Coexpert 5.1 Installation and Service Manual
Contents
1. Coexpert 5 1 Installation and Service Manual Part Number A0566980 Rev C Effective 12 12 12 Please note that our address and phone information has changed Please reference this page for updated contact information These manuals are obsolete and are provided only for their technical information data and capacities AXCAUTION Portions of these manuals detailing procedures or precautions in the operation inspection maintenance and repair of the products may be inadequate inaccurate and or incomplete and shouldn t be relied upon Please contact the ACS Group for more current information about these manuals and their warnings and precautions Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service For immediate assistance please contact North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencie2. Current Output Use this shows which analog outputs are already used by the Coexpert extruder and hauloff drive references Any output that is unused can be configured for Output to a Gauge Once this is configured the Coexpert will output a voltage that references the selected value and will scale it according to the parameters specified Terminals this shows where in the Coexpert panel the analog output should be wired from Carefully note the polarity Reference this sets up which device to examine for the signal output Ext 1 6 or Total are the available choices Units this sets up which value of the device selected under Reference you wish to measure for the signal output The choices are Lbs Hr or KGs Hr or W L or W If the first choice is selected then the output signal will output the throughput of the device selected If the second choice is selected the output will either reference the Weight per Length or the Weight per Area of the selected device depending on which recipe format the system is using see Setup Recipe Setup Output Volts Max Min set this up to correspond to the desired range of the system with which you are sending the signal to Value Range Max Min these are the values that correlate to the Max Min Output volts specified above This will scale the output The Max Value should be set higher than the maximum value you will expect to reference lt Coexpert 5 1 Installation and
3. Clear Com Counts Restart High Low Capture Calibrate Layer RPM in Monitor Function Entering in Service Passwords Advanced Settings Median Width Calculation Points Layer Deadband in Maximum Input Change in Maximum Input Change Before Alarm Number of Maximum Inputs Before Alarm Extruder Drive Offset Section Maximum Input Output Voltages Voltage Deadband in Refresh Rate in Seconds Advanced Control Settings Polling time in milliseconds Response time in milliseconds Volumetric layer control option Force I O Functions Calculator Functions Exiting the Calculator Save Alarms to Disk Print Log Exit Alarm Log Service Use Minimizing the Coexpert Program Exiting the Coexpert Program Coexpert 5 1 Menu Structure Breakdown and Explanation Overall View Page Description The overall view page is accessed by simply touching the Overall View button on the top of the Coexpert screen This page shows the status and value of all extrusion process items From this page the operator can monitor information about the extrusion layer structure rpm values individual blender status and other recipe related information For this reason the overall view page is the best page to view during normal operation Explanation of Items Shown Target Lbs Hr or Kgs Hr the current set target rate that is calculated based on the recipe that the operator has entered on the Process Page This value is only shown when the line is in Co
4. The recipe for that blender can also be changed This feature can be disabled by deselecting it under Setup Blender Network Setup ID Setup Edit Item Process Page Page 4 of 31 Description The process page is accessed by touching the Process button located on the top of the Coexpert screen From this screen the operator can modify the current mode of operation Stop Monitor Only Control by RPM Control by Weight Go to RPM mode with DROOL speed setpoints The operator also can modify all RPM Hauloff speed and Recipe setpoints as well as access the Coexpert Recipe Book where recipes have been previously stored Explanation of Items Shown Current Gear Choice the current selected gear for the hauloff This is only available once Line Speed Control under Setup has been selected and multigear hauloff under Setup Extruder and Hauloff Setup has been enabled The line must be stopped before the operator can change the gear choice selection Ramp to Stop button this button is one of the operation mode selectors Touch this button to stop the extrusion line When this button has been touched the Coexpert will go into control mode indicated by blue light on panel front and then will evenly ramp the line down to stop In Ramp to Stop mode no values can be entered in on the Process Page but the operator can access the Recipe Book If the line was running prior to hitting this button then a warning message will appear ask
5. Low Tolerance entry box this box is located on the right side of the graph Touching this box brings up a number pad that allows the operator to enter in the acceptable low tolerance of the product Current Value this is located on the upper right side of the graph and displays the real time value of the product Out of Spec Message this red message tells the operator that the product is not within the high and low tolerance values of the product Unstable Gauge Message this red message tells the operator that the measured voltage from the gauge is jumping around greater than the deadband volts configured under Setup Gauging Interface Setup Graph Data the graph that is shown is real time This data is not stored to disk for long term trending and is only available for the operator to monitor F Coexpert 5 1 Installation and Service Manual Setup Page Description This page is accessed by touching the Setup button that is located on the top of the Coexpert screen and is only available when the setup buttons are turned on If this button is not visible then double touch the blank area between the Gauging and Calculator buttons This brings up a password entry form The password is always SETUPON and cannot be modified However enabling the setup buttons does not allow access to anything it simply allows viewing of the Security Setup and Diagnose buttons These buttons can be turned back off unde
6. Service Manual Page 13 of 31 Other Uses for the Gauging Interface the gauging interface is simply an analog communications interface This interface could as well be used to drive a volumetric feeder a large remote display panel an extruder amp monitoring tool and any other analog type system the customer can create The uses are endless and only limited to the ability of imagination Unstable Flag this indicates that the Polled rate for a particular extruder is varying on a 1 second interval every poll greater than the Maximum Input Change Before Alarm see Advanced Settings page Once this flag is set the Unstable Count will begin to increment Once this flag is reset the Unstable Count will count back down to O Unstable Count this counter keeps track of the number of Unstable conditions that have occurred Once this counter reaches the Number of Maximum Input Changes before Alarm see Advanced Settings page then an alarm will notify the operator of the problem W Factor this number is the Weight per Percent of Drive Capacity ratio It is calculated continuously once an extruder has become stable The Weight is retrieved from the Polled number from the blender or OFC the Percent of Drive Capacity is the Speed field 0 100946 This ratio is used to determine where to set the drive to obtain a desired output It is very useful to record this number for each extruder and the hauloff Later comparison
7. and monitor that the voltage on the Input Volts under the Diagnose page follows properly and is wired into the correct input Repeat this until all of the inputs have been wired and tested Perform the Encoder Circuit Usage and Calibration section if the customer wishes to monitor the Hauloff Once this is done instruct the operator that he can go back to running the line in production while you complete the Communications testing before proceeding Step 1 Calibrating the Max RPM setting while in Monitor Only mode observe the Set RPM value on the Overall View page and compare it to the Polled value on the Diagnose page If they are not equal then enable the Calibrate Layer RPM while in Monitor mode under the Diagnose page see Diagnose page for more detail Wait about one minute and recheck the two displayed values If at this time the values are unchanged then you will need to determine why This is usually caused by the Stable Process light flashing on and off It must stay on for at least 30 seconds before this calibration can take place If it is flashing on and off wait for it to turn off and then quickly go to the Trending page Usually this is caused by the speed pot voltage being unsteady If at this time you see a bump on the graph for a particular device then you will have to manually calibrate the Max RPM value Be sure to turn the Calibrate Layer RPM while in Monitor mode off at this poin
8. extruder has an old drive and has trouble going from a dead stop to a drool or low speed The way operators would avoid this using a speed pot was that they would turn the speed pot to a higher setting for a second wait for the drive to start turning and then they would turn it back down to where it should be This feature does the same thing Whenever an extruder goes from stop to any speed it first will receive a Bump that is configurable The Bump will last for a certain amount of time that is also configurable Only use this feature if you are aware you currently have a problem with your drive Gauging Interface Setup Page Description This page is accessed by touching the Gauging Interface Setup button located on the Setup page It is used to integrate a gauging to the Coexpert system Up to 3 gauges can be integrated for the Coexpert to measure but the limit is dependent on the number of free analog inputs The Coexpert can also send analog signals to a gauging system This is also dependent on the number of free analog outputs This page shows the engineer what are free and how to configure them Explanation of Items Shown Reference from Gauge to Coexpert Section Current Input Use this shows which analog inputs are already used by the Coexpert system for extruder and hauloff speed pots hauloff encoder circuit Any input that is labeled unused can be selected as Input From Gauge Once this is configured the Coe
9. of the Coexpert program on the customer s training computer load in this configuration and then configure the system for Simulation see Setup lt Coexpert 5 1 Installation and Service Manual Page 21 of 31 Service Notes Page 22 of 31 F Coexpert 5 1 Installation and Service Manual Service Notes crc lt Coexpert 5 1 Installation and Service Manual Page 23 of 31 Communications Testing Instructions The interconnecting communications cables that connect the Coexpert to each blender or OFC is to first be installed and wired according to print by the customer Using the Setup Blender Network Setup page you will be able to test communications to each device This is done automatically and it is not necessary to push the Push to Test button After you observe that the Coexpert is communicating to each device red is also an indication of a blender or OFC alarm be sure not to confuse this with a communications failure that will be indicated by a Communications Failure message in the Message Box and a Coexpert Communications Alarm you need to ensure that the device with ID 1 is above extruder number 1 and so forth see Setup Blender Network Setup page of this manual for details on configuring the ID of each unit If you are having a communications failure it is more than likely an interconnect cabling problem Each Coexpert passes a quality control communications and hardware test prior to the s
10. of the condition This alarm indicates that the Coexpert cannot guarantee the quality of the product In order to obtain the best performance and quality for the product the system is usually limited to 98 max and 5 min for this setting Altering this setting can produce unwanted results caused by the inconsistent output of the extruder at these extremely high or low rates lt Coexpert 5 1 Installation and Service Manual Page 11 of 31 The Com alarm indicates a communications network failure on one of the blender or OFC units This is usually caused by the unit either being powered off or unplugged from the network This alarm will occur in all modes of operation including Stop mode Ratio the Haul off Speed in RPM mode this is used to tell the Coexpert whether or not the Master Control found on Process page ratio will adjust the speed of the hauloff Some customers chose to ramp the extruders up together while maintaining the speed of the hauloff Usually this is done while the line is in start up and the hauloff is not actually pulling material It is recommended in order to keep the ramping benefits of the Coexpert that this value be enabled Use Multiple Gear Control enable this if the hauloff device that you are using has a multiple gear gearbox and you intend on using more than one of these gears Typically this is only used in the Wire and Cable industry Bump Start Speeds and Time this feature is useful if the
11. the Coexpert Panel on terminals 18a b measures exactly 9 999 volts as close to 10 without hitting 10 Press the calibration button once Sixth step turn the hauloff speed pot down until the output voltage of the line speed box this can also be measured in the Coexpert Panel on terminals 18a b measures exactly 001 volts as close to 0 without hitting 0 Press the calibration button once Seventh step press the calibration once to exit and save the calibration You are now ready to test the feedback voltage of the encoder circuit Use the same test as described for testing the Customer s 0 10 volt feedback signal but instead use the voltage found on terminals 18a b of the Coexpert instead of the customer s feedback signal If this does not test out then recalibrate the hardware of the encoder circuit and repeat the test until it does lt Coexpert 5 1 Installation and Service Manual Page 19 of 31 Integration Issues Integration of the Speed Pot Signals these signals are referred to as the Speed Pot signals but can actually be any 0 10 volt signal that represents the drive speed of a particular device This speed is actually not a representation of RPM but instead is a reference to where the drive is currently set to in accordance to Drive Capacity The 0 10 volt signal is an industrial standard If it is found that a customer has a signal that actually measures 0 10 9 volts then this range is due to a faulty power sup
12. your capstan The system is designed to handle up to 6 gears Maximum Extruder Rate this number does not have to be manually entered The Coexpert will calculate this using the throughput information from the blender or OFC once the Stable Process light has been lit for 30 seconds Use Trim Option enable this if you wish to input trim below the blender or OFC Carefully see the section for this under Process Page before configuring After enabling this feature you will be able to select which layer contains trim Extruder and Hauloff Drool Speeds the drool speed feature of the Coexpert allows a preset speed for each device to be programmed From the Process page the operator can touch the Go to RPM Mode with Drool Speed Set points and the line will ramp to these preset speeds A remote button can be wired into the Coexpert to emulate the same function see print for wiring detail This allows the operator to place the line in Drool without going to the Coexpert panel from the die or other remote location System Speed Limits once the line is in Control by Weight mode and a recipe has been entered successfully the Coexpert will monitor the speeds of each extruder and hauloff In order to maintain the extruder output the Coexpert will adjust for screen pack build up and other physical properties of the line that cause output to fall If the speed exceeds or falls below the System Speed Limits an alarm will notify the operator
13. 31 Turning on the Setup buttons The Setup buttons consist of the Security Setup and Diagnose buttons located on the top of the Coexpert screen These buttons normally do not need to be accessed frequently and are therefore hidden from the operator during normal operation This saves confusion for the operator and cleans up the display Turning them on if they are not visible to turn on the buttons double touch the blank area shown below and you will be prompted for a password Enter in This password only turns on the buttons and is Hard coded Double touch this blank area W zt HydReclatmi Caex YeiOverall View 5 8 Eq B Controlled by SIZE TARGET ACTUAL SEI TARGET ACTUAL Lbs Me Lbs He RPM Weight ree 1 SIZE TARGET ACTUAL YALUE VALUE SIMULATIG Page 18 of 31 lt Coexpert 5 1 Installation and Service Manual and ask the customer if they approve or disapprove this error this will be the error when running the line If they approve this then the customer provided feedback signal is correct to use Document this data and the customer s approval before proceeding If all of these tests fail then you must use the encoder circuit from AEC HydReclaim in order to accurately control the line Hardware Calibration of the AEC HydReclaim s Encoder Circuit mount the encoder on the hauloff motor or on the haulof
14. Suite 588 Suzhou China 215126 Dist Pune 410501 India Schaumburg IL 60173 Phone 86 8717 1919 Phone 91 21 35329112 Phone 1 847 273 7700 Fax 86 512 8717 1916 Fax 91 20 40147576 Fax 1 847 273 7804 Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin 53151 Ul Dzialkowa 115 Phone 1 262 641 8600 as Phone 48 22 390 9720 Fax 48 22 390 9724 Coexpert 5 1 Menu Structure Coexpert Overall Page Process Page Trending Page Inventory Page Gauging Page Security Page Setup Page Diagnose Page Calculator Page Alarm Log Page Help Page Minimize Button Exit Blender OFC Image Start Stop Blender OFC Change Blender Recipe Size Button Current Gear Choice Ramp to Stop Monitor Only Control by RPM Control by Weight Go to RPM mode with Drool Speed Setpoints Trim Width Coexpert Recipe Book Load and Quit Cancel Load Load a Recipe Save the Recipe Edit Make back up Floppy of all Recipes Restore Recipes from Floppy Graph of Recipe Pause Resume Data Capture Show Grid Lines Clear Inventory Generate Report Print Save to Disk Exit Gauge 1 Gauge 2 Gauge 3 High Tolerance Target Diameter Low Tolerance Administrator Password Maintenance Password Operator Password Access Privileges See Setup Page Tree on Following Page
15. al Polled the current polled rate from the blender or OFC This updates every second Highest W during a production run in Control by Weight mode the highest value ever observed for the Factor Set Rate the current target throughput rate and hauloff speed for each device This is calculated from the recipe that was entered in by the operator on the Process page and is only available when the line is in Control by Weight mode Average Rate the average observed throughput and hauloff speed for each device throughout the entire product run Clear Com Counts button this button restarts the Com Counts count The Com Counts are the max number of communications failures that have been observed Ten 10 failures must occur before a Communications Failure alarm is given The Com Counts are useful when you are diagnosing an intermittent communications problem and you want to look for possible trouble areas Restart High Low Capture the High Low capture refers to the Highest W Average W Lowest W Highest RPM Average RPM and Lowest RPM The resetting of these values occurs automatically whenever the mode of operation changes but it is useful for trouble shooting to reset it manually and then check it after a few hours of running Digital Out Data this is the decimal equivalent to the binary digital outputs All Digital Outputs are from the ADI12 16 PC card Out 0 is unused Out 1 is the Stable Proces
16. al Hauloff Feet Min or Meters Min then current actual speed of the hauloff device This value is shown in all modes of operation including Monitor Only mode but is only available when the Line Speed Control is selected under Setup lt Coexpert 5 1 Installation and Service Manual Page 3 of 31 Product in Spec Message this is found in the lower left comer of the screen and shows that the current gauge measurement is within the specifications entered in by the operator on the Gauging page This is only available when a gauge has been interfaced to the Coexpert system and configured under Setup Gauging Interface Setup Gauge Control Active Message this is found in the upper left corner of the screen and is only available if Ramp Control is selected under Setup Gauging Interface Setup see Gauging Interface Setup page This indicates that the gauging control algorithm is currently active see Gauging Interface Setup page Size Button touching this area enlarges or shrinks the data in a particular box This is useful if the operator is having trouble viewing the small text Green Indicator on Blender OFC Picture this indicates that the blender or OFC is running and currently does not have any alarms If the unit is turned off or an alarm occurs then the green indicator turns off Double Touching the Blender OFC Picture this brings up another screen where the operator can start stop the blender OFC from the Coexpert
17. alog outputs from the Coexpert system i Coexpert 5 1 Installation and Service Manual Page 27 of 31 Overview of Field Wiring Terminal Strip View of Field Wiring Terminals The Coexpert system is provided with a recessed terminal strip to ensure ease of installation and trouble shooting All wire terminations in the panel are provided with ferrules to eliminate stray wire strands that can cause noise pickup and short circuits An excellent wire number system is provided Page 28 of 31 cC F Coexpert 5 1 Installation and Service Manual Wiring the existing speed pots into the Coexpert Panel The Coexpert system replaces the function of your existing speed pot but in order to keep the system capable of being ran from the original speed pots the speed pots must be wired into the Coexpert Panel The first thing to verify is that the Coexpert system strictly works with 0 10V signals There is no problem if you are currently using a speed pot that is less than 0 10V but if your drive is using 0 12V control circuits then you will need to lower the voltage range to 0 10V before the Coexpert will perform correctly If your drive is using 4 20mA control circuits then you will need to integrate a converter so that the 0 10V signal from the Coexpert will work correctly The way that your existing drive works uses a speed pot with 3 connections One connection is for the excitation one for excitation and the other for the si
18. arn Rate Rate Ext3 Capture 0 f f fi fi 1504 1504 Exti Ext4 Toop Time 2 7 0 t fi 1 1932 1994 Ew2 p 0 7 0 fi 1 h 251 0 510 Ext3 Ext 5 0 o0 o b i 0 Ext4 Longest 0 0 0 0 0 fi 0 Exts Loop Time 0 0 lo 0 0 Ti Ext Ext6 1 fi 250 a 6024 Total LIP ra 05 4005 re Parts Department Call toll free 8am 5pm CST 800 423 3183 Parts shipped from the Schaumburg IL facility available for Next Day Air shipment up to 4 pm EST The AEC HydReclaim Parts Department is ready to provide the parts to keep your systems up and running HydReclaim OEM replacement parts ensure operation at design specifications Please have the model and serial number of your equipment when you call Service Department A 4 Call toll free 8am 5pm CST 800 233 4819 or call 847 273 7700 AEC HydReclaim has a qualified service department ready to help Service contracts are available for most AEC HydReclaim products lt Sales Department Call 8am 5pm CST 847 273 7700 AEC HydReclaim products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department 9 Call 8am 5pm CST 847 273 7700 Let AEC HydReclaim install your system The Contract Department offers any or all of these services project planning system packages including as built drawings equipment labor and construction materia
19. can indicate a possible maintenance condition such as screen pack build up screw wear etc Zero Flow rate this indicates that the Polled rate for an extruder is 0 even though the extruder drive is turning This will only be set if the Steady Flag is received from the blender or OFC first refer to blender or OFC documentation for details on why When this occurs an alarm will notify the operator of the problem Set Dag this is the D A target value in Bits that is used to ramp the output to a specific voltage The range is 0 4095 This is used in comparison with the Daq Out and the Daq Step to determine if the Ramp Flag should be set Daq Out this is the current D A output in Bits The range is 0 4095 If this number is divided by 4095 and then multiplied by the Maximum Output Voltage see Advanced Settings you will calculate the Output Volts shown on this page Daq Step this is the current increment that is added to the Daq Out to slowly ramp the extruder or hauloff to the Set This number is recalculated anytime the operator makes a process change Ramp Time this is the amount of time that each device will take to ramp the Daq Out to the Set The largest of these ramp times is shown in Max Ramp and this value is used to recalculate the equal ramping feature of the Coexpert see Extruder and Hauloff Setup Page 14 of 31 F Coexpert 5 1 Installation and Service Manu
20. curate Remember that the only control variables that any extrusion control system has are extruder throughput measured by a Gravimetrical blender or OFC and hauloff speed measured by an encoder circuit Inventory Report Setup button this button accesses the Inventory Report Setup page From this page the engineer can select from automatic report generation and clearing as well as automatic printing of the report If automatic generation is selected then the interval can be configured The start time of the first report can be entered along with intervals such as Every 8 hrs Every 12hrs Every 24hrs in the AM Every 24hrs in the PM If the customer wishes to generate reports less frequently they can select from every 30 days every 180 days or every 365 days The report will be generated with all devices shown but the printout of the report can be configured to only show what they want to see such as extruder 1 info extruder 2 info blender info from extruder 1 etc If automatic report generation is not selected then the operator can manually clear and generate reports from the Inventory page Blender Network Setup button this button accesses the Blender Network Setup page From this page the engineer can add or remove additional items to the blender network such as OA OS batch blenders that are above an OFC weigh hopper Due to high speed processing the Coexpert system is designed to only interface to b
21. f motor side of the gearbox The RPM at the mounting location cannot exceed 2300 RPM If this is a problem you can either gear the encoder using pulleys to an RPM that is lower than 2300 RPM or you can call AEC HydReclaim and replace the current encoder 250 pulse revolution with a 100 pulse revolution encoder this allows up to 5750 RPM The max input frequency of the line speed box is 10khz The encoder comes supplied with a 15 foot cable between the encoder and line speed box This is the maximum length allowed The distance between the line speed box and the Coexpert Panel can be up to 300 foot without any problems The line speed box will also need a 120VAC supply the box comes with a cable attached Once the encoder and panel are properly mounted and wired into the Coexpert Panel you will need to plug in the line speed box to the 120VAC source at least 10 minutes before you will be able to calibrate the hardware Located in the line speed boxis a frequency to voltage converter On the converter is a small rubber plug that can be removed to access the calibration button First step push and hold the calibration button for about 7 seconds Second step turn the hauloff speed pot up to 10 volts full speed Third step press the calibration button once Fourth step stop the hauloff and then press the calibration button once Fifth step turn the hauloff speed pot up until the output voltage of the line speed box this can be measured in
22. gnal You will need to run a shielded twisted pair cable from the speed pot to the Coexpert Panel Hook one of the wires from the twisted pair to the excitation do not remove this wire from the drive Remove the signal wire from the drive and wire it to the other wire from the cable DO NOT GROUND THE SHIELD AT THE SPEED POT END it is only grounded at the Coexpert Panel end The other end of the cable will wire into the Pot Inputs section of the Coexpert Panel Refer to the interconnect drawing for specific terminations Wiring the reference signals from the Coexpert Panel to each Drive You will first need to run a twisted shielded pair cable from the Coexpert panel to each drive one cable per drive The Coexpert Panel end will be wired to the Drive Reference Outputs section The other end will be wired to the drive You will hook one wire from the cable to the excitation same as where the speed pot is wired see above and the other to where the original signal wire was wired This will need to be done for each drive Refer to the interconnect drawing for specific terminations DO NOT GROUND THE SHIELD AT THE SPEED POT END it is only grounded at the Coexpert Panel end lt Coexpert 5 1 Installation and Service Manual Page 29 of 31 Entering in the Service Passwords Note Remove this page for production floor use The service passwords consist allow a service engineer access to items una
23. hipment of the unit The QC stamp that indicates that the unit passed this test is found under My computer C coex qcr aec If this file is present open it with note pad and you will see the date the unit was tested and who by This file is generated using the Coexpert Panel Tester software and is an automated process To this date there has been no documented case of a unit leaving the facility without the proper testing even prior to the existence of the Coexpert Panel Tester software To verify that the problem is in the cabling you should carry with you a straight through 50 foot DB9 serial cable This cable can quickly be plugged into the bottom of the Coexpert panel and the bottom of the blender or OFC to test communications If the customer has wired directly into the Coexpert and blender panel they have usually avoided to notice that the internal com cable that connects the Coexpert computer to the bottom of the Coexpert panel is not a standard cable It is manufactured so that they will be able to use a standard cable when interconnecting the units The following pages are given to show the entire configuration and internal jumper settings of the Coexpert computer If all else has been verified thoroughly then you will need to check these settings by carefully opening the computer removing all of the cards and checking the jumpers This should only be done by a qualified service engineer and could void your warrantee if done witho
24. horizontal axis of the graph and is scaled in seconds The far right hand side of the graph is the current time and the far left hand side is 100 seconds prior to the current time Max RPM key this is located in the upper left hand section of the page and shows what the of Max RPM axis coordinates to Key this is located in the lower left hand section of the page and shows what each color on the graph represents A different color is given for each extruder and the hauloff Show Grid lines this is located in the middle of the bottom of the page and enables the grid that overlays the graph This is useful in quantifying the actual deviation of a particular extruder or the hauloff Vertical Spacing key this is located in the lower left section of the page These values correlate to the vertical spacing of the grid Each horizontal line on the grid represents one unit of this value Each vertical line on the grid represents one second of data Pause Resume Data Capture button this button is located in the lower right of the page This is used to pause or resume the scrolling of the data that is shown In order to measure how much an extruder has changed it is best to first pause the data capture doesn t affect anything except the graph and then to enable the grid to calculate the change in RPMs lt Coexpert 5 1 Installation and Service Manual Page 7 of 31 Small dashes near left of graph these dashes are sho
25. icated by Stable Process message on Overall View page enter the Trim Width on the Coexpert program You will be prompted for a password before the Coexpert will allow the program to run This is to prevent illegal installations To obtain a password the customer must call AEC HydReclaim on the day of installation and ask for the Pirate Protection Password This password changes every day and therefore can only be generated on the day of installation It is possible for AEC HydReclaim to generate a password for a certain date if the installation is to be done on the weekend Once the password has been entered on the system you will never see this display again It is only necessary for the installation After the system has been authorized and the program boots go to Setup Configuration Utilities and select Load a Configuration Pick the name of the configuration that was previously written down and the system will restart with the Coexpert configured as before All Coexpert configurations are forward and reverse compatible therefore if you are running version 1 0 you can easily upgrade to version 5 1 or if you are running version 5 1 you can easily go back to version 1 0 Because of this software upgrades are very easy to accomplish but some basic knowledge of WIN95 shortcuts and functions are required For information on where to find the configuration files directly from WIN95 see Hard Drive File Structure Extruder and Hauloff Set
26. icular item for communications Once turned off touch the item to test and push the Push to Page 10 of 31 F Coexpert 5 1 Installation and Service Manual Test button If a Test String response is shown in the Message window then the unit is communicating A tag indicated by red means either that the unit is not communicating or currently has an alarm This page is only used during start up These Maximum settings are setup differently depending on whether or not the encoder circuit is being used and if Multiple Gear Hauloff is enabled The Use Multiple Gear Control should be enabled if you are using a capstan that has more than one gear selection Some lines have these capstans but are never switched and therefore should not be configured for Use Multiple Gear Control To determine if the encoder circuit should be enabled and to examine the calibration procedure for each type of hauloff see Encoder Circuit Usage and Calibration In all cases this setting for the Maximum RPM of the Hauloff and the gear ratio for the hauloff found under Multiple Gear Setup will automatically be adjusted by the calibration procedure and should not be manually entered Hauloff Calibration Factor see Encoder Circuit Usage and Calibration Number of Gears this is found by touching the Multigear Hauloff Setup button and is only available when the Use Multiple Gear Control has been enabled Set this to the number of gears available on
27. iewed from within WIN95 If viewing from WINSO5 it is advisable to disable the alarm log prior to viewing For F Coexpert 5 1 Installation and Service Manual information on where to find the alarm log file and see Hard Drive File Structure Use Tahoma Font when Printing this feature selects the Tahoma Font for all printout functions including printing the verbose configuration report the inventory reports and the alarm log report Trending Page Description This page is accessed by touching the Trending button that is located on the top of the Coexpert screen This page is used to observe the current extruder RPMs and Hauloff speeds for the last 100 seconds This is useful to show an operator how the line is responding to the values that they have entered very useful training tool Trending is also used by the service engineer when starting up the system It is useful in determining speed pot voltage stability while in Monitor Only mode and for diagnosing a problem extruder This page is not intended to be a long term monitoring tool The service engineer would instead use the Max File function to monitor line variables over a length of time see Setup enabling the Max File Explanation of Items Shown of Max RPM Axis this is the vertical axis of the graph and is scaled in percent of the maximum rpm of the extruder or the maximum hauloff speed of the hauloff Time in Seconds T axis this is the
28. ing if the operator is sure that he wants to stop the line This protects against accidentally bumping the screen The ramp that is used maintains product specifications until the last minute This minimizes variations for the product that remains in the line This function is not the same as the Remote E Stop function which ramps the line down much quicker and does not maintain product specifications F Coexpert 5 1 Installation and Service Manual Control by Weight button this button is one of the operation mode buttons Touching this button transfers the line to weight mode according to the values entered by the operator in the Control by Weight section upper right Once this button is touched the Control by Weight section will be highlighted in blue If the line is running in either Monitor Only mode or Control by RPM mode then the Coexpert checks to make sure a recipe has been entered and accepted prior to transferring to Control by Weight mode If no recipe has been entered a Check Recipe message will appear Transferring the line in this fashion is not necessarily a bumpless transfer Only if the current recipe values are exactly what the line is running will a bumpless transfer occur In order to avoid such a problem a LEARN RECIPE and TRANSFER to Control by Weight button located near top of page is available from Monitor Only or Control by RPM Touching this button causes the Coexpert to take a snapsho
29. lenders or OFC units that are actually on the same process line You cannot communicate to a batch blender that is used elsewhere in the customer s plant The Coexpert reserves network ID s of 1 6 Additional items such as batch blenders must be addressed 7 12 The Coexpert subtracts 6 from the ID to determine which extruder the batch blender is feeding You cannot add a batch blender above an OL blender In an example if you have an OL blender on extruder 1 1D 1 and an OFC hopper on extruder 2 1D 2 then you are allowed to place a batch blender above the OFC hopper of extruder 2 ID would be 8 8 672 thus extruder 2 This numbering convention must be followed The Coexpert will allow you to add up to 6 additional items but unless the extruder correlating to the ID 6 is an OFC hopper the Coexpert will not include it in the Inventory Report To add remove or edit an item touch the ID Setup button As a protection the blender network setup will not let you add or remove an item with ID 1 6 Coexpert Reserved However this protection can be bypassed by entering in the service password found on the Diagnose page see Diagnose page for more info This should only be used if for some reason an ID of 1 6 has been accidentally duplicated From Edit you can customize the name of any tagged item on the blender network Continuous Polling should be turned on during normal operation This should only be turned off when you want to test a part
30. ls union or non union installations and field supervision re i Coexpert 5 1 Installation and Service Manual Page 31 of 31 0 00 0 23 MATERIAL HEAT amp GOOL BLEND amp GRANULATE DOWNSTREAM AUTOMATE HANDLING RECLAIM EXTRUSION 1100 E Woodfield Road Suite 588 Schaumburg IL 60713 http www aecinternet com SYSTEMS CONTRACTING
31. ntrol by Weight mode Otherwise it will show O Actual Lbs Hr or Kgs Hr the current actual rate that the extruder is producing This value is shown in all modes of operation including Monitor Only mode Set RPM the current target RPM value for the extruder This value is shown in all modes of operation including Monitor Only mode Target 96 the current set target layer percentage that is calculated based on the recipe that the operator has entered on the Process Page This value is only shown when the line is in Control by Weight mode Otherwise it will show O Actual 96 the current actual layer percentage that the extruder is producing This value is shown in all modes of operation including Monitor Only mode Target Total Lbs Hr or Kgs Hr the current total target rate for all extruders based on the recipe that the operator has entered on the Process Page This value is only shown when the line is in Control by Weight mode Otherwise it will show 0 Actual Total Lbs Hr or Kgs Hr the current total actual rate for all extruders This value is shown in all modes of operation including Monitor Only mode Target Hauloff Feet Min or Meters Min the current target speed of the hauloff device such as capstan nip puller or chill roll This value is shown in all modes of operation including Monitor Only mode but is only available when the Line Speed Control is selected under Setup Actu
32. operator can enter in the recipe values After all values have been entered touch Accept New Recipe and the line will ramp to that recipe The Running Recipe boxes show what the current set recipe values are To load a previously stored recipe the operator touches the Coex Recipe Book then load a Recipe button picks the recipe number or name then Load and Quit button and finally the Accept New Recipe button The Control by Weight mode is also very useful in trimming the line to reduce material cost Usually lines are operated slightly above the minimum specifications of a product This is to ensure quality product throughout the product run With Control by Weight mode this is not necessary The Coexpert adjusts for conditions that cause the extruder output to fall and therefore ensures quality product using the minimum amount of material throughout the run of the product lt Coexpert 5 1 Installation and Service Manual Page 5 of 31 Page 6 of 31 Trim Width entry box this box can be touched to allow the operator to enter in the current measured trim width of the product This button is only available if trim entry is configured under Setup Extruder and Hauloff Setup The value can only be entered once the process has become Stable The procedure should be done exactly the same from operator to operator Bring the line up to speed using either RPM mode or Control by Weight mode let the process stabilize ind
33. planation of Items Shown Median Width this is the width of the buffer that is used to buffer the Polled rate measured at each blender OFC See Diagnose page Median Counts for more information The default for this is 20 To increase response decrease the median width To dampen out response increase the median width There is no case where this has had to be adjusted Calculation Points this is the width of the median filter that is used to average the median width buffer See Diagnose page Calc Count for more information The default for this is 30 To increase response decrease the calculation points Page 16 of 31 F Coexpert 5 1 Installation and Service Manual To dampen out response increase the calculation points There is no case where this has had to be adjusted Layer Deadband in this is the control deadband for each layer in relation to throughput control To increase response decrease the layer deadband To dampen out response increase the deadband There is no case where this has had to be adjusted Maximum Input Change in this is the allowed change that the Factor is allowed to change see Diagnose page Unstable Flag for more information The default for this is 2 To increase response decrease this value 0 is lowest To dampen out response increase this value There is no case where this has had to be adjusted cC i Coexpert 5 1 Installation and Service Manual Page 17 of
34. ply within their drive Usually this voltage can be fine tuned and the drive can they be relinearized so that the customer does not lose any drive capacity refer to the documentation of the particular drive this is to be done by the customer only If this problem is not corrected the Coexpert will not be able to properly control the line for voltages greater than 10 volts If the line is never run that high then no adjustment is necessary The speed pot signal is sometimes a 0 10 volt signal coming from the customer s PLC that normally controls the drive It is the customer s responsibility to understand how his existing controls function It is your responsibility as a service engineer to instruct the customer of what signals you will need and work with them in integrating the solution Integration s where other companies auxiliary equipment that follows either the extruder speed or the hauloff speed must be carefully done AEC HydReclaim s Coexpert is not designed to control such equipment and the integration is the customer s responsibility On analog systems systems without a PLC this integration is usually just a matter of adding a few external relays to the switch which reference the auxiliary equipment will follow Remember that the Coexpert will make speed changes and if this equipment is still following the old speed instead of the new speed erroneous results can occur Another thought when integrating to this equipment is in the ramp
35. put Volts 15 Ext 2 Ext2 25 Ext3 0 Ext4 Ext5 Ext6 5 Hauloff Clear Encoder Digital Out Data 1 Stable Process Flag 2 Alarm On Flag Stop Input 3 4 Drool Input Flag 10 Up i 5 Input Flag 10 Down ii 6 n Input Flag 7 k d Future Use System Mode 8 Index Page 30 of 31 Security Calculator Alarm Log Factory Data Analysis Com Ramp Median Unstable Unstable Wo Zero amp Counts Counts Flag Count Factor flowrate Out Step Time 0 o fps 0 0 0022 0 642 fra fo 0 lo f 0 0 9 95977 o 819 819 3 0 Ext2 fo lo 6 0 0 10 0366 0 1023 0 Ext3 0 o 0 0 0 396938 0 0 0 2047 fo Ext4 lo o fo 0 0 9 38839 0 lo fo Bo fo Ext5 0 0 0 10 026 o 0 0 Ext6 Cea 10 10 0 fo lo 207 07 0 Hauloff Com 0 Counts ee R omo Factory Data Analysis Highest Average Lowest Highest Average Lowest Calibrate Layer Polled Speed Wir W RPM RPM RPM RPM while in 0 15 1002 002 pe T foo 3953 9959 a o D are incorrect 0 25 1003 _ pee 5 25 5 shoud be 0 0 9369 9969 9953 Ext4 checked 0 0 9388 5909 3908 ess i Ext 1 0 0 foo 1002 1002 mm fo Ext6 eo 5 s 5 ls 250 250 Hauloff Ext 2 Blender Calc Polled Steady Steady First Set Average Alarm Count RPM RPM Hag Le
36. r Setup The setup page is used to configure the system for the customers exact application and therefore should only be accessed by a qualified service engineer Explanation of Items Shown Virtual Keyboard Setup button this button accesses the virtual keyboard setup page After touching this button the operator is given a message that instructs them to plug in a real keyboard to the front of the Coexpert a keyboard is shipped with all units The virtual keyboard setup page allows a customer to customize the alpha keypad that pops up whenever the operator is entering an alpha type entry To use the virtual keyboard setup routine simply touch the blank box in the upper right of the screen Then using the real keyboard type in the character you wish to display and then touch the position that you want that character to reside on the virtual keyboard When you re done touch Done or Return to Setup to quit The only way to reset the entire keypad back to factory defaults is to set the entire system back to factory defaults under Setup Configuration Utilities Number of Extruders select the appropriate number of extruders for the line The Coexpert system allows up to 6 extruders with a hauloff to be configured Versions of Coexpert prior to 5 1 only allowed up to 6 devices 6 extruders or 5 extruders with a hauloff Line Speed Control select the type of hauloff you are using or select none The current choices are none p
37. rate see Extruder and Hauloff Setup page If the Coexpert s ramp rate is too fast then this could cause problems with devices trying to follow the current speed In digital systems systems with a PLC the integration is not as simple Usually the reference speed that the auxiliary equipment is following is not switchable using external relays the reference is within the PLC In this case either the customer or the OEM of the PLC system must develop code to integrate the auxiliary equipment It is a very simple code and is usually just a matter of reading in the Coexpert s analog outputs and reading in a contact from the Coexpert telling the PLC when it should use our reference instead of theirs to control the auxiliary equipment The contact can be taken from a spare Normally Open contact off one of the relays in the back of the Coexpert panel there are 4 relays that are enabled when the Coexpert is in control When integration becomes a problem that can not be resolved in one trip then the start up can be completed for a Monitor Only application See Installation for a Monitor Only Application Page 20 of 31 F Coexpert 5 1 Installation and Service Manual Wiring in the Speed Pot signals only connect one cable at a time This allows you to test each signal as you go and will prevent any wiring mistakes After you connect each cable see print for wiring detail have the operator turn the speed pot for that device up
38. remote drool input has been closed see print for wiring detail This in turn will cause the line to switch to RMP mode with the preset drool speeds see Extruder and Hauloff Setup page 1096 UP Input Flag this flag indicates that the remote 1096 up input has been closed This in turn will bump up the Master Control ratio by 1096 see Process Page Help Page Description This page is accessed by touching the Help button on the top of the Coexpert screen From this page the engineer can obtain the current configuration name that is running and the installation path of the Coexpert program At this time is does not contain an active Help feature Exit button Description This button is accessed by touching the Exit button on the top of the Coexpert screen This will prompt the operator if he is sure he wants to exit the program and then will shut down the program returning them to the standard WIN95 screen Minimize button Description This button is accessed by touching the minimize or icon on the very top of the Coexpert program Before the program will allow you to minimize it you must enter in the 5413 Service password see Entering in the Service Passwords Advanced Settings page Description This button is accessed by touching the Advanced Settings button on the Diagnose page You must enter in the 5413 Service password see Entering in the Service Passwords before this button is visible Ex
39. s light Out 2 is the Alarm output Out 3 is the Coexpert Control signal that operates the switching relays in the back of the panel Each of these outputs would have a binary equivalent for the output number In plain English Out 0 output would be equal to 1 decimal Out 1 output would be equal to 2 decimal Out 3 output would be equal to 4 Adding the decimal value for each output energized gives you the Digital Out Data value This seems useless to most users but to the developer it is very useful in determining what outputs should be energized The I O cards process the digital output request in this format Stable Process Flag indicates the Stable Process condition Whenever this flag is 1 then the Stable Process light on the front of the panel should be on If it is not then there is either a hardware wiring problem or the light is burned out Alarm On Flag indicates the Alarm condition Whenever this flag is 1 then the Alarm light on the front of the panel should be on If it is not then there is either a hardware wiring problem or the light is burned out Stop Input Flag this flag indicates that the remote stop input has been closed see print for wiring detail This in turn will cause the line to stop quickly using the Emergency Decel Ramp Rate see Extruder and Hauloff Setup page lt Coexpert 5 1 Installation and Service Manual Page 15 of 31 Drool Input Flag this flag indicates that the
40. s after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com e Mexico Central amp South America Email acslatinamericacustserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com India 91 21 35329112 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more information please visit us at www acscorporate com United States Asia Australia India ACS India ACS Schaumburg Corporate Offices ACS Suzhou Gat No 191 1 Sandbhor Complex 1100 E Woodfield Road 109 Xingpu Road SIP Mhalunge Chakan Tal Khed
41. t If you must manually calibrate the Max RPM value refer to the Diagnose page section of this manual for detailed instructions Once all the Set RPM values match the Polled RPM values for earn extruder you will be ready for the next step Step 2 Calibrating the Max WTP setting while in Monitor Only mode observe the ACTUAL LBS HR value on the Overall View page and compare it to the Polled value on the Diagnose page If they are not equal then determine why If the stable light is not on for at least 50 seconds then this value will not update and you must adjust the Voltage Dead band in 9o see Advanced Settings page for instructions Increase this value slowly and observe the Stable Process light If this is not being caused by the voltage from the speed pots then you will need to use the Diagnose page to determine what is causing it see Diagnose page for information on all the given data Once the ACTUAL LBS HR values match the Polled values for each extruder then you have completed the installation of the system Be sure to setup the recipe format see Setup Recipe Setup page for details and properly train the operators on the use of the Coexpert before leaving the facility Normally it is best to turn off the setup buttons see Setup and save the current configuration also to floppy Keep a copy of this configuration for the records and give a copy to the engineer in charge at the facility Load a version
42. t of the current running recipe write this recipe to the Control by Weight section and then automatically transfers the line to Control by Weight mode This is similar to the cruise control function in your car Running the line in Control by Weight prevents extruder output deviation that is commonly caused by screen pack build up screw wear or build up heat setting deviations or changes in the density of the plastic Recipes can be saved to the Coex Recipe Book by touching the Coex Recipe Book button selecting Save Recipe and then picking the recipe number or name that you wish to use From the recipe book the operator or process engineer can also write new recipes edit existing recipes make back up floppies of all recipes and restore recipes from floppies This is a useful tool for the process engineer From a demo program installed on the engineers desktop PC they can write a book of recipes copy them to disk and then distribute this disk to the Coexpert systems in the plant If the Coexpert has been integrated into the customers TCP LAN Ethernet system then the engineer can remotely write and distribute these recipes An open slot is available inside the Coexpert for an Ethernet card but it is up to the customer to have one installed and configured Control by Weight mode is also very useful when developing new products The operator can simply touch the highlighted boxes which will bring up a number pad that the
43. uller nip Chill Roll and Wire and Cable Typically changing this only changes the graphic representation on the Overall View page However if you are using the Trim Entry feature under Setup Extruder and Hauloff Setup then this will affect how trim is measured See Process page Trim Width entry for more information Line Name this allows up to 10 characters to be entered to represent the name of the production line This is useful when printing out inventory reports so that you can distinguish what line the report came from Example Line 1 Extruder Name this allows up to 5 characters to be entered to represent the name of a particular extruder By default the Coexpert uses EXT 1 EXT 2 etc This allows you to customize this name which is reflected on the Process page Overall View page and the Trending page This name will not affect the Diagnose page or the Setup page lt Coexpert 5 1 Installation and Service Manual Page 9 of 31 The entries and units of each entry can be selected to match the customers product specifications sheet for their line This allows quick transition from the way that they use to run the line to the way they will run the line using Coexpert Thickness mode uses the operator entry of layer density and product laytlat to calculate a target Ibs hr of each extruder If the operator incorrectly enters in the layer density or the laytlat then the thickness will not be ac
44. up Button this button accesses the Extruder and Hauloff Setup page SEE Extruder and Hauloff Setup page Enable History Log this should only be enabled during extensive troubleshooting of the system Enabling this feature generates an on going log of all gravimetrical data and system speeds This feature will log up to 5Meg of information for diagnosing The file is not viewable directly from the Coexpert program but can be viewed from WIN95 This file is generated once a minute until the feature is turned off It should only be viewed once the logging has been turned off Viewing the data shows the polled throughput and polled extruder RPM for each extruder The data also shows volts to each drive and the current calculated Max WTP and RPMs of each extruder This is useful to verify if one of the blenders or OFC units on the system is oscillating due to a load cell or A D problem It is also useful to verify what speed changes the Coexpert has made to each drive over an extended period of time The time is also written to the log so you can correlate a speed or throughput change to a time logged event or alarm that is also stored on the hard drive For information on where to find these files and more see Hard Drive File Structure Enable Alarm Log this feature should be enabled during normal operation This will log all alarms and events operator initiated to a log that is either viewable from within the Coexpert Alarm Log page or can v
45. ut the expressed written permission of AEC HydReclaim Page 24 of 31 F Coexpert 5 1 Installation and Service Manual AEC HydReclaim Contec System Integraiion Coexpert Control System APIO Card Sety PAGE 2 OF 6 DA12 8L PC Base Address 300h 233MMX MOTHERBOARD Boord Config 0 IRCrUnused ADI12 16 PC Base Address 1300h Board Config 1 differential IRQ Unused a 2 8 28 8 56 MODEM ADI12 1 amp PC CMOS COM hos to be disabled on the MOTHERBOARD llow for the MODEM to allow for the Configured as COM2 Configured as COM4 19200 8 n 1 Interrupt 10 Base Address 02 8 02 LABELS necessary to identify the cards without removing the cover AEC HydReclaim Contec System Integration Coexpert Control System PAGE 4 OF 6 SYGA Card Contec No 7510B cC F Coexpert 5 1 Installation and Service Manual Page 25 of 31 AEC HydReclatm Contec System Integration Coexpert Control System PAGE 6 OF 6 ADI12 16 PC 10 11 12 14 15 sje 1 2 Notes Page 26 of 31 cC F Coexpert 5 1 Installation and Service Manual Switching Relays amp Encoder Pickup Module Alarm Output dry Power Sensing Input Manual Backup to Co Expert Stable Output dry Switching Relays Close up of relay group This section of the interface backplate contains the switching relays to divert the signal from the manual potentiometers on the extruder system over to the an
46. vailable during normal operation The list of specific passwords and access are listed below 5413 Service Password once this has been enabled the engineer will gain access to Force I O functions Diagnose page access to the Advanced Settings and Advanced Control Settings pages from Diagnose page can view the alarm log s hidden event log to identify the keystrokes that the operator has pressed allows the Minimizing of the Coexpert program and allows modification including removal of ID items 1 6 see Blender Network Setup page 3145348 Service Password once this has been enabled the engineer will gain access to Force I O functions page and access to the Advanced Settings and Advanced Control Settings pages including the Run Extruder in Volumetric Always setting under the Advanced Control Settings How to Enter either password on the Diagnose page certain boxes are actually buttons Using these buttons an engineer can enter in the numbers 1 8 and there is also a clear button Whenever entering in a password always hit clear first to ensure you are starting with a new password Also be sure not to leave a Service password enabled once you are done servicing the unit To turn off a service password simply hit clear The buttons are shown below Overall d amp D Process Trending A E aj al Input Out
47. wn in the case that two or more extruders are overlapping each other Without these indicators you would not be able to see the some of the extruders if they were at the same position on the graph Gauging Page Page 8 of 31 Description This page is accessed by touching the Gauging button that is located on the top of the Coexpert screen and is only available when a gauge has been interfaced under Setup Gauging Interface Setup This page shows a graphical representation of the up to three gauges The current value of the gauge and gauge setpoints are also shown This is a real time measuring system for interfacing an analog output from a gauge into the Coexpert system Explanation of Items Shown Gauge 1 Gauge 2 and Gauge 3 buttons these buttons are located on the left side of the page If only one gauge has been interfaced then you will not see the other two buttons The current selected gauge will have a yellow light on its button Touch the gauge that you wish to view and the corresponding gauge data will be shown on the graph High Tolerance entry box this box is located on the right side of the graph Touching this box brings up a number pad that allows the operator to enter in the acceptable high tolerance of the product Target entry box this box is located on the right side of the graph Touching this box brings up a number pad that allows the operator to enter in the nominal target value of the product
48. xpert will examine the signal and scale it using the other parameters Page 12 of 31 F Coexpert 5 1 Installation and Service Manual Terminals this shows where in the Coexpert panel the analog input should be wired into Carefully note the polarity Reference this is only used with the Ramp Control algorithm It determines which extruder you want to be affected by the Ramp Control algorithm Adjust the set points on the Gauging page so that the product is in the In Spec range Next slow the Master Control ratio to a realistic value that would be used by the operator slow the line down for a paper change Using the Gauging page watch the gauge change Don t adjust any speeds After 2 6 minutes you will see the gauge start to climb back to where it should be Record this time and set the Ramp Control Steady Timer to a value that is greater than this time To finalize this setting enable the Ramp Control algorithm and run the line in Control by Weight mode Slow the line down by entering in a lower line speed and examine both the Gauging page and the Gauge Control Active message on the Overall View page Run the test until the Gauge Control Active message goes off for a few minutes This ensures that the Ramp Control algorithm is finished By analyzing the results you should be able to fine tune the algorithm and reduce the amount of product that falls Out of Spec Reference from Coexpert to Gauge Section
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