IND780batch

1. IND780batch EM, CM, and Material Path setup

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

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.

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

5. IND780batch - Configuration • First let’s setup the Equipment Modules and Control I/O Modules for the Scale. 1 - Scale

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 0.6.2 • Material 1 = Output 0.5.1 • Material 2 = Output 0.5.2 • Material 3 = Output 0.5.3 • Material 4 = Output 0.5.4 • Material 5 = Output 1.0.1 • Hand Add = Manual Operation • Discharge = Output 0.6.1 • Auxiliary Mixer Control = Output 0.6.3

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.

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.

9. IND780batch – Control ModuleConfiguration 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.

10. IND780batch – Control ModuleConfiguration Next, we need to configure the Weigh In Control Module

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

12. IND780batch – Control ModuleConfiguration 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.

13. IND780batch – Control ModuleConfiguration 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.

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

15. IND780batch – Control ModuleConfiguration 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 0.6.3.

16. IND780batch – Control ModuleConfiguration 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.

17. IND780batch - Configuration 2 – Operator Action Station • Next let’s setup the Equipment Modules and Control I/O Modules for the Operator Action Station.

18. IND780batch - Configuration • For the Operator Action EM and CM we have the following I/O assignments: • Start/Resume PB = Input 0.5.2 • Pause/Abort PB = Input 0.5.3 • Stop button = Input 0.5.1 • Attention Light = Output 0.6.4

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

20. IND780batch – Control ModuleConfiguration 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 0.5.2 for the Start/Resume PB, 0.5.3 for the Pause/Abort PB (Pause Batch and Abort Batch Inputs), and 0.5.1 for the Emergency Stop PB (Batch Run Permissive).

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 0.6.4.

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.

23. IND780batch – Material Path Configuration • Material Path Configuration Material Path 5 Material Path 3 Material Path 2 Material Path 4 Material Path 1 Material Path 6 Material Path 7

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

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.

26. IND780batch – Feed Algorithms • 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 Qi’s accuracy and repeatability at higher flow rates Non Linear effect Linear effect Final Spill value Final Spill. Summation of all graphs Flow Rate K1 K2

27. 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 Feed Algorithms - Which one to use? The initial downwards velocity is zero

28. 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 Feed Algorithms - Which one to use? Material in suspension

29. 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 The Algorithms - Summary

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.

31. IND780batch – Material Path Configuration

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.

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”.

34. Equipment Module The flow meter Material Path Defines what material and where the material goes Control I/O Module This is the valve to control the feed 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

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

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.

37. IND780batch – Flow Meter Configuration

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

39. IND780batch – Flow Meter Configuration

40. IND780batch – Flow Meter Configuration

41. IND780batch – Flow Meter Configuration

42. IND780batch – Flow Meter Configuration

43. IND780batch – Flow Meter Configuration

44. IND780batch – Flow Meter Configuration