IND780batch EM, CM, and Material Path setup

Internal usage only 2 Batch Terminology - A Simple System Overview Control I/O Module - Defines what I/O to use Equipment Module - Defines which Scale or Flowmeter - Defines which Control I/O Module to use. - Defines Flow Rate Thresholds - Defines Process Times (Minimum Slow Step, Feed Alone, Stable Device, …) - Defines PLC Bridge Assembly Slot Material Path - Defines Source EM - Defines Destination EM - Defines Process Times (Slow Step, Minimum Open, Drain Timer) - Defines Flow and Spill Limits - Defines Jog Mode and Algorithm Correction

Internal usage only 3 IND780batch – Configuration Example This system is comprised of 1 scale, 5 automatic material feeds, 1 hand addition, 1 automatic discharge, 1 operator action station and 1 auxiliary control (mixer). The first thing to setup in this system is the Equipment modules and Control Modules for each Equipment Module.

Internal usage only 4 IND780batch - Configuration Equipment Modules in this system: 1.Scale 2.Operator Action Station 1 - Scale 2 – Operator Action Station

Internal usage only 5 IND780batch - Configuration First lets setup the Equipment Modules and Control I/O Modules for the Scale. 1 - Scale

Internal usage only 6 IND780batch - Configuration For the Scale EM and CM we have the following I/O assignments: Scale Fine Feed = ALC Card Scale Fast Feed = Output Material 1 = Output Material 2 = Output Material 3 = Output Material 4 = Output Material 5 = Output Hand Add = Manual Operation Discharge = Output Auxiliary Mixer Control = Output 0.6.3

Internal usage only 7 IND780batch - Configuration Now we can begin to setup our Equipment Modules. Fist highlight Equipment Module in the menu tree, then press Edit, New Equipment Module, and select Scale Equipment module.

Internal usage only 8 IND780batch - Configuration Next we can choose which scale this is (1 to 4), give our scale a name, and fill in the other parameter data as needed. In the next step we need to create our Control I/O Modules that are associated with Scale 1.

Internal usage only 9 IND780batch – Control Module Configuration This is the advanced tab of the Scale EM, and there are process parameters that can be adjusted here to optimize the material transfer functions.

Internal usage only 10 IND780batch – Control Module Configuration Next, we need to configure the Weigh In Control Module

Internal usage only 11 IND780batch – Control Module Configuration This is the advanced tab for the Weigh-Out CM, there are several parameters that can be configured here.

Internal usage only 12 IND780batch – Control Module Configuration Next, since we have several materials that we will Automatically feed into the system we need to create a WI Transport Header Control Module. Since we had already assigned our outputs to the materials in our example layout we can enter in these output numbers into the WI Transport Header CM screen above.

Internal usage only 13 IND780batch – Control Module Configuration Next, we need to configure the Weigh Out Control Module, and this will be the last CM for this scale. So we highlight 1-Batch Scale, then right click, select New, then Weigh- Out CM. Now you will see the screen above and since our Discharge Valve is assigned to output 0.6.1, we enter this into the Feed Control box, with the Feed Source being Other I/O, so the control know to point the discharge to this particular I/O point.

Internal usage only 14 IND780batch – Control Module Configuration This is the advanced tab for the Weigh-Out CM, there are several parameters that can be configured here.

Internal usage only 15 IND780batch – Control Module Configuration Next, we need to configure the Auxiliary Control Module for the Mixer, by right clicking on 1-Batch Scale, then New, Aux1 CM. You will not see the screen above and you can enter in the output that we assigned the Mixer control to which is

Internal usage only 16 IND780batch – Control Module Configuration Finally, we need to configure the Manual Operator Action Control Module for the Hand Add Material, by right clicking on 1-Batch Scale, then New, WI Man Operator Action CM. You will now see the screen above and you can enter in a unique description, and the I/O address for any assigned inputs and outputs associated with this Hand-Add.

Internal usage only 17 IND780batch - Configuration Next lets setup the Equipment Modules and Control I/O Modules for the Operator Action Station. 2 – Operator Action Station

Internal usage only 18 IND780batch - Configuration For the Operator Action EM and CM we have the following I/O assignments: Start/Resume PB = Input Pause/Abort PB = Input Stop button = Input Attention Light = Output 0.6.4

Internal usage only 19 IND780batch - Configuration This is the Operator Hold Equipment Module, which has been given a description of Operator Action Station.

Internal usage only 20 IND780batch – Control Module Configuration Next we need to define the Operator Action Control Module Inputs associated with this Operator Action Equipment Modules. We need to highlight the Operator Action Station, then right click, select New, then select Supervisor Action CM. Then you will see the right pane view show the above and we can enter in a unique Description, then assign the input addresses from our Operator Action Station, which is for the Start/Resume PB, for the Pause/Abort PB (Pause Batch and Abort Batch Inputs), and for the Emergency Stop PB (Batch Run Permissive).

Internal usage only 21 IND780batch - Configuration Next we need to define the Operator Action Control Module Outputs associated with this Operator Action Equipment Modules. We need to highlight the Operator Action Station, then right click, select New, then select Supervisor Status CM. Then you will see the right pane view show the above and we can enter in a unique Description, and then assign the output address for our attention light on our panel. In this case we will assign Batch Alarm and Operator Attention to our light with is output

Internal usage only 22 IND780batch: System Architecture This completes the setup of the Equipment Modules, and Control I/O Modules. Next we will look into how to setup the Material Paths.

Internal usage only 23 IND780batch – Material Path Configuration Material Path Configuration Material Path 5 Material Path 4 Material Path 3 Material Path 2 Material Path 1 Material Path 6 Material Path 7

Internal usage only 24 Feed Algorithms - Which one to use? There are three types of Gain in Weight (GIW) Algorithms - Spill (short or erratic behavior) - K1(most common) - K2(fast feeds, downwards into scale) - Hand Add These are your Loss in Weight (LIW) options - Spill - K1 (and less often, K2) - Dump to Empty (DTE) - Hand Add LIW - Hand Add DTE

Internal usage only 25 Feed Algorithms - Behavior Spill – The results of the previous feed are used to adjust the cutoff point of the next feed. Flow rate of the material is not monitored. K1 – The cutoff point is adjusted as the Flow Rate varies during the feed. This is a dynamic behavior. K2 – The cutoff point is adjusted as the Flow Rate varies during the feed. This is a dynamic behavior. Dump to Empty – will attempt to completely empty the scale. Hand Add – manual operation, waits for the operator to perform the material transfer and press OK to acknowledge material transfer is complete.

Internal usage only 26 Unfortunately the Final spill value is not always directly proportional to the Flow rate! Some components are Proportional and some are not The resultant Sum of all components is non Linear The complex mathematical algorithms are described as the PAC Algorithms - Technology patented by P&G, & exclusively licensed to Mettler Toledo It is these PAC Algorithms which result in the Qis accuracy and repeatability at higher flow rates Flow Rate Final Spill value Linear effect K1 K2 Final Spill. Summation of all graphs Non Linear effect IND780batch – Feed Algorithms

Internal usage only 27 Feed Algorithms - Which one to use? Spill Only (historic) - Very erratic flows or short feeds ( < 6seconds ) K1 - Materials which have initial downward velocity of zero i.e. horizontal entry - Materials which have slow flow rates Even if vertical entry - Flow meters, Screw Feeders, Vibratory feeders and Discharge weighing - When Spill is proportional to Flow The initial downwards velocity is zero

Internal usage only 28 Feed Algorithms - Which one to use? K2 - Materials which have fast flow rates directed downwards into the scale - i.e. there is a large deceleration force - Hint: spills are small in relation to the flow rate as the deceleration component is negative and subtracts from the inflight material - Non linear spill with regards to Flow Rate - As Flow Rate increases the amount of material in flight does so only slightly Material in suspension

Internal usage only 29 The Algorithms - Summary Spill (historic) - Very erratic flows or short feeds ( < 6seconds ) K1 - Materials which have initial downward velocity of zero Ie horizontal entry - Materials which have slow flow rates Even if vertical entry - Flowmeters - Loss In Weight Feeds K2 - Materials which have fast flow rates directed downwards into the scale - i.e. there is a large deceleration force - Hint: spills are small in relation to the flow rate as the deceleration component is negative and subtracts from the inflight material - Non linear spill, sometimes inversely proportional to flow rate

Internal usage only 30 IND780batch – Material Path Configuration To configure the Material Paths, we need to highlight Material Paths, right click and select New, then we will get a new Material Path screen on the right view pane. We can give the material a unique description, assign which scale (if more than one), this material will be assigned to, and choose the feed algorithm type, and transport header path number if there are more than one automatic material transfer.

Internal usage only 31 IND780batch – Material Path Configuration

Internal usage only 32 IND780batch – Material Path Configuration Now we need to setup Material Path 6 with is the Discharge (Dump to Empty) from the scale, so our Scale EM is 1-Batch Scale, our Destination EM is OUT_OF_CLUSTER, the Feed Algorithm is Dump to Empty, and there is no Transport Header Path # since this is a single outlet from the vessel.

Internal usage only 33 IND780batch – Material Path Configuration Finally we need to setup Material Path 7 which is the Hand Add, so our Scale EM is 1-Batch Scale, the Feed Algorithm is Hand Add.

Internal usage only 34 IND780batch – Flow Meter Configuration New to version 7.3.xx firmware, it is now possible to use a flow meter as part of your batch system. The following slides show the Flow Meter EM, CM, and MP configuration Control I/O Module This is the valve to control the feed Equipment Module The flow meter Material Path Defines what material and where the material goes

Internal usage only 35 IND780batch – Flow Meter Configuration To add a Flow Meter Equipment Module, right click on Equipment Modules and select New>Flowmeter Equipment Module

Internal usage only 36 IND780batch – Flow Meter Configuration We can choose which Flow Meter this is (1 to 4), give the Flow Meter a name, and fill in the other parameter data as needed. In the next step we need to create our Control I/O Modules that are associated with FM 1.

Internal usage only 37 IND780batch – Flow Meter Configuration

Internal usage only 38 IND780batch – Flow Meter Configuration To add a Flow Meter Control Module, right click on the Flowmeter EM and select New>Flowmeter CM

Internal usage only 39 IND780batch – Flow Meter Configuration

Internal usage only 40 IND780batch – Flow Meter Configuration

Internal usage only 41 IND780batch – Flow Meter Configuration

Internal usage only 42 IND780batch – Flow Meter Configuration

Internal usage only 43 IND780batch – Flow Meter Configuration

Internal usage only 44 IND780batch – Flow Meter Configuration