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MUSTHAVE

SHOULD

HAVE

COULDHAVE

Module # 070

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Configuring the Qi Cluster

• Objectives:• Know the sequence of configuring the Qi Cluster• Know how to setup a Channel• Know how to setup a Material Path

• Method:• Demonstrate.• Class exercise to follow.

• Reference material: – ChannelDef.doc– MaterialDef.doc

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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• ------------------------------------------------------------------------------

Control

Hardware

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PAC Config Steps – Overview (excluding Instrument setup)

• Configure Cluster (not Qi Lite)

• Set Global Parameters• Short Feeds, Comms Interfaces, K1 K2 Limits.

• Configure the Channels• PAC >> Assign Channels

• Note: if no channels have been licensed you will have access to SPILL ONLY algorithms

• Fill in the “blanks”

• Configure Material Paths• PAC >> Material Paths

• Fill in the “Blanks”• Refer: ChannelDef.doc & MaterialDef.doc

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WAIT – your PC must be Setup correctly for Qi Configuration

• Change your laptops IP address to one that is compatible with the QiMPACT subnet mask– See table on next slide

– Use Ipconfig to confirm new IP address has been accepted• A reboot may be required

• Set Webbrowser to “Refresh each visit to the page”– Very important or cached pages are displayed

– Connect app PC’s to Hubs or Switches

• Use the “Ping” command to verify comms with your partners PC

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Class IP address allocations

Group1 Master Remote part#1 part#2 part#3

100.100.100.010 100.100.100.011 100.100.100.012 100.100.100.013 100.100.100.014

Group2 Master Remote part#1 part#2 part#3

100.100.100.020 100.100.100.021 100.100.100.022 100.100.100.023 100.100.100.024

Group3 Master Remote part#1 part#2 part#3

100.100.100.030 100.100.100.031 100.100.100.032 100.100.100.033 100.100.100.034

Group4 Master Remote part#1 part#2 part#3

100.100.100.040 100.100.100.041 100.100.100.042 100.100.100.043 100.100.100.044

Group5 Master Remote part#1 part#2 part#3

100.100.100.050 100.100.100.051 100.100.100.052 100.100.100.053 100.100.100.054

Subnet mask 255.255.255.000

Browser must be set to refresh page on each visit

QiMPACT practical session network settings

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PAC Config Notes: Cluster setup

• QiMPACT must be in Program Mode• Ensure each QiMPACT has a unique number

– View via Matroller Button

– Important when more than one Qi in a Cluster

– ( Can only be edited before assigning the Master )

• Decide whether to save changes to Master Database or to All– (PAC button)

• Each QiMPACT in the Cluster must be told who the Master is – Go to each Qi in the Cluster, and enter Masters IP address

• The Master must have all IP addresses entered into its configuration

• Save Changes after checking:– “The Database Master's IP Address Has Been Entered Into All

MATROLLERS”

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System wide settings (Global)

• In Program mode > PAC button• “Enable Short Feeds” checkbox

– Must be enabled if you are expecting shorter than 7 to 8 sec feeds.• Actual limit is 6 seconds• ie Dedicated fast drum filling systems

• Once the normal operating conditions are reached it is advisable to set limits to your K1 and K2 constants– Due to the nature of the K2 algorithms, erratic systems and upsets can

cause the constants to “spike”. Enabling these limits will prevent this from causing any problems

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Global Settings

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Class Exercise

• Setup Cluster (not Qi Lite)– Refer previous slides

• Configure Global setting– Refer previous slides

• NOTE: ALL configuration is done via the PAC button– Except for Matroller number

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PAC ConfigurationButton

Matroller number

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Adding Channel 1

• QiMPACT must be in Program Mode when enabling a channel– Thereafter some parameters are editable in Runtime

– (To use K1 or K2, channels will have to be licensed at this point)

• Fill in the blanks• Refer PacDatabaseNotes.doc for detailed explanation of each

parameter– Or view “Help”

– HINT: save the page as a default and reuse

• BIG HINT: do not skip channels– Later addition of channels may move your data !

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Channel Defaults

• Channel Configuration defaults– For the actual description of the parameters see the Technical manual Chapter 4,

subsection: assigning channels or PacDatabaseNotes.doc– Some parameters can have recommended defaults, here is a list of defaults that

will get you going although they may not be the most efficient.

• Minimum Material addition 0• Dump Trip Point 2 % of the Scale Capacity• Zero Flow Rate Threshold 5 scale divisions

– (Note: unfortunately this threshold can vary quite a bit. If you have a noisy scale and the Stability light takes a long time to come on after a feed has stopped then your Zero Flow Threshold is set too low)

• Flow Rate Unstable Scale 2 times larger than the above mentioned Zero FR Threshold

• Minimum PAC Threshold 1.5 times the Zero Threshold• Feed Overide Time 0• Minimum Slow Step Time 20• Stable Measuring Device Wait Time 4

• Extract From: ChannelDef.doc• See: PACDatabaseNotes.doc for detailed explanation of parameters !!

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Class Exercise 1: add Channel

• Via the PAC button, ADD and CONFIGURE channel 1 using Scale A as the instrument.

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Adding a Material Path

• There is normally a minimum of one Material Path entry for each Control valve in the system

• However – it is possible to create multiple Material Paths in the Database for a single Control valve (physical material)

• WHY:– Routing of different materials through same pipework– A material may behave differently in certain circumstances ie batch size may be

different in a DumpTo empty situation

• QiMPACT must be in Program Mode when enabling a channel– Thereafter some parameters are editable in Runtime

• Fill in the blanks

• Refer PACDatabaseNotes.doc for detailed explanation of each parameter– Or view “Help”– HINT: save the page as a default and reuse

• Hint: editing the Average Flow and Spill requires an extra “check”

• Hint: resetting the Average Flow and Spill will cause the Algorithm parameters to be recalculated from scratch rather incremental changes

– Useful when commissioning or process changes like a new valve

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Material Path Defaults

• Some parameters can have recommended defaults, here is a list of defaults that will get you going although they will not the be the most efficient.

• Max Flow Rate Alarm Threshold 0• Algorithm - GIW Spill or K1 to start with• Algorithm – LIW DTE or Spill• Slow Step timer Factor 1.5• Alarm Only on SStep Timeout checked• Minimum Open Time 2 • Drain Time 6 • Flow Rate Limit Low 0 • Flow Rate Limit High 2 to 3 times what you are expecting• Spill Limit High 2 to 3 times what you are expecting• Spill Limit Low half the HighLimit negated• Algorithm Update 0.75• Flow Rate sample period 2• Destination Channel 255 if outside the Cluster else the

channel that this Material is feeding into• Extract From: MaterialDef.doc• See: PACDatabaseNotes.doc for detailed explanation of parameters !!

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Class Exercise 2: add a Material Path

• Via the PAC button ADD and CONFIGURE a Material Path using Scale A as the instrument.

• Add MP1 as a GIW material

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Review Questions

• What is the purpose of the “Short Feed Enable” option?

• Can you add a Material Path before any Channels?

• Can you configure the PAC and use a Qi to Control Feeds if no Channels have been licensed?

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Configuration 070 – Revision notes

• Suggested sequence of events:

• Setup and configure all Scales and Flowmeters

• Assign unique IP addresses and Matroller numbers to each QI !

• Build cluster and assign master.– Tip: master can be the least active Qi in the cluster.

• Short feed enabled, if required.

• K1 & K2 limiting, if required.

• Add channels and configure according to suggested defaults.– Tip: do not skip any installed Scales or Flow meters if possible. (recommended)

• Add material paths and configure according to suggested defaults.

• Gotcha !! Any LIW or flow meter based feeds MUST have the correct destination channel entered!

• Tip: perform initial configuration with Qi in Setup mode

• Tip: editing most channel and material path parameters can be done while in Run mode, BUT NOT WHILE THE QI IS BUSY FEEDING.