Quality Improvements Quantity Increases Quantifiable Results Configuration and Run Exercise Press the Space Bar when ready to Continue.

Configuring and Running a Q.i System  Objectives:  Exercise what you've learned for the following: - Hardware Configuration - PAC Configuration  Learn how to start and monitor a feed from the Q.i Webpages  Exercise what you've learned about monitoring a running process (controlled by Task Expert) using the IND780 Q.i Dashboard. 1 Press Space Bar When Ready to Continue

Hardware that you will need In this module we will configure a working Q.i system and run it. For this exercise, you will need an IND780 with NO option cards installed. That means no Scale cards, no Flowmeter cards, no I/O cards, nothing at all! - Except - An I-Button for Q.i with 1 PAC license (Task Expert is included with Q.i) Note that a T.E button is shown, not a Q.i Button. 2 Press Space Bar When Ready to Continue

IND780 Q.i Terminal Chassis Review TCP/IP Ethernet Serial 1 Serial 2 Six option card slots: Four scales or Twelve flow meters or Mix of scales and flow meters USB I-Button Socket I-Button (Hardware Key) PLC Comm Battery Compact Flash (Memory Card) Auto Sensing Power Supply 3 Press Space Bar When Ready to Continue

World Wide WEB Hardware that you will need - continued You will need a computer that has access to BOTH the IND780's TCP/IP Ethernet Network, AND to the Internet at that same time. LAN Wireless Suggested Configuration DHCP Enabled Other configurations may work as well, but may also require that you use different IP Addresses than what are shown in the exercise. 4 Press Space Bar When Ready to Continue

Software to be installed 5 Press Space Bar When Ready to Continue Demo Starting Configuration.exe IND780QiDashboard_V_1.1.26_setup.exe Scale Simulator Install.exe Qi PC Tool Install version exe Click on the links below to download the install files for any of the following 4 tools not yet installed on your computer. Note that they should be installed in the order shown. After they have downloaded, please run the install files.

Prepare the IND780 6 Press Space Bar When Ready to Continue Every IND780 has an Ethernet connector mounted on its Motherboard. The PC running the IND780 Q.i Dashboard needs to be connected to this connector, either directly or via a Network. Note the Ethernet Connector's proximity to the USB connector. Connect the Ethernet TCP/IP Connection Perform a Master Reset on the IND Remove AC Power 2. Press and hold the Master Reset button, then re-apply AC Power. 3. Continue holding button until unit beeps and displays the "BRAM reset to Factory" message. 4. Press Enter to acknowledge each message box as it appears. Master Reset Button

Confirm the Ethernet Connection Configuration 7 Press Space Bar When Ready to Continue Confirm Ethernet TCP/IP Port Configuration 1. Go into Setup (use the arrow buttons to get to the setup menu key) 2. Navigate to "Communication | Network | Ethernet" 3. Confirm the IP configuration is as shown. Make any needed adjustments. 4. Exit Setup by repeatedly pressing the F1 Key Setup Key F1 Key If any changes were made, the IND780 will reset. When the IND780 is ready, ping it from the PC. If the ping fails, check the following: LAN configuration on the PC (must be on the xxx network) Check Ethernet cable connection between IND780 and PC PC must be set to some address OTHER than If you continue to have trouble, seek help from your network administrator. You may have to turn off your wireless connection to get this to work.

The Demo Starting Configuration 8 Press Space Bar When Ready to Continue - minimize the amount of equipment needed. - allow an 'automated' process to run during the exercise. Our exercise is going to take advantage of some scale and flow meter simulation capability that is built into the IND780. Simulators allow us to: We will also get to practice the steps needed to restore a configuration using the IND780 Q.i Dashboard

Download the Demo Starting Configuration 9 Press Space Bar When Ready to Continue From the IND780 Q.i Dashboard, download the Demo Starting Configuration: Important! The "Demo Starting Configuration" self extracting file must have been executed PRIOR to the following steps!Demo Starting Configuration Select "Restore Cluster" from the Menu as shown. Acknowledge any popups. From the IND780 Q.i Dashboard, enter the IP address " " as shown, then click the "Add IP Address" button. Click the 'Browse' button. Continued on next slide. Acknowledge any popups.

Download the Demo Starting Configuration Continued 10 Press Space Bar When Ready to Continue Continued from previous slide Select "Demo Starting Configuration" from the directory Check the "Force Terminal to Restart after download" checkbox. Acknowledge the popup. Go! Acknowledge the popup. "C:\IND780_Qi_Dashboard\BACKUP" Then click OK. All done! Acknowledge the popup.

Hardware Configuration Set up the Cluster 11 Press Space Bar When Ready to Continue NOTE that the order of these steps is very important! 1. Set up the Cluster Settings (even if you won't be using a cluster). From the Setup Menu, navigate to "Communications | Network | Cluster | This Terminal" and press Enter The Multicast IP Address MUST be unique from any other clusters. Do NOT leave this at the default address where it might conflict with any other IND780's on the network! Change the Node Number to 1

12 Press Space Bar When Ready to Continue From the Q.i's Setup Menu, navigate to "Application | Q.i Configuration | Terminal" and press Enter 2. Configure the Q.i Master Node (even if there is only 1 node) Hardware Configuration Q.i Master Node Change the "Master Terminal" setting to "Yes" Then exit the menu by pressing F1

13 Press Space Bar When Ready to Continue Even with the simulators in use, the Flow Meter configuration is almost the same as when using live Flow Meters. From the Setup menu, navigate to "Flow Meter | Channel 1" and press Enter 3. Configure the Flow Meters Hardware Configuration Flow Meter Setup Enter the settings shown. Scroll down and enter these settings as well. Do the same thing for Flow Meter Channel 2, except name it "FM2" instead. Exit the menu by pressing F1

14 Press Space Bar When Ready to Continue Start the Scale Simulator installed earlier 4. Configure the Scale Simulator Scale Simulator Setup Click 'Edit', and then 'Setup'. Click '+' Click 'Scale 1', and then enter the setting shown (5000 x 1, scale units = g) Click 'Apply', then 'OK' Select " " Click "Connect" When the simulator connects, the IND780 should now look like this:

15 PAC Configuration Overview 1. Control I/O Module 2. Equipment Channel Module 3. Material Path Defines what I/O to use Assigns an Instrument (Scale or Flowmeter) to a Channel. Defines which PAC algorithm to use, and ties everything together. Press Space Bar When Ready to Continue Now we're ready to start configuring the PAC Database. The PAC configuration consist of 3 major components

16 Start the Q.i Configuration Tool Press Space Bar When Ready to Continue Enter " " for the IP Address Then click "Connect"

17 Define Scale Control I/O Module Press Space Bar When Ready to Continue Click on "Control I/O Module" then "Scale" Enter the information as shown. Then click "Save" Followed by 'Cancel'

18 Define Flow Meter Control I/O Module Press Space Bar When Ready to Continue Click on "Control I/O Module" then "Flow Meter" Enter the information as shown. Then click "Save" Followed by 'Cancel'

19 Define Scale Equipment Channel Module Press Space Bar When Ready to Continue Click on "Equipment Channel Module" then "Scale" Enter the information as shown. Then click "Save" Followed by 'Cancel'

20 Define Flow Meter Equipment Channel Module 1 Press Space Bar When Ready to Continue Click on "Equipment Channel Module" then "Flow Meter" Enter the information as shown. Then click "Save" Followed by 'Cancel'

21 Define Flow Meter Equipment Channel Module 2 Press Space Bar When Ready to Continue Click on "Default" then "Save" Type "3" followed by a Tab. Click on "Default" then "Recall" Edit the circled information to match what is shown. Then click "Save" Followed by 'Cancel' This time, we'll take advantage of the Default "Save" and "Recall" feature.

22 Confirm the Equipment Summary Press Space Bar When Ready to Continue The form should now look like this. Now we can define the Material Paths. Make sure that yours matches this!

23 Define MP1 - DTE Press Space Bar When Ready to Continue Click on "Material Path" then "Material Path" Enter the information as shown. Then click "Save" Click on "Default" then "Save"

24 Define MP2 – K1 GIW Press Space Bar When Ready to Continue Type "2" followed by a Tab. Click on "Default" then "Recall" Edit the circled information to match what is shown. Then click "Save"

25 Define MP3 – FM1 K1 Feed Press Space Bar When Ready to Continue Type "3" followed by a Tab. When done, click on "Default" then "Save" Enter the information to match what is shown. Then click "Save"

26 Define MP4 – FM2 Spill Only Feed Press Space Bar When Ready to Continue Type "4" followed by a Tab. Click on "Default" then "Recall" Edit the information to match what is shown. Then click "Save" Followed by "Cancel"

27 Write the Configuration to the Q.i Database Press Space Bar When Ready to Continue The Configuration is complete! Now we have to tell the Q.i to use it. Click on "File" then "Synchronize All" We're Done! Acknowledge the nag.

28 Get Ready to Trigger Some Feeds Press Space Bar When Ready to Continue Let's see if everything works Make sure that the scale simulator is connected as shown. On the IND780 Q.i Dashboard, right-click on the Connection Status button for the IP address Right-clickClick Then click on "WEB Page" from the context menu. The IND780 Q.i Web Page should come up in your browser. Click Click on "PAC" Click on "Material Transfer Control"

29 Trigger a Gain In Weight Scale Feed Press Space Bar When Ready to Continue Type '1' in the Equipment Channel Module box Check the "Assume Control of Material Transfer" checkbox. Trigger a feed from the Web Page Acknowledge the nag. Select MP 2 Enter a Target Click the "Start Material Transfer" button. You should see the weight value increasing on the Terminal Display

30 Try Some Feeds On Your Own Press Space Bar When Ready to Continue Try the following feeds on your own 1.Main Scale Dump To Empty (DTE) Equipment Channel Module (ECM) = 1 Material Path (MP) = 1 Target = 0 2. Flowmeter 1 Feed ECM = 2 MP = 3 Target = Flowmeter 2 Feed ECM = 3 MP = 4 Target = 250 Hints: Use the "Home" button, then select "Material Transfer Control" when using a new ECM. If the "Start Material Transfer" won't enable, you may need to click "Start Refresh", "Stop Refresh", or "Material Transfer Acknowledge"

31 Material Transfer View Press Space Bar When Ready to Continue Try another feed. But this time, click the "Material Transfer View" button after the feed starts. From here you can monitor the progress of the feed When the feed completes, you can see the status – - as well as the statistics The form will continue to update if the ECM runs another feed.

32 Monitor a Running Process Press Space Bar When Ready to Continue On the IND780 Q.i Dashboard, click the "Connect" button. Make sure that the Trace Level is set to 2. On the IND780, press the F2 key. Then press the F1 key to start the process. The Dashboard will start collecting data as the process runs.

33 Monitor a Running Process Press Space Bar When Ready to Continue After letting several feeds run (5 minutes or so), click the "Archive Now" button. Accept the default settings by clicking "Archive" The "Archiving…" indication will flash. You will also see Excel run while it stores Feed History Records into a spreadsheet.

34 Locate the Collected Data Press Space Bar When Ready to Continue Click on "File", then click on "Explore Data" A Windows Explorer window will open, already pointing at the last data to be collected. Note that the data appears under the IND780_Qi_Dashboard's "Data" directory, in a subdirectory named after the current date.

35 Look at the Collected Data Press Space Bar When Ready to Continue The Summary report will show any errors that were recorded. Start your analysis here. The QITxx followed by a number is a unique tag associated with this error message. Copy it so we can search for it in the data. Open the Data File that's inside of this zip file. After finding the unique tag, you can look around here in the data to see what's going on. But mainly we're interested in the history record located below the error. Note that the mp=3, and the em=2, matches the 2 nd and 3 rd numbers of the record. The number just ahead of it (14) is the sequence number. We'll use this to find the History Record in the spreadsheet.

36 Locate the History Record Press Space Bar When Ready to Continue Open the History Record spreadsheet. Remember that we wanted Sequence #14 for em (chann) = 2 and MP = 3

37 Analyze the History Record Press Space Bar When Ready to Continue Because the Diagnostic Status is Negative, we have to add this value to it before we use it. So, paste it here, and then auto-sum the two together Copy the Diagnostic Status Then click on the "Decode" tab Note the Average Flow Rate

38 Analyze the History Record - Continued Press Space Bar When Ready to Continue Copy and paste the result here. Clues!Typo! These together suggest that the PAC algorithm never ran. Look at the EM configuration for EM2 to see what's going on. The flow rate (which we noted in the previous slide) is only 10 g/s. This is well below 50 g/s, so the PAC algorithm never got started. This is the problem! Fix it (should be 5, not 50) and we're done. Note that if the Diagnostic Status is positive to start with, we could just paste it into the top of column B without the Auto-Sum.

Farther down on the 'Decode' tab 39 More Information Press Space Bar When Ready to Continue Assembly 1 Status Assembly 2 Status Scroll this way to see the configuration. Scroll this way to see even more.

Congratulations! You made it! The End