1. Module # 020 MUST HAVE SHOULD HAVE COULD HAVE
Talk about how it all fits together
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. 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
Valves controlled by Qi Matroller
Valves controlled by Qi Matroller
Flowmeter
Reports
Controlled via JagBASIC
JagBASIC writes to shared data variables
“Lite” will Support
Two speed feed !

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

6. Optional A Qi Cluster - simple SeparateEthernet
PLC is starting feeds using hardwired logic into the Matroller Inputs
Only for small systems !!
Optional
Qi 365 !
SCADA
Valves controlled by Qi Matroller AND PLC
Valves controlled by Qi Matroller AND PLC
SeparateEthernet
Flowmeter
PLC
Start
Abort
2x Scale
Control of Matroller via discrete I/O
NB: only for small systems due to limited I/O available
Control wiring omitted for clarity
4x FlowM
JagBASIC program required !
Valves controlled by Qi Matroller AND PLC

7. Optional A Qi Cluster - simple SeparateEthernet Qi 365 ! SCADA
Valves controlled by Qi Matroller AND PLC
Valves controlled by Qi Matroller AND PLC
Optional
Qi 365 !
SeparateEthernet
SCADA
Flowmeter
PLC
CNet
2x Scale
PLC with one Qi on ControlNet
Hub not shown
4x FlowM
Valves controlled by Qi Matroller AND PLC

8. Requires a CNet comms card for CNet AND EtherNetIP !!
A Larger Cluster
Requires a CNet comms card for CNet AND EtherNetIP !!
2x Scale
Term 4
CNet
4x FlowM
2x Scale
Term 1
SeparateEthernet
4x FlowM
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
4x FlowM
Term 2
4x FlowM
4x FlowM
Illustrate that there as the system grows additional “bridge” Qi will be required.
Which is the Master?
2x Scale
Term 3
2x Scale
Ethernet Switch

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
HMI
PLC
Qi Matroller
Batch Server
Multiple Recipes
Target &
Material Path
Recipe
Illustrating the movement of Command
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
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. Material controlled by PLC
Qi wiring example 1
Material controlled by PLC +V
MP2
MP3
CNet
FCE Status is
Read via the CNet
Network
MP1
Cyclic data is a slow update
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. Material controlled by PLC
Qi wiring example 2
Material controlled by PLC +V
MP2
MP3
CNet
FCE Wired
Directly
To PLC
MP1
PLC has a finite cycle time. This adds a varying delay to the Cutoff Control and degrades the accuracy
3 materials Controlled by PLC
PLC reads status of Qi FCE
PLC introduces delay !!
Qi must NOT be wired like this

14. Material selected by PLC
Qi wiring example 3
Material selected by PLC
(steering Matrix) +V
FCE
MP2
MP3
CNet
MP1
Same O/P is used by Qi to Control 3 Materials.
PLC only ever has ONE of its Material Enables on at any one time.
Called the Steering Matrix
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 Qi FCE MP1 En MP2 En MP3 En Start Cmd MP1
Feeding
Feeding
Feeding
Qi FCE
MP1 En
Note the OFF Delay !
MP2 En
Special Note: The Material Enable (Select) MUST always stay on longer than the FCE O/P
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
Two, each Channel operates independently
Qi will complete the Feed normally

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