsize time to balance the times from shot to shot. If
“Time Correction” is enabled a message of “T” will appear next to the “Correction
Limit” setpoint. Alternating Time Correction is typically used for Two-Sided shuttle
continuous extrusion machines and attempts to balance the variation in Sync
Times from Side 1 to Side 2 of the machine. If “Alternating Time Correction” is
enabled a message of “A” will appear next to the “Correction Limit” setpoint.
5.1.5 Actual Position Value
The head position values (Head 1 and Head 2) are the current process value for
each respective loop.
5.1.6 Percent Out Value
The head percent out values (Head 1 and Head 2) are the current output
demand value for each respective loop.
5.1.7 Head Target Values
The head target values (Head 1 and Head 2) are the current target value for
each respective loop.
5.1.8 Profile Point Values
The profile points values represent what profile point is being generate
when in “Run Mode.”
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5.1.9 Cycle Counter Value
In the Run mode, the total cycle value increments by one each time the profile
segment reaches profile point 1.
setpoint (on the Parison Setup screen).
5.1.10
Sync Time Values
The sync time values are the last 5 sync-to-sync time values.
5.1.11
Machine Monitor Messages
Run: OFF
Machine function key 1 is toggled Off (the LED will be off) and the Breeze is in
the idle mode. The diegap opening is determined by the respective Head 1/Head
2 idle diegap setpoint.
Run: ON
Machine function key 1 is toggled On (the LED will be on) and the Breeze is in
the profile mode.
Sensor out of Range
the "Input V" is more than 0.500 volts outside of the calibration range. On a time
based machine, the outputs are disabled. To recover, follow this procedure:
Verify the wire connections and sensor integrity.
Enter the calibration mode to regain loop outputs and verify calibration.
Adjust gain and reset for quick response with minimal overshoot of zero and
span (view "Input V" and compare it to Low V/High V to determine overshoot/
undershoot at the calibration voltage).
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Figure 6 Machine Monitor (4 Head Time Based)
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Figure 7 Machine Monitor (2 Head Position Based)
5.2
Position Based Monitor
Note: The position based machine monitor screen displays monitor information
for two die heads. If only one is used, it should be Head 1. If any changes are
made to the setpoints on this screen, be sure to do a "Save Setpoint" .
5.2.1 Shotsize Setpoint
This setpoint determines the shotsize (in engineering units) and is based on the
Loop 5 Accum. 1 Range setpoint (0 to 100) on the Tuning/Calibrate screen
(Figure 11). If other than 0-100% engineering units are desired, change the Loop
5 Accum 1 Range setpoint.
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5.2.2 Cushion Setpoint
This setpoint determines the cushion or accumulator empty (in engineering units)
and is based on the
Loop 5 Accum 1 Range setpoint (0 to 100) on the Tuning/Calibrate screen
(Figure 11). If other than 0-100% engineering units are desired, change the Loop
5 Accum 1 Range setpoint.
5.2.3 Actual Position Value
The head position values (Heads 1-4) are the current process value for each
respective loop.
5.2.4 Percent Out Value
The head percent out values (Heads 1-4) are the current percent output value for
each respective loop.
5.2.5 Target Values
The head target values (Heads 1-4) are the current target value for each
respective loop.
5.2.6 Accumulator Position Value
The accumulator position value is the accumulator position based on the Loop 5
Accum 1 Range setpoint (0-100) on the Tuning/Calibrate
5.2.7 Cycle Time
The cycle time value is the elapsed time between Run Profile signals. The Run
Profile signal is generated by either the accumulator reaching shotsize or the
accumulator reaching shotsize in conjunction with Logic Input 1 going high
( Shoot )
5.2.8 Total Cycles
The total cycles value is the total number of Run Profile signals during the Auto
(Run) mode.
5.2.9 Machine Monitor Messages
Run: Off (Manual Mode)
Machine function key 1 ("Run") is toggled Off and the Breeze IIc is in the manual
mode. Manual “Fill” and manual “Purge” momentary screen buttons are
functional. Note that the Run mode being off is required in order to perform
calibration of the heads.
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Run: On (Auto Mode)
Machine function key 1 ("Run") is toggled On (the LED will be on) and the Breeze
is in the automatic mode. Run Mode is required in order to recognize the initiate
shot (DC In 1).
Shoot:
The accumulator is moving toward cushion.
Fill:
The fill delay timer has expired. The fill speed DC Out 1 are energized.
Timeout:
Auto cycle has aborted due to shot or fill timeout (investigate the physical
condition of the machine and recover via manual [Run = Off] mode).
Sensor out of Range
The "Input V" is more than 0.500 volts outside of the calibration range. On a
position based machine, the outputs are disabled and the cycle in progress is
aborted. To recover, follow this procedure:
Verify the wire connections and sensor integrity.
Enter the calibration mode to regain loop outputs and verify calibration.
Adjust gain and reset for quick response with minimal overshoot of zero and
span (view "Input V" and compare it to Low V/High V to determine overshoot/
undershoot at the calibration voltage).be 10 or 15% for the “OL” setpoints and
10.00 or 15.00 seconds for the calibrate timer.
First, make sure that “Run” is turned off so that calibration can take placed.
Second, make sure that the proper tooling is selected, either converging or
diverging. Third, Select the Input to calibrate. Fourth, Select Zero. The calibration
timer should time down to Zero and then Calibration Enable should turn On for a
few seconds and then turn off. After turning off you should see the Lw Volt
number automatically change to what the voltage was at Zero. Fifth, repeat the
above procedure for Span. Repeat for any Input calibration that is desired. Last,
remember to “Save Setpoint” on button 9.
5.3
Accumulator (A1) Calibration (Position Based only)
Note that the accumulator sensor must be wired so that the sensor signal
DECREASES as the accumulator moves from shotsize to cushion. Move the
accumulator by hand to zero and span and note the voltage at each position.
Enter the lesser of the two voltages (watch "Input V") as the A1 "Low V" setpoint
and the greater of the two as the A1 "High V" setpoint.
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Figure 8 Machine Monitor (2 Head Position Based 2 Accum.)
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Figure 9 Machine Monitor (4 Head Position Based)
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Figure 10 Profiler & StateSetup (Time Based)
6. Parison Setup
The parison setup screen will vary slightly depending on whether a time based or
position based system has been ordered (see Figures 2 and 3). Note: The 24
vdc Input #3 on this unit must be wired to a contact that denotes that the
machine has its hydraulic pumps running and that an Emergency Stop is
not active so that the machine is ready to safely operate. If Input #3 is wired
correctly a “Ready” message will appear indicating that you are ready for
safe Breeze IIC automatic operation.
6.1
Time Based Parison Setup
Refer to Figure 11. Profiler Setup, Allocation State Setup, Tuning, Control Span,
and Span (analog output) must be left as set at the factory. The tuning settings
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for gain and reset may require changing. If changes are made, be sure to do a
"Save Setpoints” using the button 9 on the right of the screen.
6.1.1 Control Span and Span 1-4
These are locked at 100.00% from the factory and determine the control scale
and output span. In this case both are set to 100.00%
6.2
Gain & Reset
After calibration is complete, gain and reset can be adjusted (slowly) in order to
optimize performance. Good starting numbers are generally in the range of: Gain
= 0.5 and Reset = 5. On the “Machine Monitor” screen with run off you should be
able to enter tooling target numbers into the idle setpoint and observe how the
tooling responds when moving from entries of 10% to 90%. If the tooling
responds quickly and is able to hold position at target with little error, you are
probably close enough to start running in automatic by turning run on and putting
the machine in automatic. Final tuning adjustments can be made using the
Linegraph screen to see how closely the actual value follows the target for the
parison tooling.
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6.3
Loop Config
The loop config setpoints determine the action or function of the loops inputs and
outputs. See the table and example below.
Example of Parison Loop Configuration
If Converging = 9, which is 1 + 8: Repeats/Min + Bipolar Output; then diverging should be
1 + 2 + 8 + 16 + 16384 = 16411 which is:
+1
=
+2
=
+8
=
+16
=
+16384 =
Repeats/Min
Invert Output
Bipolar
Swap Zero/Span
Use Tune Set 1
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Figure 11 Parison Setup (Position Based 2 Head 2 Accum.)
6.4
Position Based Parison Setup
Refer to Figure 12. Profiler Setup, Allocation State Setup, Tuning, Control Span,
and Span (analog output) must be left as set at the factory. The tuning settings
for gain and reset may require changing. If changes are made, be sure to do a
"Save Setpoints” using the button 9 on the right of the screen.
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Figure 12 Tuning & Calibration
7. Calibration
The parison tuning and calibration screen will vary slightly depending on whether
a time based or position based system has been ordered (see Figure 4 - note
that time based systems do not have accumulator entries).
"Lw Volt" and "HI Volt" represents the measured voltages at either 0 or 100% of
diegap, depending on whether the head is converging or diverging. The sensor
should be wired so that for CONVERGING tooling voltage ("Input V" above)
DECREASES as the head approaches 0% diegap. Conversely, wire the sensor
so that for DIVERGING tooling voltage INCREASES as the head approaches 0%
diegap.
7.1
Selection of Head Tooling Type (converging or diverging)
Touching the Select button is used to toggle between converging and diverging
(Note: The message to the right of the “Select” button will toggle between
Converge or Diverge). All heads will be of the same head tooling type.
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Remember to press the “Save Setpoints” button on the middle right of the screen
to save the Converging or Diverging Selection.
7.2
Loops 1 – 4 Config. Setpoints
Converging Head
A converging head Loop Config 1 setpoint will be either "9" or "11." Entering the
wrong number will result in a process readout 180 degrees out of phase with the
actual head position. Entries of “11” invert the output versus entries of “9”
Normally, 9 (converge) is used in conjunction with 16411 (diverge) else it would
be 11 (converge) or 16409 (diverge).
Diverging Head
A diverging head Loop Config 2 setpoint will be either "16411" or "16409."
Entering the wrong number will result in a process readout 180 degrees out of
phase with the actual head position. Entries of “16409” invert the output versus
entries of “16411”. Normally, 9 (converge) is used in conjunction with 16411
(diverge) else it would be 11 (converge) or 16409 (diverge).
NOTE: See Table 1 for a full definition of the Loop Config entry.
7.3
Open Loop Automatic Head Calibration
The calibration procedure is Open Loop in its nature for Analog Inputs 1 – 4
which are wired to the “LVDT’s” for head tooling 1 – 4. Thus, entries for
“OpenOL” and “CloseOL” are required to get output to move the head tooling.
These are out of 100% of output span. Thus, an entry of 10% would equal 1 DC
volt outputted to the servo valve. Also, there needs to be a non-zero entry
present for the calibrate time setpoint. This setpoint should be set long enough to
allow time for the head tooling to move full stroke. Good starting numbers would
be 10 or 15% for the “OL” setpoints and 10.00 or 15.00 seconds for the calibrate
timer.
First, make sure that “Run” is turned off so that calibration can take placed.
Second, make sure that the proper tooling is selected, either converging or
diverging. Third, Select the Input to calibrate. Fourth, Select Zero. The calibration
timer should time down to Zero and then Calibration Enable should turn On for a
few seconds and then turn off. After turning off you should see the Lw Volt
number automatically change to what the voltage was at Zero. Fifth, repeat the
above procedure for Span. Repeat for any Input calibration that is desired. Last,
remember to “Save Setpoint” on button 9.
7.4
Accumulator (A1) Calibration (Position Based only)
Note that the accumulator sensor must be wired so that the sensor signal
DECREASES as the accumulator moves from shotsize to cushion. Move the
accumulator by hand to zero and span and note the voltage at each position.
Enter the lesser of the two voltages (watch "Input V") as the A1 "Low V" setpoint
and the greater of the two as the A1 "High V" setpoint.
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Figure 13 Output Linearization
8. Output Linearization Tables
Note that these setpoints MUST be entered BEFORE pumps are turned ON.
Note also that before adding any segments to these setpoints that pumps
MUST be turned OFF.
These setpoints determine the output voltage associated with a percent output.
Each output can have up to 8 linear regions defined using "% Demand"
and "Out Volts". These setpoints allow the use to effectively eliminate and null in the
valves. Refer to the table below.
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% Demand
Output Volts
Figure 14 Linearization example
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Figure 15 Option Setup (Time Based)
9. Option Setup Time Based
9.1 Head Tooling Setup
These push buttons determine the head toolings that the system is configured for. The
“<”beside the button indicates which selection the system is currently configured for. NOTE that
changes made to these selects will need to be “saved” by pressing the Save Setpoints button.
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9.2 Time Correction
These push buttons turn on and off Time Correction and well as Alternating Time Correction.
For Alternating Time Correction to function BOTH push buttons must be set to the ON
position. (For an explanation of the function refer to section 5.1.4)
9.3 Comparator Setup
These Setpoints configure the Comparators 1 and 2. These Comparators determine the
functionality of DC Output 1 and 2 ( Time Based) or DC Output 3 and 4 ( Position Based).
Each Comparator requires and IN A, IN B, Type and CompSP setpoints to be entered.
Refer to Figure 20 for a list of commonly used Modbus ID numbers to be entered into the
IN A Sel and IN B Sel setpoints as well the numbers to be entered into the type setpoint
for the different types of comparators. Note that the if either of the IN A Sel or IN B Sel
setpoints are set to “19817” or “19818” then the CompSP will be utilized by the
comparator and must have a number entered into it that is scaled the same as the value
it is being compared to.
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Figure 16 Option Setup (Position Based 1 Accum.)
10. Option Setup 1- 2 Head Position Based, 1 Accumulator
10.1 Head Tooling Setup
Pressing the # of Heads Select button will toggle between 1 head and 2 head configurations.
NOTE that any changes should be saved by pressing the Save Setpoints Button.
10.2 Parison Shot Start Type
This button Enables and Disables the use of DC Input 1 as an OK to shoot input. When this
button is Enabled the system will wait to turn on the Run Profile until the Accumulator has
reached Shotsize AND DC Input 1 is turned ON. This can be used to ensure the machine is ready
to accept the Parison. If this input is not necessary to the cycle of the machine it can be Disabled
and the system will turn on the Run Profile once the accumulator reaches Shotsize.
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Figure 17 Option Setup (Position Based 2 Accum.)
11. Option Setup 1- 2 Head Position Based, 2 Accumulator
11.1 Accumulator Selection
Pressing the # of Accumulators will change the number of Accumulators that the system is
configured for. The number of Accumulators required is determined by the physical machine.
Note that changes to this selection should be saved by pressing the Saved Setpoints button.
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11.2 Comparator Setup
In addition to comparator 1 and 2 there are comparators 3 and 4 which configure outputs 3 and 4
on the Option slot B DC I/O installed only when the unit was ordered as a 2 Accumulator type system.
These comparators configure the same as those described in section 9.3 (refer to Figure 20)
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Figure 18 Option Setup (Position Based 4 Head)
12. Option Setup 1- 4 Head Position Based, 1 Accumulator
12. 1 Head Tooling Selection
These push buttons determine the head toolings that the system is configured for. The “<”beside
the button indicates which selection the system is currently configured for. NOTE that changes made to
these selects will need to be “saved” by pressing the Save Setpoints button
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Figure 19 Parison Comp Help
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Figure 20 Line Graphs
13. Line graphs
Line graphs can be used to display setpoints, values, and output signals. The line
graph display can plot 4 separate graphs. Refer to Figures 22 for available
variables. Note that the Line Graph Channel 1 assignment can be displayed on
the parison profile graph screen (but will not include the weight setting).
GRAPHS SETUP Changing this setpoint ( 1- 4 ) will setup the graph to display
the graphs for heads 1- 4 respectively.
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HOLD GRAPHS – This command toggles the display between a Run and a Hold
state. In the Run state the display updates with new information on each machine
cycle or time period. In the Hold state the display is not updated.
The Hold state is typically used to study the displayed graphs. To toggle between
the two, use the cursor keys to select the command and then press the Enter
key. A message will display the status.
SAMPLE – This setpoint indicates the time period for the 100 points displayed on
the line graph. Entering a setpoint of 10.0 seconds will cause sampling to occur
every 0.1 seconds. Entry range is 0 to 65.0 seconds.
PHASE – This setpoint allows selection of either segmenter based sampling or
time based sampling. The following setpoints can be entered:
1 = Time Based This mode allows sampling based on a time entry. The
sampling starts after the Graph Trigger is energized. In this mode, a Sample
Time setpoint entry must be made.
3 = Segmenter Based This mode samples 100 points within the shotsize period
(position or time based). The linegraph will update at the end of shotsize.
FILL – When Fill is selected the area under the first line graph will be filled in
(rather than displayed as a line graph it is displayed as a solid – useful when
plotting values against setpoints).
DISPLAY MIN/MAX SETPOlNTS – The Minimum and Maximum Display
setpoints scale the "Y" axis (vertical) values. To separate data, different offsets
can be achieved by using different minimum setpoints.
CURSOR – The cursor is indicated by a vertical bar. The current position for the
cursor is indicated in the lower right position on the screen. The values of the line
graphs at the current cursor position are shown below the line graphs.
Cursor position is changed by using the Cursor Right/Cursor Left soft keys. The
values for all channels are updated as the cursor is moved. The current cursor
position ( 1-100) as well as the time is reflected in the values just below the
graph.
Pos – is a setpoint (1-100) that will cause the cursor to move to the position
Mult – a non zero entry into this setpoint tells the graph to enter into a Multi
graph mode. In this mode the display will draw multiple traces for each channel 1
for each trigger up to the value of this setpoint. Once this setpoint is reached it
will redraw to graph on the next trigger signal and start over. Each cycle of multi
graphs will generate a Multigraph.csv file in the Compact flash that can be used
to document the consistency of the profiling.
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Figure 21 Line Graph Help
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Figure 22 Security Change
14. Security Change
14.1 Security Change Screen
The security change screen allows passwords to be changed at the
operator station (an operation that formerly required screen editing). Up to 40
different passwords per security level can be programmed from this screen.
Enter the number of the setpoint to be reviewed or changed. Once the existing
password is displayed, enter a new password. To accept the change, cursor to
the active area and press return.
The passwords will be stored in the display. On power-up (or Display Reset) the
display checks to see if new user screens have been downloaded. If new
screens have been downloaded, the display will automatically update the local
passwords to the passwords used in the new screen set. This update creates 40
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password positions per security level. If a screen set had more than 40 per level
only the first 40 would be utilized. If there is less than 40 (more likely), then
blanks will be loaded in the remaining spaces. This automatic update means
that if the local passwords were different from those used in the newly
downloaded screen set the local passwords will have to be re-entered.
There are several methods of securing the password display and limiting
changes to passwords for a given level. This can be accomplished by security
level (protection of the screen or individual elements) or by limiting the security
pointer range to less than its maximum of 200. For example, if the security
pointer range is limited from 0 to 120, then only levels 1, 2 and 3 (not 4 or 5)
could be changed. Note that level 5 security does not allow any additional
changes beyond level 4, so that setting a range of 0 to 160 can prevent a user
from changing an OEM’s highest level of security codes.
14.2 Setpoints
14.2.1
Password Change Pointer
The password change pointer setpoint is used to move to a specific position in
the password file.
14.2.2
New Password Change
The new password change setpoint is the setpoint used to enter a new
password. Once the new password is entered here, pressing enter will cause it to
appear as the “proposed password.”
14.3 Values
14.3.1
Security Level Password Pointer
This value is used to display the security level of the current password change
pointer setpoint. The value will correspond to the levels shown in figure 1 above.
Password 1-40 are level 1; 41-80 are level 2; 81-120 are level 3; 121-160 are
level 4; and 161-200 are level 5.
14.4 System Commands
14.4.1
Accept New Password
Once a “proposed password” is displayed, this system command is used to make
the “proposed password” the “existing password.”
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14.5 New Module ASCII Strings
14.5.1
Current Password
This module ASCII string is used to display the password currently pointed at by
the password change pointer setpoint. Note that the content of a module ASCII
string cannot be programmed (internal firmware determines the character string
that appears within the area). If programming this to a screen, be certain to
assign enough space for the entire string of 13 characters.
14.5.2
New Password
This module ASCII string is used to display the new (proposed) password. Once
the new password has been accepted, it will appear in both the current and new
message blocks. Note that the content of a module ASCII string cannot be
programmed (internal firmware determines the character string that appears
within the area). If programming this to a screen, be certain to assign enough
space for the entire string of 13 characters.
14.6 Module Displayable Messages
14.6.1
Password Index Level 1-4
These 4 module displayable messages can be used to display a message (for
instance, an operator’s name) with a specific password. In order to use this
function, you need to know how many passwords will exist for each security
level. Use the Message Editor (in the screen editor program) to create a series of
messages relating to each security level. Each series should start with a blank
message. For example, say that 3 operators require a Level 2 security password.
You will need 4 contiguous locations in the message file (a blank message, Tom,
Dick and Jane). Once the messages are created, use the screen editor to lay
down the “Password index level 2” message block and point to the blank
message as the message source. Whenever the password assigned to position
41 is being used on the machine, the word “Tom” will appear as the message.
14.6.2
Password Index-complete
This module displayable message works in exactly the same manner as the
“Password Index Level x” messages described above except that this message
requires 201 positions in the message file (a blank message followed by a
message location for every potential password). This message has been created
in order to provide for the original version of the Security Change function.
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Starting Factory Security Codes
Level
1
2
3
4
Code
1
222
5966
123
8118
1397
6800
159753
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15 SPC Introduction
Statistical Process Control (SPC) is a software option to the MACO control system.
SPC provides for the simultaneous calculation of 10 different user selected
parameters. Any process value from the system can be selected as an SPC
parameter. Each of the 10 parameters allows selection of sample size, time or
event triggering, time between readings, time between sample groups, upper and
lower specification limits. The software will calculate and display each sample
group’s X-Bar, R, Cr, Cpk and Cp. The Iast 100 calculated values for each
parameter will remain in the SPC buffer memory. SPC X-Bar and R charts, along
with the last 100 samples can be printed (via the optional printer port) on demand,
event based, or automatically after 100 points have been gathered.
SPC can also be performed on setpoints provided for that purpose in the Data
Handler modfile (Spare Setpoint #1 thru #8). These setpoints allow the calculation
of statistical data on as many as eight parameters which are not directly measured
by the system, such as part weights or dimensions. The data is measured by the
machine operator and then manually entered as the setpoint.
Titles for the parameters as well as the menus for the parameter choices are
entered when screen programming is performed. When programming screens, up
to thirty machine parameters may be chosen. Any value or setpoint from any
controller can be used. Ten of the thirty can then be selected for SPC data
collection. Screens are also made available for X-Bar and R chart display and
distribution curves.
15.1 Definitions
Sample Size: Number of readings in a group (2 to 25)
Sample Time: Time between individual samples (1 to 999 seconds)
Trigger Mode: Time based or event based through sequence logic
Group Period: Time between beginning of sample groups (0 to 65535 seconds)
Upper Specification Limit (USL): The highest acceptable limit
Lower Specification Limit (LSL): The lowest acceptable limit
X-Bar: Average of all samples in the sample group
X-BarBar: Average of all X-Bars on the X-Bar chart
R: Range: The difference between the largest sample of the subgroup and the
smallest sample
R-Bar: Average of all the ranges on the Range chart
STDV: Standard Deviation
UCLR: Upper control limit for Range values
LCLR: Lower control limit for Range values
UCLX: Upper control limit for X-Bar values
LCLX: Lower control limit for X-Bar values
Cpk: Process Capability Index
Cr: Capability Ratio
Cp: Inverse of Cr
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Figure 23 SPC Setup
16 SPC Setup Setpoints
16.1 Trig
SPC can be set up to sample data at a specific event (through the
logic program) or at specified time intervals. Enter "1" for event based initiation, or
enter "0" for time based initiation.
Control relays CR 6633 through CR 6640 are used to start the sampling in event based
operation. The trigger CR must be energized at least 1 second (when
deenergized it must also remain deenergized for 1 second).
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16.2 Sample Size
Enter the number of measurement readings, from 2 to 25, that are
to constitute the sample. SPC data that has accumulated up to this point will be
cleared when sample size is changed.
16.3 Sample Time
This is the time between samples when the variable has been set
to the time based mode. Units are in seconds and can range from 0 to 999 (16-2/
3 minutes). The minimum entry is 1. An entry of 0 will cause the sampling to cease.
16.4 Group Period
This is the time between the beginning of each sample group. The
units are in seconds and can range from 0 to 65535 (18-1/5 hours). If the setpoint
is 0 or is less than the time required to collect a sample group, then the channel
will be sampled continuously at the sample rate with no time lapses between the
end of one sample and the beginning of another. This setpoint is also active when
in the CR Triggered mode.
Figure 24 Group Period diagram
16.5 LSL Spec limit
This is usually set to the lower limit of acceptability for the parameter being monitored.
When a sampled sub-group average is less than this entry, then the specification alarm
control relay for this channel will be activated. This entry is also used in the calculations
for Cr, Cp, and Cpk. The number of decimal places for this entry is the same as the
sampled parameter (and is determined in the SPCSetup.csv file in the Nand Flash).
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16.6 USL Spec limit
This is usually set to the Upper limit of acceptability for the parameter being monitored.
When a sampled sub-group average is less than this entry, then the specification alarm
control relay for this channel will be activated. This entry is also used in the calculations
for Cr, Cp, and Cpk. The number of decimal places for this entry is the same as the
sampled parameter (and is determined in the SPCSetup.csv file in the Nand Flash).
16.7 Recalc Limits
The upper and lower control limits are automatically calculated
after the first twenty-five sample groups have been collected (an "F" will appear on
the setup screen, indicating the limits have been calculated).
These limits will remain in effect until the SPC data is cleared or until Recalc limits are
entered. Recalc limits are used to recalculate control limits on a specific group of SPC
data after the limits have been frozen. For example, a change in material may cause the
transfer pressure to increase for a given part.
For the lower recalc limit, enter the lowest numbered sample group to be used in
the limits calculation. For the upper recalc limit, enter the highest numbered
sample group to be used in the limits calculation.
Most recent sample groups have the highest sample group number. The oldest
data will have the lowest sample group number. There must be a difference of five
between the group numbers and the lower recalc limit must always be lower than the
upper recalc limit. In addition, a statistically significant R-Bar must exist.
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Figure 25 SPC X-Bar Data
17 SPC Screens
17.1 SPC X-BAR Values
The screen in Figure 26 shows current values for X-Bar, X-BarBar, Upper and Lower
Control Limits for X-Bar values, and the Standard Deviations for all 10 variables.
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Figure 26 SPC Range Data
17.2 SPC Range Values
This screen in Figure 27 is similar to Figure 26 except that it is for the Range values.
Shown are the current values for R, R-Bar, Upper and Lower Control Limits, Cr
(Capability Ratio), and Cpk (Process Capability Index).
Figure 26 and Figure 27 both contain messages such as S, X, R and F. These
messages are controlled by data handler control relays (CR 785-814). When one
or more of these control relays energizes one the following messages will appear:
S – Specification Alarm
X – X-Bar Trend Alarm
R – R-Bar Trend Alarm
F – Upper and Lower Control Limits are Frozen
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Figure 27 SPC Graphs
17.3 SPC Graphs
Figure 28 is a graphic screens. The screent is a plot of both the X-Bar and Range values
on the same screen. The up and down arrows as well as the setpoint below allow the displayed
graph to be changed to display a graph of any of the configured selections.
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Figure 28 SPC Table Data
17.4 SPC Table Data
The SPC Tabular Data screen (Figure 29) is a listing of all 100 data points. Included
on the screen are the X-Bar and Range values as well as the sample time. Scroll
Up and Down functions allow you to access the other points as only 30 can be
displayed on a screen. The screen also has provisions for removing a data point
if desired. To remove a data point simply enter the number of the point to be
removed. Lower numbered data points will then be shifted up one position.
An up arrow will be displayed to the right of each line which has an X-Bar data point
greater than the current upper spec limit (USL). A down arrow will be displayed to
the right of each line which has an X-Bar data point less than the current lower spec
limit (LSL). If the X-Bar is within the spec limits (or none have been entered) a dash
will be displayed.
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Figure 29 SPC Distribution Curve
17.4 SPC Distribution Curve
Each sampled channel has 2 distribution curves (Figure 30). One is the distribution
of the last 100 subgroups sampled. The other is the total history distribution since
the channel has been setup and the control limits have been calculated. The
curves are not be displayed until control limits have been calculated.
Each distribution curve is formed with a series of twenty vertical bar graphs. There
are six equally sized divisions on both sides of the centerline. One group extends
to the LCL and the other to the UCL. There are also four more divisions above and
below the control limits.
The distribution curves are saved in battery-backed RAM and so are available on
powerup.
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Figure 30 Head 1 Setpoints
18 Parison Head 100 Setpoint Screens
There are up to 4 screens that display the current setpoint value of all 100 Profile
setpoints for the displayed. Each setpoint can be changed from this screen regardless of
whether it is defined as a master point or not. Changes to these setpoints will
automatically change the profile. To view changes made to the profile on the Parison
Graph screen a Read Profile will have to initiated. Interpellation of non master points will
not function on this screen.
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Figure 31 Head 2 Setpoints
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Figure 32 Display Config
19 Parison Head 100 Setpoint Screens
This screen contains functions that allow for changes to how display functions.
Changes can be made to the color pallet, security timeouts, how the highlighted
cursor is displayed, as well as touch screen calibration.
19.1 Flash Reload Count / Scroll Rates
Flash Reload count- The flash reload count determines the rate at which the cursor flashes. This
setpoint is shipped from the factory set at approximately 0.30 seconds and
should be left somewhere close to that setting. Using a much faster or much
slower setting makes determining the location of the cursor difficult (leave it
alone).
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Scroll Rates- The scroll rate setpoints determine the rate at which the flashing cursor moves from
one reverse video area to the next when a cursor key is pressed.
The scroll rate mode setpoints provide three “gears” for the scroll rate. When a
cursor key is initially held depressed, the cursor will move at the rate determined
by scroll rate mode 1. Releasing the key and then pressing that key or any other
cursor key will cause the cursor to move at the rate determined by scroll rate mode
2. Releasing the key again and then again pressing that key or any other cursor
key will cause the cursor to move at the rate determined by scroll rate mode 3.
These setpoints are initially shipped from the factory set at approximately 0.20
seconds. Try settings of 0.20; 0.15; and 0.10 for Scroll Rate Mode 1, 2 and 3,
respectively.
Scroll Dead Time- The scroll dead time setpoint determines how soon the cursor moves after a cursor
key is pressed. The scroll dead time setpoint is initially shipped from the factory set
at approximately 0.40 seconds (leave as is).
BlnkTmr- The blank reload count setpoint determines the time between keystrokes before
the display “blanks out.” The minimum setting is 60.00 (seconds). Setting this entry
to zero disables screen blanking (which may cause damage to the display).
This setpoint is initially shipped from the factory set at 600.00 seconds (10
minutes). Settings on the order of 300.00 seconds (5 minutes) might be desirable.
Anything less than 5 minutes could be a nuisance (Don’t mess with fractional
second settings).
Vectr 1- 4 – These setpoints determine the screen number the display will vector when the corresponding
Alarm Cr is energized in RLD. Note that these are NOT utilized in Version 2.1 of the
Breeze IIC
Key1CLM – Ket3CLM- These determine which column in the Bitmap_Keyword_Setup_Assignments.csv
will utilize to the functionality of Bitmap keys on the left and right of the display. These setpoints will
change automatically if the configuration of the Unit is changed ( DO NOT make manual changes to these
setpoints.)
Save SP Time - This is the amount of time in seconds before the system will automatically save all
setpoints. This timer will only time when there is no display activity. Setting this timer to 0 will cause the
system not to function as the system will constantly be saving setpoints and will not allow for any other
functions. ( NOTE for best results leave at the default of 600.00 sec.)
Operator 17-32/ Selector SW 1-4- These setpoints are the system save the state of control relays. They
are populated by the system and no entry should be made.
I/O Slot #- Leave at factory setting of 3( Note pertinent to the Breeze IIC )
Scrn Capture Loc- This determines where the system will store the generated .BPM files when a screen
capture is preformed. 0 = Nand Flash ( DO NOT USE) 1= USB 1 2= USB 2 3= Compact Flash Card (
Factory default and should be left at 3)
Sec Time Out- The minimum security reload setpoint is a timer setpoint (in seconds) used to
determine the starting point of a countdown to zero. The minimum setting is 60
seconds; the maximum setting is 655.35 seconds. Each keystroke resets the
count to the setpoint. Once this timer counts to zero, the security level will be set
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to the "Timeout Security Level" (see below).
Sec Time Out Level- The timeout security level setpoint determines the security level of the system after
the minimum security reload timer setting times out. This setting, along with the
timeout setting above, can be used to prevent an unattended machine from
inadvertently being left at a high security level. The minimum setting is 1 (Level 1)
and the maximum setting is 4 (Level 4).
Touch Screen Calibration- Pressing this button will initiate the calibration routine. Once the calibration is
complete the display will return to this screen.
Sys Mess as Numbers- enabling this function will display any generated system messages to be
displayed in HEX code number for factory troubleshooting ( NOTE do not enable)
Enable Limit Display- Should be enable by default. This displays the setpoint limits for the selected
setpoint. ( Note that must be disabled if the Enable ID display is enabled )
Enable ID Display- When enabled allows the display to Modbus ID along with the HEX ID for any
setpoint or value highlighted by the cursor. ( Note must be disabled if the Enable Limit display is enabled)
Copy all files to USB- This function will copy all files stored in the Nand flash to the USB memory stick.
Capture All Screens- separate functions for user screens and system screen. Initiating the user screen
this function will automatically start at screen #1 and generate and store .BMP files for each screen in the
user screen set. Once completed the display will return to this display config screen. Initiating the system
screen function will start at screen at # 257 and generate and store .BMP files for each system screen in
the system. Once completed the display will return to these display config screen.
Color Pallet Setpoints – each color in the pallet has separate RGB settings. Each color has a reset push
button to return settings to factory defaults. Color settings should be left at “as shipped” settings as these
have been set to match colors utilized in the bitmaps. The above figure 33 shows the correct settings.
(Note if changes are made a save setpoints should be preformed )
Cursor Mode – changes the appearance of the selected element when highlighted. 0= default 1= 2
boxes outside of selection 2= one box outside of selection.
Box Color – numbers entered match the color pallet number 0- 15
Color for customer descriptions- numbers entered match the color pallet number 0- 15. (Note not
utilized in ver. 2.1 of the Breeze IIC )
Store Modfile Desc. In Recipes- defines if the modfile descriptions of the setpoints are included within
the recipe file. 0= No ( Default) 1= Yes 2= store in Unicode format
Location for Customer Descriptions- 0= messages will display on the mini screen 1= messages will
display on the mini screen area.( NOTE not utilized in ver. 2.1 of the Breeze IIC)
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