Quick Start Guide

Configure the connection to your PLC or valve controller.

1. Launch the Dilution Control System
2. Go to Settings > Connection
3. Select your PLC Type:
   • Modbus TCP - Generic controllers, Festo CPX
   • Siemens S7 - Siemens S7-1200/1500
   • Beckhoff - Beckhoff EK9000, TwinCAT
4. Enter the IP Address of the PLC
5. Configure the Port (default: 502 for Modbus)
6. Click Test Connection to verify
7. Click Save when successful

Set up the dilution valve configuration to match your headbox.

1. Go to Settings > Actuator Configuration
2. Set the Number of Zones (typically 24-96)
3. Configure zone parameters:
   • Minimum Position: 0% (fully closed)
   • Maximum Position: 100% (fully open)
   • Stepping Limit: Maximum change per cycle (e.g., 5%)
4. Set register addresses if required (see PLC Integration)
5. Click Save Configuration

Configure the connection to your QCS/scanner system for profile data.

1. Go to Settings > Scanner Configuration
2. Select your Scanner Type:
   • ABB DIU / Accuray AC6
   • Honeywell Experion
   • Valmet / Metso IQ
   • Yokogawa CENTUM
   • JASCH
   • Generic Modbus
3. Enter the scanner IP Address and Port
4. Configure Profile Settings:
   • Databoxes: Number of measurement points (e.g., 200)
   • Update Rate: Profile update interval
5. Set Zone Mapping (front/back offsets)
6. Click Test to verify profile reception
7. Click Save

Before enabling automatic control, verify the system works correctly in manual mode.

1. Ensure the system is in Manual Mode (global mode selector)
2. Select a single zone in the Zone Control Panel
3. Manually adjust the setpoint:
   • Increase position by 10%
   • Verify the valve moves (check feedback)
   • Observe the effect on the profile
4. Test several zones across the web width
5. Verify the profile responds in the correct direction:
   • Increasing dilution should decrease basis weight
   • Decreasing dilution should increase basis weight

After successful manual testing, enable automatic control for profile uniformity.

1. Set initial Control Parameters:

   Control Mode	Integrating (recommended)
   Control Gain	0.3 (conservative start)
   Deadband	1.0 g/m²
   Control Interval	60 seconds

2. Set the Target Profile:
   • Use the profile average as the initial target, OR
   • Set a flat target at the desired basis weight
3. Switch individual zones to AUTO mode:
   • Start with center zones first
   • Gradually add edge zones
4. Monitor the system response:
   • Watch the error profile decrease
   • Verify valves are adjusting gradually
   • Check for oscillations (reduce gain if necessary)
5. Once stable, switch Global Mode to AUTO