Max Machinery MP370 User manual

Users Guide for MP370
Touch Panel Control System

Table of contents
Screens
Home ...................................... pg 3
Component .............................. pg 4
Calibrate ................................ pg 5
Component Alarm ................... pg 6
Component PID Temp ............... pg 8
Component PID Flow ................ pg 9
Heater ................................... pg 10
Heater Alarm .......................... pg 11
Heater PID Temp .................... pg 1 2
Chiller .................................... pg 13
Chi ller Alarm ........................... pg 1 4
Mixer ..................................... pg 15
Mixer Alarm ............................ pg 16
Mixer Purge/ Flush /Lube .......... pg 1 7
Vacuum Cold Trap .................. pg 1 9
Vacuum Cold Trap Alarm ......... pg 20
System ................................... pg 21
Timer ..................................... pg 22
Administration ........................ pg 23
Alarm Log .............................. pg 24
Security Access ....................... pg 25
Back up and Restore ............... pg 26
Screen navigation ......................... pg 27
Please Note: this manual is designed to be a quick reference guide and training aid in the use of
the MP370 machine interface. The operation of the Max urethane processor is easily mastered
and with this guide, yo u will be able to operate the machine quickly and with confidence.
Areas regarding the mechanical systems and maintenance of the machine can be found in the
main processor manual.
Configurations and q uestions not covered in this manual should be referred to the Technical
Service Department at Max Machinery, Inc (707) 433 - 7281
© Max Machinery, Inc. Rev. 7 /2/07

Screens
Home
The Home Screen is the main operator interface to the machine. All standard operating
pa rameters are displayed for easy verification of proper operation. Each tank icon contains that
components ’ tank level, tank and processing temperature, pouring and recirculation pressure,
the flow set point, the actual flow rate the flow control mode and whether the pour valve is
currently enabled.
The Mix head icon reports the current temperature and mixer RPM. To the left is an indication
of the shot time and sum of the flow set points. To the right is a report of the mixer switch
position and the prog rammed response of the pot life timer.
If installed, t he icons along the bottom access Log -out, recipes (an optional function) , the
heater /chiller (s), vacuum pump(s), the muting of the alarm and the System Screen
Touching the top half of the tank icon will access the component screen and alarm input
screens.
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User Name
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12
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31
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2000 10
:
59
:
59
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Run
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Timer
:
Off
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Total Delivery
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Pour Time
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Potlife Action
_
None
_
Mixer State
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Off
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OFF
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C
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OFF
_
D
_
OFF
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B
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000 °C
_
Tank
_
Pour
_
Recirc
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000 °C
_
Line
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000
°C
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Tank
_
Pour
_
Recirc
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000
°C
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Line
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000 °C
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Tank
_
Pour
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Recirc
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000 °C
_
Line
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000
_
OFF
_
A
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Po
ur
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Recirc
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000
°C
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0000
.
00
_
g/min
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0000
.
00
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g/min
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0000
.
00
_
g/min
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0000
.
00
g/min
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0000
.
00
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g/min
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0000
.
00
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g/min
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0000
.
00
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g/min
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0000
.
00
_
g/min
_
0000
ps
i
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0000
psi
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0000
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psi
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0000
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psi
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000
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0000
psi
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0000
psi
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0000
psi
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0000
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psi
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0000
_
rpm
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N
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N
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N
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N
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0000
.
00
g/min
_
000
_
%
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0000
.
00
_
sec
_
000
_
%
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000
_
%
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000
_
%
_
Line
_
Tank
°C
°C
_1
_2
_1
_2

Screens
Component
The Component screen is where the operator controls T emperature, Flow Rate, Level and
Pressure. The operator can also access the Temperature P.I.D, Flo w Rate P.I.D, Calibration
and Component Alarm windows.
There are multiple temperature zones. The drop down menu allows you to individually select
the temperature offset of the zone relative to the process temperature shown above. Process
temperature typi cally refers to Line temperature at the 3 - way valve.
Level control will operate the automatic fill valve to start and stop the filling process. Note: to
start the flow from a new supply barrel may require cycling the control button several times
until th e material reaches the fill valve level probe. A time out function is used to prevent the
imploding of empty barrels. Repeated activations will rewet the probe.
Flow rate can be controlled by monitoring the pump speed or the flow meter output signal.
Se lect the appropriate control point and input the set point for your recipe.
Pressure is usually controlled automatically. In the manual mode you can bias the recirculation
pressure for very short shots – please consult the factory for direction.
Agitator control is an On/Off choice.
Icons at the bottom are links to the following pages.
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12
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2000 10
:
59
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59
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Run
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Timer
:
Off
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0000
.
00
_
OFF
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Set Point
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Error
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0000
.
00
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0000
.
00
_
g/min
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0000
.
00
_
Control
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Output
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OFF
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Control
_
g/min
_
00
.
0
_
%
_
%
_
Pour
_
Recirc
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Delta
_
Pressure
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0000
_
0000
_
0000
_
Mode
_
psi
_
Level
_
000
_
000
_
000
_
°C
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A
_
A
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Flowrate
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Pumprate
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Temperature
_
A
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Flow Rate
_
A
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Agitator
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A
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000
°C
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000
°C
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000 °C
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000
_
Control
_
000
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Off
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Manual
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Start
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psi
_
psi
_
%
_
%
_
%
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Tank Stop
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Tank Level
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Tank Start
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Fill Valve
_
%
_
Text
_
g/min
_
F
ill Level
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LINE
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Zone
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Current
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Offset
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Control
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Off
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Heat
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Cool
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Off
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Run
_
Standby
_
Off

Screens
Calibrate
The Calibrate screen is used to calibrate the flow meter and pump output for an individual
component, line pressure can a lso be monitored and controlled from the calibrate screen.
NOTE: You cannot enter the calibration screen during a pour, flush or material purge of the
mix head. Entering or leaving this screen will set all pour valves to “N” to prevent
unintentional pour ing of chemicals.
Before any short duration shots are performed, the pour and recirculation pressure need to be
balanced. Establish the flow rate you intend to use. Cycle the pour valve and compare the
displayed values. In automatic mode, the PLC will b alance the two values. In manual mode,
you can use the +/ - keys to adjust the recirculation pressure until it matches the pour pressure.
A calibration check should be done for both the Flow Control choice and the Pump Control
choice. ( In systems that do not have flow meters , only the Pump Control choice will be valid.)
The intended flow rate for this component should be entered as the Set Point. Select a pour
time that will create a sample of at least 100 grams. Push the “start pour” button on the mix
head control box, collect and weigh the sample. Input the sample weight into the “Measured
Pour” field and hit the “Calibrate” button.
Calibration values that exceed the previously defined maximum Flow or Pump rate, or that
change the density value by mo re than 10% will trigger a warning message. Double check the
weight and entered value before accepting the adjustment.
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12
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2000 10
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59
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59
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Run
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Timer
:
Off
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0000
.
00
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0000
.
00
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Set Point
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0000
.
00
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0000
.
00
_
0000
.
00
_
Pour Time
_
000
.
00
_
sec
_
Control
_
Measured Pour
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Pump Max
_
OFF
g/min
g/min
g/min
g/min
_
Flow Max
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Flowrate
_
Pumprate
_
N
_
Pour
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0000
.
00
g/min
gram
s
_
Calibrate
_
Reject
_
Accept
_
CALIBRATION CHANGED MORE THAN
10
%
_
CHECK YOUR SETTINGS
!!
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Pour
_
Recirc
_
Pressure
_
0000
_
0000
_
Mode
psi
_
Manual
psi
_
A
_
Calibration
_
A

Screens
Component Alarm
The Component Alarm screen is where the operator sets alarm limits and actions for
component Temperature, Flow Rate, Level and Pressure.
Temperature: Select which zone to set alarm settings for by selecting the Zone list box. Set the
desired Hi and Lo temperature alarm set points and the associated actions. The Lo 2
temperature alarm set point value is an absolute value and its action is hard coded as “MO” -
motor off.
Flow Rate: Set the desired Hi1, Hi2, Lo1, Lo2 flow rate alarm set points and the associated
actions. All alarm set points are relative to the current flow rate.
Tank Level: Set the desired Hi and Lo Tank level alarm set points and the associated actions.
All alarm set points are absolute values.
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12
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31
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2000
10
:
59
:
59
_
Run
_
Timer
:
Off
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000
_
000
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FS
_
%
_
%
_
000
_
000
_
NA
_
psi
_
psi
_
000
_
000
_
psi
_
psi
_
000
_
000
_
000
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NA
_
NA
_
%
_
%
_
%
_
000
_
000
_
NA
_
NA
_
%
_
%
_
00
0
_
000
_
%
_
%
_
0000
.
00
_
%
_
LINE
_
000
_
000
_
000
_
NA
_
NA
°C
_
Zone
_
000
°C
°C
_
MO
_
Tank Level
_
A
_
Flow Rate
_
A
_
Temperature
_
A
_
Fill Level
_
A
_
Pressure
_
A
_
Delta Pressure
_
A
°C
°C
Actions:
IP - Inhibit next pour SP – Stop pour
MO - Motor off FS – Filling stopped VO - Vacuum off

Fill Level: Set the desired Lo supply level alarm set point. The Lo supply level alarm action is
hard coded as FS.
Pressure: Set the desired Hi pressure alarm set point and the associated action. The Hi
pressure alarm set point is an absolute value.
Delta - Pressure: Set the desired Hi pressure alarm set point and the associated action. The Hi
pressure ala rm set point is an absolute value.

Screens
Component PID for Temp
Each temperature zone has P.I.D. tuning for optimum temperature control. These values are set
at the factory and are based on the response rate of the tanks, lines and other components to the
input of hot glycol. These values should not be adjusted without first consulting with the
Technical Service Department at Max Machinery.
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12
/
31
/
2000 10
:
59
:
59
_
Run
_
Timer
:
Off
_
LINE
_
Current
_
Bandwidth
_
Duty
Cycle
_
Zone
_
Temperature P
.
I
.
D
.
_
Auto Reset
_
000
°C
_
00
.
0
_
000
_
0000
_
%
_
000
°C
_
000
°C
_
Run
_
Standby
°C
_
sec
_
A
_
PID Reset
_
Reset

Screens
Component PID for Flow
Both the flow meter signal and the pump motor controller have P.I.D. tuning for optimum
closed loop control. These values are set at the factory and are based on the response rate of
the pumps and meters to a change in flow conditions or set point. These values should not be
adjusted without first consulting with the Technical Service Department at Max Machinery.

Screens
Heater
Each glycol heater system can be independently activated and be set with a Run temperature
and a standby temperature. The control options are Off, run the pump only, or run the heater
and pump. Additional safety feature information is also displayed: The back up safety
thermocouple, the delta temperature between the two probes and the level in the glycol
reservoir – any of which will shut off the heater if a fault is detected.
The heater alarm configuration screen is accessed by selecting the “Beacon” button
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12
/
31
/
2000 10
:
59
:
59
_
Run
_
Timer
:
Off
_
OFF
_
000
_
000
_
000
_
000
_
000
_
Current
_
Safety
_
Delta
_
Level
_
000
°C
°
C
°C
°C
°C
_
Control
_
%
_
R
un
_
Standby
_
1
_
Primary Heater
_
Temperature

Screens
Heater Alarm
The Main Glycol heater has redundant safety settings. All alarm set poi nts are hard coded
to shut off the heater if any parameter is out of limits. These values are set to typical
operating ranges and do not need adjustment. Lower trigger points can be programmed if
desired.

Screens
Heat er PID for Temp
The glycol heater has P.I.D. tuning for optimum temperature control. These values are set
at the factory and are based on the response rate of the heater relative to the demand. These
values should not be adjusted without first consulting wit h the Technical Service
Department at Max Machinery.
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_
12
/
31
/
2000 10
:
59
:
59
_
Run
_
Timer
:
Off
_
Auto Reset
_
BandWidth
_
Duty Cycle
_
Current
_
000
°C
_
000
°C
_
000
°C
_
000
_
%
_
00
.
0
_
00
.
0
_
Run
_
Standby
°C
_
min
_
1
_
Primary Heater
_
Temperature P
.
I.
D
.
_
0000
.
0
_
Error
_
PID Reset
_
Reset
°C

Screens
Chiller
The Chiller screen is where the operator can turn the Chiller on and off, set the desired
temperature and monitor current temperature.
The chiller alarm configuration screen is accessed by selecting the “Beacon” button.
_
_
12
/
31
/
2000 10
:
59
:
59
_
Run
_
Timer
:
Off
_
000
_
000
_
Setpoint
_
Current
°C
_
Control
_
Off
°C
_
Chiller
_
1
_
Temperature

Screens
Chiller Alarm
The Chiller Alarm screen is where the operator sets the high alarm and monitors the current
temperature.
_
_
12
/
31
/
2000 10
:
59
:
59
_
Run
_
Timer
:
Off
_
000
°C
_
000
°C
_
Chiller
_
1
_
Temperature

Screens
Mi xer
The Main mixer screen offers temperature, mixing and flushing control. The mixer zone has its
own run and standby temperature settings, the ability to activate the control function and a
direct shut off of the heating function.
The Pour Type ch oices are timed duration, continuous pouring on “start” until the “stop” button
is pushed and momentary pouring as long as the “start” button is depressed. The mix motor
can be set to run continuously or only during the pouring interval. To insure proper mixing of
the chemicals, during shot operation, an up - to -speed setting of mixer RPM will delay the pour
valves until the mixer is spinning at the minimum desired speed. The actual speed is indicated
as is the level of the mixers lubrication supply.
The p ot life action choices are; none, warning only, automatic flushing or reci pe purge. The
chosen action is initiated if mixed material remains in the mix chamber longer than the selected
time. At the end of each pour, the remaining pot life will appear in the indication window. As
a reference, the flushing solvent level is also displayed on this screen.
The center icons access the PID settings for the temperature control and the purge/flush/lube
settings.

Screens
Mixer Alarm
Available alarms and a ctions for the Mix head are temperature, lubrication level and solvent
level. The high and low temperature alarms can be set to either inhibit the next pour or stop the
pouring, with the low - low alarm hard coded to stop all pouring. The action available for the
low lube and low solvent is to inhibit the next pour.

Screens
Mixer Purge/Flush/Lube
Th e action choices for clearing the mix head of reacting material are a recipe purge to refresh
the mix chamber or a solvent flush. The duration of the material purge should be enough time
to displace one chamber’s worth of the current recipe. This value can be calculated by dividing
the mix chamber volume by the flow rate of the complete mixture.
The Auto Flush cycle uses a repeated sequence of air and solvent injections separated by a high
speed rotation of the mixer shaft in a chamber full of solvent. Depending on the reactivity of
the urethane, 2 or 3 cycles are usually sufficient. The factory settings for the air, wash and soak
durations we re tested before shipment. If you find build up in the chamber, consult with the
Max Technical Service staff before changing these time durations.
Mix head lubrication should be set to Auto Lube. The accumulated pouring time and the
duration of the lube flow are set at the factory. The Start/Stop controls are provided to recharge
the mixer bearing gland following a mix head servicing. Do not run the bearings without
lubricant. Use the start command until lubricant appears in the top drain line, then set the
control to Auto.

Screens
Mixer_PID_Temp
The mix head temperature zone has P.I.D. tuning for optimum temperature control. These
values are set at the factory and are based on the response rate of the mix head t emperature to
the input of hot glycol. These values should not be adjusted without first consulting with the
Technical Service Department at Max Machinery.
_
_
12
/
31
/
2000 10
:
59
:
59
_
Run
_
Timer
:
Off
_
Current
_
BandWidth
_
Duty Cycle
_
Reset
_
000
°C
_
Run
_
Standby
_
000
°C
_
000
°C
_
00
.
0
_
00
.
0
_
0000
_
min
_
%
°C
_
Reset
_
PID Reset
_
Mixer
_
Temperature P
.
I
.
D
.

Screens
VacColdTrap
The vacuum pump oil is protected by the co ld trap. To prevent chemical emissions from
entering the pump or work environment, the pump is interlocked to the cold trap and should not
be operated until the cold trap reaches operating temperature. The control of the Vacuum pump
is Off, immediate On or Auto. In the Auto position the pump will start running as soon as the
cold trap reaches the Start temperature.
The control of the Cold Trap is either Off, On to chill the trap or Defrost to reverse the
compressor and melt out the accumulated vapors.
_
OFF
_
Start
/
Stop
_
000
°C
_
Control
_
OFF
_0
00
_
Current
_
Defrost
_
000
°C
_
Control
°C
_
Vacuum Pump
_
1
_
Temperature
_
Cold Trap
_
1
_
Temperature

Screens
VacColdTrap_Alarm
The cold trap temperature can be alarmed as an alternative to being interlocked to the vacuum
pump. The action choice is VO, vacuum off. Setting this temperature will disable the vacuum
p ump, even if the pump is set to the ON position.
_
_
12
/
31
/
2000 10
:
59
:
59
_
Run
_
Timer
:
Off
_
000
°C
_
000
°C
_
NA
_
Cold Tr
ap
_1
_
Temperature