must have should have could have module # 020. qi system architecture objectives know where the qi...
TRANSCRIPT
MUSTHAVE
SHOULD
HAVE
COULDHAVE
Module # 020
Qi System ArchitectureQi 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
Configuration & Setup SequenceConfiguration & 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
A Qi Cluster - standaloneA Qi Cluster - standalone
Reports
Controlled via JagBASIC
“Lite” will Support
Two speed feed !
Valves controlled by Qi
Matroller
Valves controlled by Qi
Matroller
Flowmeter
A Qi Cluster – PC ControlA Qi Cluster – PC Control
Reports
Controlled via PC based application
Ethernet
Valves controlled by Qi
Matroller
Valves controlled by Qi
Matroller
Flowmeter
Use:
•Mettler Toledo API•UDP Commands
Qi 365 !
User Program
A Qi Cluster - simpleA 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
Valves controlled by Qi Matroller AND
PLC
Valves controlled by Qi Matroller AND
PLC
Flowmeter
Qi 365 !
SeparateEthernet
Optional
A Qi Cluster - simpleA Qi Cluster - simple
CNet
2x Scale
4x FlowM
PLC
SeparateEthernet
Valves controlled by Qi Matroller AND
PLC
Valves controlled by Qi Matroller AND
PLC
Flowmeter
Valves controlled by Qi Matroller AND
PLCSCADA
Qi 365 !
Optional
A Larger ClusterA 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
4x FlowM4x FlowM4x FlowM
Ethernet Switch
Term 1
Term 2
Term 32x Scale2x Scale
2x Scale
4x FlowMTerm 4
SeparateEthernet
Requires a CNet comms card for CNet AND EtherNetIP !!
Qi Matroller position in a Batching SystemQi 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
HMI PLC Qi Matroller
Qi processes the Recipe One Material (phase) at a time. Keeps a Channel and Material database
Batch Server
Multiple Recipes
CommandsCommands 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
Command Responses: (Command Responses: (availableavailable after every commandafter 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.
Qi wiring example 1Qi wiring example 1+V
CNetFCE Status is Read via the CNet Network
MP1
MP2 MP3
• 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
Qi wiring example 2Qi wiring example 2+V
CNet FCE WiredDirectlyTo PLC MP1
MP2 MP3
• 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
Qi wiring example 3Qi wiring example 3+V
CNet
FCE
MP1
MP2 MP3
• 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)
Timing diagram – 3 MPsTiming diagram – 3 MPs
Qi FCE
MP1 En
MP2 En
MP3 En
Start Cmd MP1
Start Cmd MP2
Start Cmd MP3
Feeding Feeding Feeding
Note the OFF Delay !
Review questionsReview 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
Architecture, 020 - Revision notesArchitecture, 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