IND780batch EM, CM, and Material Path setup. Internal usage only 2 Batch Terminology - A Simple System Overview Control I/O Module - Defines what I/O.

IND780batch

EM, CM, and Material Path

setup

Internal usage only2

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


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.


IND780batch - Configuration

Equipment Modules in this system:1. Scale2. Operator Action Station

1 - Scale

2 – Operator Action Station



First let’s setup the Equipment Modules and Control I/O Modules for the Scale.

1 - Scale



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





Hand Add = Manual Operation

Discharge = Output 0.6.1

Auxiliary Mixer Control = Output 0.6.3



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.



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.


IND780batch – Control Module Configuration

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.



Next, we need to configure the Weigh In Control Module



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



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.



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.



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



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.



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.



Next let’s setup the Equipment Modules and Control I/O Modules for the Operator Action Station.

2 – Operator Action Station



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



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



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).



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.


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.


IND780batch – Material Path Configuration

Material Path Configuration Material Path 5

Material Path 4

Material Path 3

Material Path 2

Material Path 1

Material Path 6

Material Path 7


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


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.


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

Flow Rate

Fina

l Spi

ll v

alue Linear effect

K1K2

Final Spill. Summation of all graphs

Non Linear effect

IND780batch – Feed Algorithms


Feed Algorithms - Which one to use? 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 The initial downwards

velocity is zero


Feed Algorithms - Which one to use?

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

Material in suspension


The Algorithms - Summary

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



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.





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.



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”.


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

Control I/O ModuleThis is the valve to control the feed

Equipment ModuleThe flow meter

Material PathDefines what material and where the material goes



To add a Flow Meter Equipment Module, right click on Equipment Modules and select New>Flowmeter Equipment Module



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.





To add a Flow Meter Control Module, right click on the Flowmeter EM and select New>Flowmeter CM













IND780batch EM, CM, and Material Path setup. Internal usage only 2 Batch Terminology - A Simple System Overview Control I/O Module - Defines what I/O.

Documents

control module slide

internal usage

scale slide

control modules

scale equipment module

auxiliary control module

control io modules

ind780batch em