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MUST HAVE SHOULD HAVE COULD HAVE Module # 020. Qi System Architecture Objectives Know where the Qi physically fits, in the Control system Aware of Clusters.

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Presentation on theme: "MUST HAVE SHOULD HAVE COULD HAVE Module # 020. Qi System Architecture Objectives Know where the Qi physically fits, in the Control system Aware of Clusters."— Presentation transcript:

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 Clusters 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 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 Control Hardware

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

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

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

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

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

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

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 Restart Auto 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: ( available after every command ) 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. 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.

12 Qi wiring example 1 +V CNet FCE Status is Read via the CNet Network MP1 MP2MP3 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 Material controlled by PLC

13 Qi wiring example 2 +V CNetFCE Wired Directly To PLC MP1 MP2MP3 3 materials Controlled by PLC PLC reads status of Qi FCE PLC introduces delay !! Qi must NOT be wired like this Material controlled by PLC

14 Qi wiring example 3 +V CNet FCE MP1 MP2MP3 3 material Controlled by 1 Qi O/P Qi is in DIRECT Control of the FEED Qi MUST be wired like this Material selected by PLC (steering Matrix)

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

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, 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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