Paper Machine Operator Interfaces

New Operator Interfaces were installed on a paper machine to replace obsolete CTC Access 4000 Panels. These are on-machine devices mounted in the operator bench boards. Columbia Automation Systems provided a system of fourteen Siemens MP270 Windows CE touch panel terminals on Profibus DP. The new panels connect to the existing AutoMax drive system using the Profibus scanner for Reliance AutoMax (SST-PFB-REL) from SST.

The AutoMax software has been revised for the new panels. The Profibus scanner is configured as a generic module in the AutoMax with variable names entered in the variable configurator. Additionally, a master reference task in function block language is used to replace the basic task used with the CTC panels. This provides a much cleaner software layout than the original system.

Information and control available to the operator is substantially increased with the new panels. These are full color graphical displays that have many more possibilities than the CTC panels. Standard paper machine drive system control features from CAS include the following:

Single screen overview of each section for ease of use
Full machine overview screen on each panel
Master machine speed on each panel
Speed, percent (%) load, & amps feedback displays
Start, stop, jog, and thread buttons
Speed, draw, and warm-up setpoint entry
Loadshare setpoints and monitoring
Redundant setpoint entry from neighboring benchboards allows uninterrupted machine control if one panel should fail as well as providing the operators flexibility during start-up
Pop-Up alarms and alarm history
Permissives overview and pop-up information on missing interlocks giving operators immediate information whenever a section will not start thus decreasing start-up time

The Siemens MP270 panels provide a low cost solution with many features such as built-in Profibus, Serial, and Ethernet ports. Siemens ProTool software runtime license is included on each panel. With this approach, we were able to meet our customer's needs by providing a leading edge system of operator interfaces directly conneceted to the existing drive system for minimal cost. The project was completed in three phases on regulary scheduled shutdowns over a six month period.