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MUST HAVE

MUST HAVE. SHOULD HAVE. COULD HAVE. 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

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MUST HAVE

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  1. MUST HAVE SHOULD HAVE COULD HAVE Module # 020

  2. 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

  3. Hardware Control 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

  4. Flowmeter A Qi Cluster - standalone Valves controlled by Qi Matroller Valves controlled by Qi Matroller Reports Controlled via JagBASIC “Lite” will Support Two speed feed !

  5. Flowmeter A Qi Cluster – PC Control Controlled via PC based application Valves controlled by Qi Matroller Valves controlled by Qi Matroller Reports Ethernet Qi 365 ! User Program • Use: • Mettler Toledo API • UDP Commands

  6. Flowmeter A Qi Cluster - simple Optional Qi 365 ! SCADA • PLC is starting feeds using hardwired logic into the Matroller Inputs • Only for small systems !! Valves controlled by Qi Matroller AND PLC Valves controlled by Qi Matroller AND PLC SeparateEthernet PLC Start Abort 2x Scale 4x FlowM JagBASIC program required ! Valves controlled by Qi Matroller AND PLC

  7. Flowmeter A Qi Cluster - simple Valves controlled by Qi Matroller AND PLC Valves controlled by Qi Matroller AND PLC Optional Qi 365 ! SeparateEthernet SCADA PLC CNet 2x Scale 4x FlowM Valves controlled by Qi Matroller AND PLC

  8. A Larger Cluster Requires a CNet comms card for CNet AND EtherNetIP !! • 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 2x Scale Term 4 CNet 4x FlowM 2x Scale Term 1 SeparateEthernet 4x FlowM 4x FlowM Term 2 4x FlowM 4x FlowM 2x Scale Term 3 2x Scale Ethernet Switch

  9. 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 Qi Matroller position in a Batching System HMI PLC Qi Matroller Batch Server Multiple Recipes Target & Material Path Recipe • Qi processes the Recipe One Material (phase) at a time. • Keeps a Channel and Material database

  10. 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 • RestartAuto 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

  11. Command Responses: (availableafter every command) • 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. • 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.

  12. Qi wiring example 1 Material controlled by PLC +V MP2 MP3 CNet FCE Status is Read via the CNet Network MP1 • 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

  13. Qi wiring example 2 Material controlled by PLC +V MP2 MP3 CNet FCE Wired Directly To PLC MP1 • 3 materials Controlled by PLC • PLC reads status of Qi FCE • PLC introduces delay !! • Qi must NOT be wired like this

  14. Qi wiring example 3 Material selected by PLC (steering Matrix) +V FCE MP2 MP3 CNet MP1 • 3 material Controlled by 1 Qi O/P • Qi is in DIRECT Control of the FEED • Qi MUST be wired like this

  15. Timing diagram – 3 MPs Feeding Feeding Feeding Qi FCE MP1 En Note the OFF Delay ! MP2 En MP3 En Start Cmd MP1 Start Cmd MP2 Start Cmd MP3

  16. 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

  17. 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

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