Module # 020 MUST HAVE SHOULD HAVE COULD HAVE Talk about how it all fits together Module # 020

Qi System Architecture Objectives Know where the Qi physically fits, in the Control system Aware of Cluster’s and their growth structure  Be able to describe the function of the Matroller Be able to describe where the Matroller takes control of the batch sequence, and where it relinquishes control. Reference material: Qi –Technical Manual Ch 11 - Glossary

Configuration & Setup Sequence Plan hardware options (scale, flowmeter cards, etc) Construct (install cards) Calibrate instruments ------------------------------------------------------------------------------ Plan PAC configuration (# Material Paths, Channels) Configure PAC database Commision Materials and Channels Optimize PAC parameters System Overview Control Hardware

A Qi Cluster - standalone Valves controlled by Qi Matroller Valves controlled by Qi Matroller Flowmeter Reports Controlled via JagBASIC JagBASIC writes to shared data variables “Lite” will Support Two speed feed !

A Qi Cluster – PC Control Controlled via PC based application Valves controlled by Qi Matroller Valves controlled by Qi Matroller Flowmeter Reports Ethernet Qi 365 ! JagBASIC writes to shared data variables User Program Use: Mettler Toledo API UDP Commands

Optional A Qi Cluster - simple SeparateEthernet PLC is starting feeds using hardwired logic into the Matroller Inputs Only for small systems !! Optional Qi 365 ! SCADA Valves controlled by Qi Matroller AND PLC Valves controlled by Qi Matroller AND PLC SeparateEthernet Flowmeter PLC Start Abort 2x Scale Control of Matroller via discrete I/O NB: only for small systems due to limited I/O available Control wiring omitted for clarity 4x FlowM JagBASIC program required ! Valves controlled by Qi Matroller AND PLC

Optional A Qi Cluster - simple SeparateEthernet Qi 365 ! SCADA Valves controlled by Qi Matroller AND PLC Valves controlled by Qi Matroller AND PLC Optional Qi 365 ! SeparateEthernet SCADA Flowmeter PLC CNet 2x Scale PLC with one Qi on ControlNet Hub not shown 4x FlowM Valves controlled by Qi Matroller AND PLC

Requires a CNet comms card for CNet AND EtherNetIP !! A Larger Cluster Requires a CNet comms card for CNet AND EtherNetIP !! 2x Scale Term 4 CNet 4x FlowM 2x Scale Term 1 SeparateEthernet 4x FlowM 1 x ControlNet network 2 x Qi “Bridges” 1 x Qi “Master” 3 x Qi “Remote” 28 x Channels ( 1 to 28 ) 22 x Assembly Slots (1 to22), bridge 1 6 x Assembly Slots (1 to 6), bridge 2 1 x Ethernet TCP/IP network 4x FlowM Term 2 4x FlowM 4x FlowM Illustrate that there as the system grows additional “bridge” Qi will be required. Which is the Master? 2x Scale Term 3 2x Scale Ethernet Switch

Qi Matroller position in a Batching System Last control component in the sequence Receives Target and Material info (with implied Start Command) Reports back to Control system at the end of the Feed HMI PLC Qi Matroller Batch Server Multiple Recipes Target & Material Path Recipe Illustrating the movement of Command Qi processes the Recipe One Material (phase) at a time. Keeps a Channel and Material database

Commands The Matroller supports the following commands: Start Material Transfer. Start Material Transfer with Gross Weight Target. Start Hand Add. Acknowledge Material Transfer or Hand Add Complete Abort Material Transfer Reset Slow Step Timer Start Manual Mode Turn on FCE in Manual Mode – Target is ON Time Turn off FCE in Manual Mode Restart Auto Mode Complete Feed in Manual Mode Master Reset – Instrument channel Report Last Status Master Reset – Cluster Validate Aggregate Secondary Feeds Reset Local ControlNet Card Reset all ControlNet Cards in Cluster

Command Responses: (available after every command) After every command a response (Status) is available. SUCCESS – Command Complete SUCCESS – Start Gain-In-Weight Material Transfer Complete SUCCESS – Start Loss-In-Weight Material Transfer Complete. SUCCESS – Start Flow Meter Material Transfer Complete. SUCCESS – Start Validate Aggregate Feed Complete. SUCCESS – Start Hand Add Command Complete. Command Not Complete – Request status again after delay ERROR – Invalid Instrument Channel Number ERROR – Invalid Material-Path Table Index Number ERROR – Invalid Algorithm in Material-Path Table Entry ERROR – Invalid Feed Type in Material-Path Table Entry ERROR – Invalid Measuring Device Channel ERROR – Invalid Gain In Weight Feed and Dump to Empty Algorithm ERROR – Invalid Destination in Material Path Table Entry. ERROR – Other invalid data in Material Path Table Entry ERROR – Invalid data In Measuring Device Channel Table Entry ERROR – Requested add amount would bring Scale over capacity ERROR – Scale Device Currently over Capacity WARNING – Delayed start to feed due to overlapping feed. WARNING – Abort ignored, Time to Complete < Feed Override Time WARNING – Waiting for All Secondary Requests. WARNING – Waiting for Measuring Device Stability. ERROR – Device not configured or calibrated properly. ERROR – Communications Error ERROR – Invalid Command ERROR – Overlap Feed Request Error ERROR – Invalid Mode for Command ERROR – Requested add amount too small ERROR – Scale Device Currently under Zero ERROR – Instrument Malfunction ERROR – Target Weight is less than Spill ERROR – Response Timeout ERROR – Too many overlapping feeds ERROR – Invalid overlap group number ERROR – Not Enough Material.

Material controlled by PLC Qi wiring example 1 Material controlled by PLC +V MP2 MP3 CNet FCE Status is Read via the CNet Network MP1 Cyclic data is a slow update 3 materials Controlled by PLC PLC reads status of Qi FCE via CNet etc !! Update rate via Cnet is 500mS !! Qi must NOT be used like this - ever

Material controlled by PLC Qi wiring example 2 Material controlled by PLC +V MP2 MP3 CNet FCE Wired Directly To PLC MP1 PLC has a finite cycle time. This adds a varying delay to the Cutoff Control and degrades the accuracy 3 materials Controlled by PLC PLC reads status of Qi FCE PLC introduces delay !! Qi must NOT be wired like this

Material selected by PLC Qi wiring example 3 Material selected by PLC (steering Matrix) +V FCE MP2 MP3 CNet MP1 Same O/P is used by Qi to Control 3 Materials. PLC only ever has ONE of its Material Enables on at any one time. Called the Steering Matrix 3 material Controlled by 1 Qi O/P Qi is in DIRECT Control of the FEED Qi MUST be wired like this

Timing diagram – 3 MPs Qi FCE MP1 En MP2 En MP3 En Start Cmd MP1 Feeding Feeding Feeding Qi FCE MP1 En Note the OFF Delay ! MP2 En Special Note: The Material Enable (Select) MUST always stay on longer than the FCE O/P MP3 En Start Cmd MP1 Start Cmd MP2 Start Cmd MP3

Review questions How many simultaneous feeds can there be in a Matroller with 1 scale and 1 flowmeter  What will happen if the comms between the PLC and Matroller fails during a Feed Two, each Channel operates independently Qi will complete the Feed normally

Architecture, 020 - Revision notes The Qi Ethernet network must be physically separate from the admin and plant control network. (VLAN is sometimes acceptable) Do not rely on an Ethernet Switch to separate network traffic. Note the correct way of wiring the Qi O/P Controller board O/P1 is associated with ScaleA Controller board O/P2 is associated with ScaleB etc