MUST HAVE

1. MUST HAVE SHOULD HAVE COULD HAVE Module # 120

2. Communicating with a Host Controller • Will know: • Supported communications • Sequence of events when talking to a Qi Matroller • Tools available to simplify the process

3. Batch Control Software PAM & CPM Services FBM Fieldbus Ethernet TCP/IP 1 Measurement Devices Scales & Flowmeters

4. Qi  Host, Communications • ControlNet • Scheduled (All Channel data) • Unscheduled (Commands to QiMPACT) • EthernetIP • ControlNet over Ethernet • Unscheduled only • Uses same ControlNet board • NOTE: Must be enabled, as ControlNet is default setting • ProfiBus • Scheduled only • Honeywell C200 – same as ControlNet • Scheduled (All Channel data) • Unscheduled (Commands to QiMPACT) • DeltaV • EthernetIP, (also has a ProfibusDP interface)

5. ControlNet • ControlNet • Two type of communications • Scheduled (Cyclic) • Unscheduled • Ethernet IP • Unscheduled only

6. A Qi Cluster(single PAC database throughout) • 1 x ControlNet network • 2 x Qi “Bridge” • 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 2x Scale Term 4 CNet 4x FlowM 2x Scale Term 1 4x FlowM 4x FlowM Term 2 4x FlowM 4x FlowM 2x Scale Term 3 2x Scale Ethernet Hub

7. A Qi Cluster(single database throughout) • 2 x Qi “Bridge” • 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 • Ethernet IP between the PLC and QiMPACT • NOTE: ControlNet board is required! # 4 2x Scale 4x FlowM Ethernet IP 2x Scale # 1 4x FlowM 4x FlowM # 2 4x FlowM 4x FlowM 2x Scale # 3 2x Scale Ethernet Hub

8. System info (8 wrds) Assy Slot 1 (10 wrds) Assy Slot 2 (10 words) Assy Slot 3 (10 words) Assy Slot 24 (10 words) Cyclic Data Flow Scheduled CNet comms (cyclic) Note: Channel data is not fixed to an Assembly Slot !! CNet Bridge 248 words retrieved by PLC per Qi bridge Remote Remote Cyclic data block Qi Bridge and remotes

9. Values Channel Gross Weight Feed Weight Flow rate Time to complete Slow step timer Status bits Alternating bit Channel OK! Scale under zero Scale in motion Transfer active Control O/P ON (FCE) Feed Failed Comms error Waiting for Ack Scheduled CNet comms (content) For the detailed content see document Cmds&Stat.doc

10. Command to Start Transfer sent to Qi Pause Read and confirm command has been actioned Some Status responses: 0 to 5 = command success 6 processing command – retry 9 invalid command Range is 0 to 34 Start Mat Transfer command Read status back Unscheduled – Typ. command sequence Pause

11. Unscheduled Cnet comms (Commands) • Used to send commands to Qi • Ie • Start Material Transfer: • Channel # • Sequence # • Material path • Command number : • 1 for “Start Material Transfer” • 4 for “Ack Material Transfer Complete” • Target Weight and Tolerance • User defined text string • Used to read data from the QiMPACT • Ie the result of the Command just sent • Used Access any other data (shared data)

12. Host Controller Integration – some tips Pg. 1 of 3extracted from: “Qi_Integration - Best Practices.doc” • Qi Ready to Start ? • There are aprox 8 bits available to the controller via the cyclic data which should be examined to determine whether the Qi is in a state to accept a new “Feed Command”. These should be evaluated! • Time interval between sending commands to the Qi Matroller • The time that the Qi takes to evaluate and act on a command varies from 60 mS to 300 mS. Factors which influence the response time are whether it is a local or remote channel or a scale or flow meter based feed (scale is faster) Be sure to evaluate command response code “6” if sending commands in less than 300 mS • Matching the Command sent with the Response read • A mechanism exists whereby it is possible to make sure that the command response that you have just read is the latest response or the previous commands response (ie old data). Essentially, some of the “Sent” data is echoed in the “Response” data. You MUST compare and match these fields correctly! ! “Best Practices” when integrating with a Qi Matroller !

13. Host Controller Integration – some tips Pg. 2 of 3extracted from: “Qi_Integration - Best Practices.doc” • Getting out of Synchronization (Lockstep) • Your application should be structured so that a command can be edited and repeated. This is required in the case of an invalid command being sent which is then rejected by the Qi. The Qi will then be ready to accept another (valid) command. • Are we in Control ?? • The Qi Matroller is an autonomous device. And like all such devices which act independently, they should be monitored constantly to ensure that they are functioning correctly. There are a number of parameters which MUST be monitored contantly. If any of these are not in their “normal” state then the feed should be stopped immediately. Refer to above mentioned doc for details • Stopping Feeds • It is essential that a PLC controlled relay contact is in series with each of the Qi FCE O/P’s, even flow meter based feeds. This allows the PLC to be in “ultimate control” should their be a catastrophic failure of the Qi. ! “Best Practices” when integrating with a Qi Matroller !

14. Host Controller Integration – some tips Pg. 3 of 3extracted from: “Qi_Integration - Best Practices.doc” • Selecting an Ethernet Switch • Mettler-Toledo recommends that any Ethernet switch selected for use within a Q.i Matroller cluster should be capable of having its ports manually set to operate in the following mode: • 10 Mbits/second, HALF-Duplex, NO AUTO-NEGOTIATE. • Some switches set to the AUTO-NEGOTIATE mode have been found to incorrectly select FULL-DUPLEXfor the port setting if the negotiation process fails. This can lead to unreliable communications between the terminal and other devices

15. Command & message sequence • PLC reports to Scada • Next sequence will start • High Speed control done entirely by the QiMPACT • Recipe resides in SCADA • PLC will initiate sequence • PLC retrieves Recipe or next ingredient • PLC composes message and sends StarFeed command to QiMPACT • QiMPACT takes control of the Feed • QiMPACT completes the feed • QiMPACT reports end of feed data to PLC SCADA PLC CNet 2x Scale 4x FlowM

16. Tools to Simplify the Integration process • AIM – (Application Interface Module) • AIM Explorer • AIM Simulator • Note: Explorer and Simulator are one item. • These tools currently only exist for some Allen Bradley products • Read and take special note of: Qi_Integration - Best Practices.doc • Other “must have docs” for integrators: • Apc_mesg.doc (covers comms structure) • Sharedat.doc (list of all accessible shared data variables) • Documents available for FTP transfer from: • ftp://ftp.usa.mt.com/pub/indmkg/Qi - LOOK HERE!/

17. The AIM • AIM is PLC code • AIM takes care of low level comms to the Qi MAtroller • User application talks to the AIM and not directly to the Qi • The AIM is optional but recommended • The Aim is purchased separately PLC program User PLC Code AIM

18. Target Target Target Target MP MP MP MP ScA ScC ScB Start Start Start Start Finished Finished Finished Finished Flw1 The AIM in detail • The AIM is scaleable • Will work with the largest Cluster Register Array Aim scans all channel data USER APPLICATION The “AIM”

19. AIM Explorer and Simulator • AIMse – is a PC based application • Upload/download of AIM configurations to/from PLC • Logging of AIM data values to PC • Available in Standard and Professional versions • Professional offers simulation capability • Reference: AP01.BR04 AIMse.pdf for a more detailed description • Explorer is used to configure the AIM in the PLC • Setup number of channels and various parameters associated with these intruments and timers. • Simulator is used to simulate a Qi for design and development purposes • AIM is switched to simulation mode • Simulator places data into the input buffers of the AIM in the PLC • User Application now thinks that there are Qi Matrollers connected • Simulator uses RSLinx to communicate with the AIM’s data registers over EthernetTCP/IP • Reference: AP01.BR04 AIMse.pdf for a more detailed description

20. AIMse • Switch between comms to Qi or AIMse • AIMse will simulate Qi behavior Normal & Simulation AIMse RsLinx Ethernet Application CNet AIM I/P Buffer

21. AIMse Screen captures

22. Review Questions • The commmunications between the PLC and The Qi is: • a) Parallel • b) Serial • What is the purpose of the AIM • Must the AIM always be used

23. Ethernet IP comms • Only Unscheduled comms only • Sending commands and reading data identical to CNET • Note: MSG addressing is different • The scheduled cyclic data accessed by using an unscheduled message read to the relevant address • This read command must be set to run every 500 to 1000ms • The content and structure of the message blocks is the same as with CNet

24. 120T - Revision notes • ControlNet is enabled by default • EthernetIP must be enabled and its IP and subnet mask entered. • Qi does not support DHCP • The Assembly slot is the Channels indexed position in the Cyclic data to the host controller. (Assembly slot number is found on the Channel config page) • After sending a Command always read the Command Status. • The Command Status MUST ALWAYS be made available to the operators, especially when the Status value is > than 5. • The AIM is optional code which simplifies interfacing to the Qi Matroller • The AIMse can be used to simulate a large cluster of Qi’s • Commands must be sent sequentially to the Qi. • If a Channel is busy feeding you cannot send another command to that channel • Monitor channels toggle bit, if it stops toggling disable material feeds • Monitor channelOK status bit, if it turn Off, disable feed and abort any feeds using this channel