BatchTron III User's Manual
Contents
1. 18 5 7 PRINTER FAILURE eese 32 3 6 TIMER SETUP 6 2 19 5 8 MODEM OPERATION 33 3 6 1 Master Mix Slumpmeter 5 9 DIAGNOSTICS SCREEN eene 33 Settings ecd metet 20 3 7 LIQUID UNITS PULSE AND UNITS 21 60 APPENDIX rere 34 61 PASSWORDS 420 222 34 BatchTron Ill Ver 1 0 1 1 0 Introduction BatchTron is the latest advance in batching controllers Integrating scale indicators liquid counters controls indicators and formula database BatchTron is the world s first screens wil not be described here but their features and operation conform to the standards of this manual 2 1 1 Batching screen completely touch screen controlled batching system This technology gives the advantages of higher reliability better control and faster operating speed at a low overall cost Changes are easier too Because controls are on the touch TARGETS ACTUALS screen new controls and complete screens can be added in software allowing additions and changes to be made and loaded from a computer or through line modem BatchTron Ill stores a FORMULA variable number of formulas 208 ID depending of the number of d ingredients e g for 16 ingredients there are 260 formulas available allows adjustment of batching parameters and is completely self tuni2. Ti MAX FORM 395 The maximum number of fields per formula is 32 The maximum number of formulas for the specific application the type of ingredients per scale and the ingredients used per mixer are shown after scales parameters screen 24 ingredients per scale screens 27 30 and setup liquids per mixer screens 31 33 are done The last input field in the formula is the target value for moisture sensor if used For water meter or MasterMix formulas this value represent the water cement water total solids ratio and will change whenever the water value or total cement total solids values are changed allowing the operator to watch both related values simultaneously Once all ingredients are entered and correct store the formula by pressing STORE To modify a formula retrieve it if necessary by selecting its formula number and pressing VIEW Use the E and buttons to locate and modify the ingredient amounts This formula can be stored by pressing STORE or it can be stored at another location by entering a new formula number and pressing STORE This is a convenient way to copy a formula with minor changes Ensure that you do not override an existing formula 3 3 Ingredient Settings INGREDIENT SETTINGS screens can be accessed by appropriate PASSWORD in the DATA ENTRY MENU screen Up to 64 ingredients can be entered in two tables each one containing 32 ingredients INGREDIENT SETTINGS 1 TO
3. Use the and buttons to scroll through the formulas in memory to the required one and then press ENTER The cursor moves to the BATCH SIZE column If a 10096 batch is required simply press ENTER For a different size use the keypad to enter the desired batch size as a percentage of the formula size then press ENTER NOTE Concrete formulas are normally stored as one cubic yard or cubic meter which is equal to 100 To batch a 2 cu yd or cu m mix enter 200 To batch a 3 4 yd cu m mix enter 75 The cursor moves to the BATCHES column Enter the number of batches desired for the production run and press ENTER The TOTAL QTY column calculates the total quantity based on the mixer capacity in the SETUP menu and the number of batches If the operation calls for continuous production enter 0 in the BATCHES column followed by ENTER The process will then not stop unless stopped externally by the demand station switches Note that RESET BATCH wil return the system to the beginning of the production cycle Press READY in order to effect these changes on the next batch If external demand stations are used the REM buttons on the mixer screen enable the system to accept batch calls from each station The station controls must then be set correctly in order to start batching These are customized to the plant and are explained specifically during startup The SIMULATE button allows the production cycle to
4. jog will continue until the target weight less the preact is reached The dribble amount should initially be set to a high value allowing the gate to close before the weight BatchTron Ver 1 0 18 BIN 7 ON GREEN OFF RED ingredient Both dribble and preact will self adjust over the first few batches NOTE typical values for dribble and preact are 500 lb 250 kg for aggregate dribble 10 lb 5kg for aggregate preact and 4016 20 kg for cement preact TOLERANCE CHECK This feature allows you to stop the batching process and sound an alarm if any ingredient weight is not within the specified tolerance amount Decide on the accuracy requirement of your mix design and enter the tolerance value as a percentage of the batched weight TOL Example if the mix design calls for 2 accuracy on aggregates and 1 for cements enter 2 for AGG TOL and 1 for CEM TOL MIN values are the minimum values that are taken in Ib or kg depending on the scale units when calculating tolerances on small batch sizes If a percentage of the formula value were used the calculated tolerance could be too small for the feeder to handle without giving frequent tolerance errors These values should be set to the smallest practical tolerance band Ib or kg that the feeders can attain NOTE Typical values for small concrete batch plants are 20 16 10 kg for aggregates and 10 16 5 kg for cements 3 6 Time
5. reversing conveyors the arrow buttons are directional RUN buttons When the mixer is full the mixer symbol turns to the MIX representation After all ingredients have been discharged into the mixer and mixed for a preset time the mixer symbol flashes This indicates that the mixer is ready for discharge The scale vibrator signs will turn RED when MIXER 2 e d CLOSE OPEN ees PEN STOP ce 0 0 0 0 0 0 MOTOR WATER DEMAND 3 SCREEN MENU BATCH UIS related vibrators activated in automatic mode or manually when buttons are pressed off position is B LUE To discharge the mixer manually when the bucket or container is under the discharge door press the OPEN button on the MIXER CONTROL screen to open the discharge door 106 button if present has to be pressed afterwards if jog mode is used to open the door Pressing CLOSE wil close it This method will open the door regardless of whether the mix is ready and is not the best method To manually initiate an automatic discharge when the mix is ready ensure that the AUTO discharge button is off BLUE When the bucket or container is in place press the AUTO discharge button Now when the mix is ready the door will open automatically discharge the mix and close when its discharge time is done This method ensures that the mixing cycle is complete and will discharge the mixer as soon as it is rea
6. 322 106 0PE type are screens Therefore it is a good idea to periodically update these values INGREDIENT TABLES from SCALE 1 TO 5 SETTING after automatically tuned in by the PLC in good operational conditions The maximum number of ingredients per scales and NAME TYPE DRIBBLE PREACT STONE 3 4 AGGREGATE 98 T UR i 990 9 9 9_9 9 9 _9_9 G_9 9 9 _G_9 G_9 9 9 9 9 9_9 H 9 _9 9 9_9 WHITE PORTL CEMENT 2 E NESE 616 6 6 6 S G 6 616 S 8 6 EE OJO Oe o fo e Se 9 9 9 S o 99 9 999 Solo S99 9960 0900 910 0 9 9 0919 G6 S G 6 9 9 9 9 6 6 mH oO 9_9 9_9 Scale 1 12 ingred Scale 2 12 ingred Scale 3 12 ingred Scale 4 4 ingred Scale 5 4 ingred Water 3 ingred Admixes 12 ingred per mixer Sw When NAME and TYPE selected by touching the entry area an alphanumeric keyboard pops up automatically NAME and TYPE must be 12 characters max When dribble preact and jog open time are selected a numeric keyboard pops up These values need to be set initially for each solid ingredient used and will be loaded automatically into SCALE 1 TO 5 SETTING screens if ENABLE LOAD Dr Pr button is highlighted See paragraph 3 4 for detailed explanation of these terms The dribble preact and jog open time will be automatically tuned for the corresponding scale they are used They will not be updated in the INGREDIENT TABLES
7. Below the scales are the flop gates symbols witch will change the position to the mixer used 1 or 2 in relationship with the Demand started Underneath the flop gates are themixer symbols The top zone of the mixer is the mixer start stop switch RED when stopped When it is pressed the MIXER START ALARM sounds for 10 seconds before starting the mixer This zone turns GREEN to indicate that the mixer is running When the mixer is full it appears as below representing the MIX Mn The scale vibrator signs will turn RED when related vibrators activated in automatic mode or when buttons are pressed off position is BLUE The body of the mixer turns YELLOW when the mixer is empty The water and admix symbols turn DARK BLUE when filling is in process Three buttons control the batching action RUN restarts operation when stopped STOP halts material feed or scale discharge ABORT allows the batching process to be cleared when BatchTron Ver 1 0 a fault has occurred The batch must already have been stopped before it can be aborted ALL AUTO sets al the AUTO buttons throughout the system to GREEN with one operation Most AUTO buttons revert to OFF when power is turned off or lost In AUTO mode discharge occurs automatically when the mixing time is complete and the external input if connected is enabled The scales will automatically discharge into the mixer provided that the previous mixer cy
8. DATE HOUR MIN SEC lines in turn using the E and buttons and enter the value by the keypad followed by ENTER Finally press the SET button to set and restart the clock LAST REPORT prints the report of the last batch made This is useful if the last batch printout was not obtained due to a printer malfunction or lack of paper Note that this information is available only up to the start of the next batch When BATCHLINK is used this button will retransmit data to the computer for testing purposes FORMULAS not available some systems prints all stored formulas ALL DATA not available on some systems prints formulas plus all setup data This should be used to keep a record of all parameters in case the PLC unit has to be replaced BatchTron 1 Ver 1 0 10 2 3 Optional Controls 2 3 1 Running the skip hoist SKIP HOIST Available on systems with skip hoist option the skip hoist screen allows the skip hoist to be controlled Use the button to locate this Screen Always ensure that during normal running the AUTO button is ON green which allows automatic charging of the mixer During operation the skip can be stopped by pressing the MAN button on this screen and can then be raised or lowered by pressing the E and buttons Pressing AUTO will restart the operation where it left off under the control of the batching system Skip position DOWN HOLDING and DISCHARGE is shown by the graphic symbols w
9. Ver 1 0 INPUT NEW 0 0 0 0 Then the calculated moisture and the uncompensated reading R should be entered in the LAB TEST table After the values are entered in the table for the two different points the CALIB button is pressed and the COMPENSATION VALUES offset and slope Will automatically change upon the data entered and the actual compensated moisture reading will change maching the new calibration curve A second calibration procedure can be used by input the compensation values directly into the INPUT NEW COMPENSATION VALUES table and pressing the CALIB button Both procedures can be repeated any time for each Radartron sensor By simply touching the entry area the entry will be highlighted and the decimal keypad will pop up Then highlight the selected entry area using the E buttons on the keypad Up to 12 Radartron sensors can be accomodated 2 2 8 Print Reports TOTALS prints total usage quantities of individual aggregates and cements since last This is available only on those systems with a TOTALS RESET usually at end of day TOTALS RESET clears the REPORT PRINTER memory of stored totals it is normally pressed after each TOTAL unless continue accumulating total s DATE HOUR 0000 5 0000 nn YEAR MONTH 0000 MENU BHO uus E printer and a time and date option To enter Time and Date press STOP to allow entry Highlight the YEAR MONTH
10. and the ingredient settings to be entered or modified BatchTron 1 Ver 1 0 INTERNAL DATA IS ACCESSIBLE ONLY BY PASSWORD THERE ARE SEPARATE PASSWORDS FOR EACH SCREEN SYSTEM RESET IS ALSO POSSIBLE FROM THIS SCREEN TYPE THE PASSWORD FOR THE MENU TO BE ACCESSED 14 SETUP PARAMETER SCREENS allows access to those screens that are needed to setup the operational parameters SYSTEM RESET resets all batch operation sequences to their initial state This is useful after major breakdowns RADARTRON CALIBRATION allows access to the to RADARTRON moisture sensor calibration screen Radartron sensors are previously calibrated if however the measurements on site differ a correction can be made allowing sensor indication values to match the lab test values For more information on this screen see Section 2 2 7 DEMANDS allows Demands screen to be accessed in to start batches in low priority as an alternative to Order Entry Batch Screen operation if host computer not operational 3 2 Formula Entry From the FORMULA ENTRY screen you can enter and store formulas retrieve formulas for viewing modify a formula being run or copy a formula from one memory location for storage at another location FORMULA ENTRY MIXER 1 INGREDIENTS MIXER 2 INGREDIENTS MIXER 3 INGREDIENTS Mount 1 STONE 3 4 STONE 3 4 AGGREGATE WHITE PORTL PORTLAND WATER REDUC WATER
11. directly constituting reference values in case of plant breakdown or scales malfunctioning affecting the tuned values in SCALE 1 0 5 SETTING BatchTron Ver 1 0 16 3 4 Scales Setup SCALE CAPACITIES enter the desired capacity for each scale scales 1 to 3 allow 5 digits input values ZERO CHECK BAND the weight Ib or kg within which the system will start a batch and discharge will be terminated If material buildup exceeds this value the batch will not start The entered values should be smaller than the desired accuracy for the average batch but ENG SYS LB SCALES SETUP NOTE Changing the scale capacity or units will alter the calibration and give incorrect scale readings After these items are changed scale calibration must be carried out using weights or a SHUNT CALIBRATION UNIT call Scale Tron for details The type of scale the number of bins per scale and mixer into which each scale feeds button selected must be entered before configuring individual scales in SCALE 1 TO 5 SETTING Simultaneously after pressing the ENTER button on the keypad the names of ingredients and the number of ingredients per type of ingredient will appear pis SCALE USED PER MIXER CAPACITY in the FORMULA SCREEN MIXER3 If the scale is not used by mixer the TYPE field should be empty and the numb
12. gear from the hopper and adjust the ZERO control to obtain a zero reading again This completes calibration repeat for each scale Shunt cal If you have a SHUNT CALIBRATION TESTER connect it now and record the readings for later use in checking and recalibration Damping For faster scale response turn DAMPING fully counterclockwise If mechanical vibration or electrical interference causes erratic readings turn DAMPING clockwise to increase the response time and filter out the disturbance If the height from the aggregate gates to the scale hopper is large the momentum of the falling material can cause overshoot which can cause the feed to cut off prematurely Turn the damping control clockwise to compensate for this BatchTron Ver 1 0 27 5 0 MAINTENANCE and FAULT FINDING 5 1 Scale calibration It is important to verify the scale calibration regularly We recommend that the scales be checked EACH DAY at the start of operation by having an employee stand on or hang from each scale hopper in turn while having an associate read the weight display This will show up any major error before any faulty product is produced A more accurate check using test weights or the Scale Tron Shunt Calibration Tester should be carried out once per week and the scales should be verified by a qualified scale technician and test weights every 6 months It is your responsibility to verify the accuracy of the scales a
13. is the slower the moisture reading will follow the BatchTron 1 Ver 1 0 20 NOTE 11 delays after Mixer full delay except l Assresate delay after discharge begins 2 2 5 delay after Cement in S amp dmix 6 delay after Water in READING TIME OUT Time in seconds witch will force the end of the dry and wet measurement if stability is not reached WINDOW LENGHT This is the number of seconds that moisture has to be within stability value before signaling that is stable This value can run from 1 to 10 and the bigger the slower to indicate stability SLUMP NUM RDNGS Is the number of readings to average the slump sensor input Larger values will give more stable reading but will increase the response time POWER DN RDNGS 15 the number of readings every 5 seconds to indicate the slump system that the power has started to drop 3 7 Liquid Units Pulse and Units name of the ingredient will appear Simultaneously the names of ingredients will appear in the LIQUIDS FORMULA SCREEN UNITS PULSE BATCHING SCREEN MIXER 1 MIXER 2 MIXER 3 SI The Dribble Preact and gt i 830206 admix Water are not 9 0000 imported from the INGREDIENTS TABLE and must be manually input in the LIQUID SETTINGS screens ADNTXES oo sujo a slo m elo m 8 9 Sie SIS 66 BATCH SCREEN For each of the waters and admixes the meter pulse ratio must be entered
14. lit If fuses are not the problem check the output associated with the device Each output has an LED indicator at the top of its PLC module if the LED is illuminated the output should be on Check the output terminal and its associated power wire at the COM terminal or A terminal if all A s on the terminal strip are jumpered with a voltmeter If the voltage is present at the input but zero at the output the PLC output module should be replaced 5 3 Screen failure If the screen fails to light up check the 24 volt power supply inside the cabinet Its output should be between 22 and 28 volts DC Next check the backlight section 4 6 If the screen shows RECEIVE ERROR plus one of several detail messages such as PARITY ERROR etc communication with the PLC is faulty due to a faulty screen unit PLC or a communication setting has been changed Refer to the appendix for screen communication settings If the message TIME OUT is displayed the cable from screen to PLC is probably disconnected 5 4 Screen error messages The OMRON screen unit provides for multiple error messages If the screen shows PARITY ERROR communication with the PLC is faulty due to a faulty screen unit PLC or a communication setting has been changed and the OMRON Operation Manual should be referred to When a communications error occurs the buzzer sounds Pressing the OK button on the ERROR SCREEN will return it to the operational screen and the operation wi
15. off completely to compensate for the material iafe aina ht already falling into the scale and for the gate closing or conveyor stopping delay The preact amount should be set to your best estimate of the amount of free fall for each OJO Ou 8 99 9 OOJO 9 ASO oun MOISTURE SENSORS BIN 1 F BIN 2 BIN 3 BIN 4 F BIN 5 BIN 6 F BIN 8 BIN 9 BIN BATCH MENU followed by ENTER This can be changed at any time to map the ingredients to the bins Materials will feed in the numerical order shown in the table The name of the ingredient the Dribble Preact and J og open time values for solid ingredients will appear if button ENABLE LOAD Dr Pr in INGREDIENT SETTINGS TABLES is selected Simultaneously the names of ingredients will appear in the FORMULA SCREEN and BATCHING SCREEN The AUTOMATIC FEEDER TUNING feature will adjust the dribble preact and jog open time values during operation They need to be set initially in INGREDIENT SETTINGS TABLES however and may need to be corrected if a plant breakdown material bridging or an empty bin has circumvented the automatic process DRIBBLE is the amount prior to the target weight at which the feeder will commence jog or dribble feed For example if the target weight is 1000 kg and the dribble is set to 200 kg the main feed will cut off at 800 kg and slow feed
16. target in water units is exceeded requires the water to be metered even if the moisture target from the formula or from the remote thumbweel switch moisture dial if any when Remote moisture dial button in screen is On is not yet reached The water limit target can be set in AUTO mode when the system is calculating the maximum from the formula used dry ingredient and the maximum percentage of moisture value set in Micromix settings screen or in MAN when the operator overrides the automatic target calculated by the system Semiautomatic and automatic Semiautomatic The system calculates the moisture offset by using the value of the wet moisture entered manually by the operator Automatic The system calculates the moisture offset by using the moisture value in the aggregates either input manually or by Radartron moisture sensor To start a calibration press the i FORMULA NR 1 BATCH 8 2 100 2 34 MasterMix The MasterMix screen is available only with the MasterMix option It is used in fast high production plants MasterMix measures the moisture of the ingredients after a preset dry mix time delay Based on the known weight of materials in the mixer the water required for the mix is calculated from the formula value minus the amount contained in the aggregates The water is then added quickly via FAST and SLOW WATER valves This method is very accurate Water target
17. the unit is stopped The screen will display voltage is lowered when switching on the power or when checking the Battery mode in SYS TEM MENU Maintenance The battery must be replaced within 5 days of the warning using the following BatchTron 1 Ver 1 0 32 procedure Ensure that the unit has been powered for at least 5 minutes to charge the capacitor and then turn off the power This gives 5 minutes to replace the battery before the memory is lost With a screwdriver prise off the battery cover located at the left top corner on the rear face of the unit Remove the battery that is secured under the battery cover grip the cable and pull the connector straight out Insert the connector of the new battery into the connector on the unit making sure that the projection on it faces left and press it fully home while keeping it straight Close the battery cover making sure that the cable is not trapped 5 7 Printer failure Verify that the printer is turned on its power indicator is illuminated and is on line Check the paper supply and verify that the print head is not jammed Turn the printer power off then on again to clear any internal faults Verify that the printer goes through its normalization procedure Locate the section in the printer manual which details how to do a print test This is usually done by holding one or more buttons down while turning the power on If the printer performs its te
18. there is no need for separate alarm and reduced voltage starting delay relays All mixers MUST be fitted with a startup alarm buzzer which is energized for 10 seconds prior to the mixer starting Likewise mixer cover interlock switches MUST be wired to the enable input Reduced voltage star delta starters have separate start and run outputs provided Direct starters should be wired to the MIXER RUN output Note a separate motor cutoff switch must be wired into the three phase power to the motor in a convenient position to allow the cleaning and maintenance personnel to cut off and lock out the primary power This switch must be opened and locked out before anyone has access to the mixer If the mixer requires a hydraulic pump output this is also provided It is interlocked with the mixer motor when in automatic mode 4 5 Load cell connection In multiple load cell scales all load cells of the same scale should be electrically summed at a summing junction box These are available from Scale Tron The INDICATOR output from the summing box or the single load cell in mechanical scale conversions should be wired to the connector on the load cell transmitter located in the BatchTron cabinet Four conductor SHIELDED cable must be used with conductor size 16 to 24 gauge Connect the shield directly to the BatchTron cabinet ground next to the terminal strip Route the cables through the cable duct and the rear or bottom openings pro
19. BatchTron III User s Manual VERSION 3 Oct 2003 INFORMATION HOTLINE Should you have any difficulty in installation operation or maintenance of your BatchTron III batching system our staffs are available to help you during normal business hours and at any other time by special arrangement CALL 514 634 7083 FAX 514 639 6945 Web site www scaletron com E mail scaletron scaletron com Use of this manual for any purpose other than as an aid to operation and service of the equipment described herein is strictly prohibited No part of this document may be reproduced transcribed or transmitted to other parties without the express written permission of Scale Tron Inc 440 19th Avenue Lachine Quebec H8S 3S2 Canada 5 10 INTRODUCTION 2 3 8 JOGGING CHANGE PASSWORDS 22 20 OPERATIONAL SCREENS 2 3 9 METRIC OR ENGLISH UNITS 22 2 1 CONTROL 5 2 3 10 SCALE INSPECT ROUTINE 23 211 Batching 2 3 11 SECOND LANGUAGE SCREENS 23 2 12 Water Admix eene 4 2 1 3 Mixer screen 44 4 4 207 UNSTADEATIONANDSETUP Ss 2A 2 2 RUNABATGH ine PORE 5 4 1 POWER 24 2 2 1 From DEMAND button 5 4 2 INPUT AND OUTPUT CONNECTION 24 2 2 2 From Batch Link Order Entry 4 3 SPECIAL INPUT
20. CK MENU Buzzer Check Touch S witch Battery LED Check LCD Check Backlight Check Select each device as required Buzzer Check if the buzzer functions correctly it will sound continuously At this time the Buzzer Check wil be displayed in reverse video To stop the buzzer press Buzzer Check again LED Check it wil be displayed in reverse video and will flash green and red if the RUN LED is functioning normally To end the check touch the LED Check again LCD Check the check screen displays all the dots on the screen for three seconds for each color in turn On completion of the display it returns to the DEVICE CHECK MENU Backlight Check it wil be in reverse video and wil flash if normal Touch to end check DO NOT select Screen Data Memory except under instruction as it deletes all the operational screens during the test and these will need to be reloaded DIP switch Touch Switch a grid will be displayed and the TOUCH SWITCH areas displayed When the top right corner block is displayed in YELLOW the touch switch blocks can be touched in turn This will not affect plant operation If correct each block will be displayed in reverse video while pressed Press the top right corner block to return to DEVICE CHECK MENU Battery Check displays the internal battery status BATTERY CHECK The voltage is within the normal range The voltage is within the normal range Or The volt
21. E DISCHARGE ENABLE interlocks the scale discharge This is in addition to the built in mixer interlocks which do not allow the scales to discharge if the mixer is not empty closed and running If this input is connected to the bin level indicator in the concrete holding hopper the batch will be weighed up and held in the scales allowing it to be mixed as soon as the hopper is low This gives faster delivery For automatic scale refilling connect the BATCH START input to the switched power line or request DE MAND operation MIXER DISCHARGE ENABLE interlocks the mixer discharge This will allow automatic mixer discharge if the mixer discharge button is in AUTO mode when the circuit is energized If this input is connected to the bin level indicator in the concrete holding hopper the batch will be held in the mixer until the hopper level is low This is not recommended for high speed mixers turbine and countercurrent because the mix can overheat This input can also be used for wet cast operations to signal that the bucket or container is in place for filling MIXER RUN ENABLE interlocks the mixer motor This is normally connected to the mixer cover safety switches to prevent the mixer being started if any of the covers are open All cover switches and any other mixer safety interlocks should be connected in series with this input 4 4 Special outputs MIXER OUTPUTS BatchTronJll provides complete mixer motor sequencing
22. IEW button For a detailed description of the FORMULA Screen see section 3 0 SYSTEM SETUP FORMULA ENTRY MIXER 1 INGREDIENTS MIXER 2 INGREDIENTS INGREDIENTS TYPE Mount 1 STONE 3 4 STONE 3 4 AGGREGATE VIEN WHITE PORTL PORTLAND WATER REDUC WATER REDUC o o o o o o o o o o o o o o o o o o o o o o o o o o o the messages will alternate To return to the Screen you were viewing press the RESET button BatchTron 1 Ver 1 0 MENU NOTE for MasterMix the value of 18 W Cem W Tot x 1000 for SlumpMeter the value of Ins 198 SLUMP 2 2 5 Feeder timing The AUTOMATIC FEEDER TUNING feature will adjust the dribble preact and jog open time values during operation They may need to be corrected if a plant breakdown material bridging or an empty bin has circumvented the automatic process If you do need to adjust the performance of ingredients these settings are entered on the SCALE 1TO 5 SETTINGS screens Also these settings preloaded from INGREDIENTS SETTINGS screens when screens button Enable Load Dr Pr is activated see paragraph 3 3 Ingredient Settings for details SCALE 1 SETTINGS BIN INGR INGRED NAME DRIBBLE PREACT MIN JOG OPEN MOISTURE D 1 4 1 2 2 6 Aggregate M oisture The surface moisture in aggregates will cause an error in the batch
23. It is possible to operate in this condition but Scale Tron Inc cannot be held responsible for the consequences BatchTron 1 Ver 1 0 26 4 10 Setup parameters To prepare for running the scale and other parameters must be entered Press the MENU button to display the DATA ENTRY MENU and enter the password followed by ENTER The password is given in the APPENDIX Enter the required values for the parameters in all the setup screens See Section 3 0 for descriptions NOTE The scale capacities and units must be entered before calibration is carried out If the capacity is changed after calibration the calibration procedure will have to be repeated Turn power OFF and ON again before proceeding with calibration 4 11 Scale Calibration Before starting calibration verify that a reading is displayed on each of the scale symbols on the screen Have an associate stand on or hang from each scale hopper somewhere near each load cell Alternatively use test weights The readings obtained should be similar for each load cell and the weight display should show an increase not a decrease in value each time Corner adjustment Verify that the hopper is empty and attach weight lifting gear such as chain hoists etc to the hopper Using a small amount of test weights place the weights on the hopper or scale structure near each load cell in turn and verify that the readings are identical If not identical adjust the summing uni
24. REDUC HSYSPSSOPNSSP SPS PH IVS P SPH OOO 000 0000 99999 MENU To enter a formula enter the desired formula number in FORMULA box If you are unsure whether there is already a formula at a particular location press VIEW to retrieve data stored there If the location holds a valid formula which you want to preserve choose another formula number If the data is unimportant or is zero enter your new formula over the old Use the and buttons to locate each of the ingredients or touch the entry area to relocate the cursor Enter the desired values on the keypad followed by ENTER The C button clears a wrong entry When formula is viewed the type of mixer cycle and water control will be shown by the buttons Press WATER CTRL BY METER or SENSOR to select method if applicable BatchTron 1 Ver 1 0 NOTE for MasterMix the value of 218 W Cem W Tot 1000 SlumpMeter the value of Ims 13 LUMP X 12 15 If WATER CTRL BY SENSOR chousen select MASTERMIX MICROMIX or SLUMPMETER if applicable If MASTERMIX selected press button WATER CEMENT or WATER TOTAL to select desired method Select TYPE OF MIXER CYCLE standard STD lightweight LWT or others up to four different mixer cycles To select the Cycle first deselect the Cycle already selected if any then press the new desired CYCLE Cycle 2 LWT can not be selected if WATER CTRL BY METER is highlighted
25. S 24 Operation andres 6 4 4 SPECIAL 25 2 2 3 Alarm 1 4 5 LOAD CELL CONNECTION 25 2 2 4 Ingredient trimming 7 4 6 PRINTER BATCHLINK CONNECTION 25 2 2 5 Feeder 8 47 MODEM 25 2 2 6 Aggregate 4 8 MOISTURE SENSOR CONNECTION 25 Moisture eee 8 4 9 WIRING VERIFICATION nnn 26 2 2 Radartron calibration screen 9 4 10 26 2 2 8 Print Reports ences 10 411 SCALE CALIBRATION 26 2 3 OPTIONAL CONTROLS 11 2 3 1 Running the skip hoist 11 2 AND FAULT 28 2 3 2 Slump M eter ttes Gey pce pq vt 2 3 3 M iCFOM IX cet cs 12 5 1 SCALE CALIBRATION eee 28 3 0 SYSTEM SETUP s 14 5 2 OUTPUT FAILURE 200 28 53 SCREEN FAILURE eene 28 3 1 55 8 14 5 4 SCREEN ERROR 55 8 28 3 2 00 2 15 5 4 1 Screen device checks 29 3 3 INGREDIENT 8 2 211 16 5 5 PIC UNITS ette er 30 3 4 SCALES 5 2200002200 17 5 6 SCREEN UNIT 31 3 5 SCALE 1 TO 5 SETTINGS
26. This screen also allows the passwords other than SETUP to be changed Select the function to have its password changed Enter the new password and press the ENTER button to save it SCREEN 2 ALARMS When two screens are employed for the operating system e g BATCH on screen one and MIXER on screen two only screen one carries the alarms In the unlikely event of screen failing the ALARMS would be lost In this event pressing SCREEN 2 ALARMS transfers the alarm function to screen two 3 9 Metric or English Units The system allows the customer to chose operation in English units or Metric units or BatchTron Ill Ver 1 0 22 FORMULAS 1 CEM 1 INGREDIENTS B 2 sc 3 SYSTEM RESET CH FORMULAS ERESET EM CALIEBE SETUP SET as specia feature both systems interchangable from a screen button In the latter case the operator must first set up the scale capacities ingredient units liquids units pulse ingredients used per scale water and admixes used etc then by going in the Data entry menu and typing the right password from Jogging Password screen the values in the other units will be automatically set up with a very good aproximation requiers the liquid units for the other system to be allready setup The operator can manually override the settings at any time The units in use wil ap
27. U button and appropriate PASSWORD E amp DARTEOM CALIBRATION RADARTRON 0 SENSOR READING Z COMPENSATION VALUES COMPENS UNCOMP OFFSET SLOPE 0 0 0 0 0 0 0 0 LAB TEST R Read M Measured COMPENSATION VALUES 9 0 0 0 OFFSET 10 0 0 0 0 SLOPE CALIB OTE Input first the Radartron sensor number In LAB TEST table input the Dry and Wet moisture values Read uncompensated then press Calibration land Measured or input new values for Offset and Slope button The operator selects first the appropriate Radarton number SENSOR READINGS table shows the actual moisture values compensated and uncompensated for the selected Radartron sensor number COMPENSATION VALUES table shows the offset and slope values for the selected Radartron sensor number These values applied to the uncompensated sensor reading will give the compensated sensor value The calculation formula Moisture comp Reading uncompensated Offset Slope The compensated and uncompensated values will coincide initially when the offset equals 0 and the slope equals 1 The operator will take sand samples to determine the humidity upon the dry oven procedure and must write down the moisture M measured and R read uncompensated from the SENSOR READING table at that specific time In order to make a good calibration two different moisture readings in a sufficient range of humidity dry and wet should be taken BatchTron
28. age lowered is displayed in which case replace the battery immediately Press Quit to return to DEVICE CHECK MENU The PRINTER screen is not valid with the printer connection used and should be ignored BatchTron Ver 1 0 30 5 5 PLC unit The following diagram shows the basic Lock the CPU to the adjacent Module Indicators Pulse I O connector CQM1 CPU43 E only ABS interface connector CQM1 CPU44 E only Analog setting controls CQM1 CPU42 E only RS 232C Port except CQM1 CPU11 E Used for communications with external devices or other PLCs Peripheral Port Used to connect to Peripheral Devices such as a Programming Console or a computer running LSS components of the CPU that are used in the general operation of the PLC DIP Switch The DIP switch is located in the battery compartment of the CPU The switches should normally be set to the following Pin 1 2 3 4 5 6 Off Off On On Off Off Replacing the Battery The CPU contains a lithium battery for memory back up The battery type 3G2A9 BATO0S8 is good for 5 years at an ambient temperature of 25 C 80 F Higher ambience will reduce this time Replacement is warned by the RUN LED showing orange during operation or red when the unit is stopped The screen will display voltage is lowered when switching on the power or when checking the Battery mode in SYS TEM MENU Maintenance The battery must be replaced within 5 days of
29. can be based on water cement ratio for wet cast or water total solids ratio moisture for dry cast pavers and block Target moisture or water cement ratio water total and choice of Standard or Lightweight concrete are stored in the batch formulas allowing different moistures and mixing sequences to be preset for different products FAST WATER and SLOW WATER buttons can be used for manual water feed MASTERMIX CALIBRATION Calibration is performed by recording the moisture values while a mix is being processed The dry material moisture reading is taken after the material has been mixed and stabilized then water is added and once stabilized the wet material reading is taken There are two types of calibration BatchTron 1 Ver 1 0 3 6 calibration button in MASTERMIX screen once the mixer has been filled with material The calibration screen shows a few other buttons described as follows 25 veL Me 25 MOISTURE SLOW 507 Auto SemiAuto This button changes the type of calibration describe above Global Store This button lets you store the actual calibration in all formulas Single Store This button lets you store calibration parameters for the actual formula only formula into the mixer Default This button loads the default parameters to the run time area These parameters are set by factory and are very close final calibration parameters to real ones after calibration If i
30. cept 1 Aggregate delay after discharge begins 2 2 5 delay after Cement in S Admix 6 delay after Water in The surface moisture in aggregates will cause an error in the batched weights unless compensated for BatchTron allows both manual and automatic entry of moisture values Once entered the target weights of aggregates and water are automatically corrected and the water value is reduced as a result You will notice that the aggregate target weights on the batch screen will be higher compensation than they before To enter manual values select the field for aggregate 1 to 6 using the E and buttons Enter the moisture value with decimal point followed by the ENTER arrow initiate automatic moisture compensation from a sensor such as the Radartron 1400C press the AUTO button picture of sensor for the appropriate aggregate which will turn green when activated Typically one or two aggregates will use automatic sensors and the others will have manual moisture entry If an automatic sensor is faulty turn it off by pressing AUTO a second time and enter the value on the keyboard BatchTron Ver 1 0 19 MIXING TIME SEC this is the time taken for mixing after the last ingredient is added before mixer discharge is enabled In the case of moisture metered water MicroMix or Lesueur this is the minimum mixing time after cement and admixes are added witch runs concurrently
31. cle is completed if the mixer symbol on the batch screen is representing the MIX it signifies that a mixer cycle is in progress To cancel a mixer cycle the discharge must run its full course in AUTO mode or the discharge door must be opened in MAN mode for at least the normal discharge period see SETUP menu for time For MANUAL control see section 2 1 3 The scale discharge sequence is defined from the delay times in the SETUP menu Normally aggregate discharges first followed by cement water and admixes Three buttons are common to all other Control screens MENU wil bring up the DATA ENTRY MENU for System Setup BATCH SCREEN wil return to the Batch screen DEMAND wil bring up the SET UP FORMULA SIZE TO RUN screen for normal cycle settings if in normal operation the demands are started from Order entry in host computer this screen will be accessed by password if Batch Link computer faulty demands will start in Low priority Refer to Batch Link Manual for Order Entry operation JOB ID DELIVERY ID and LOAD ID wil be available only for Order Entry operation 2 1 2 Water Admix WATER 8 ADMIXTURES MIXER 1 2 1 3 Mixer screen Each mixer plus the controls associated with charging and discharging is displayed on a separate screen To access the individual mixer controls press nA nA 77 AD ane AG n 811 the button until the desired 0 e e
32. dy To turn the AUTO button off press the CLOSE or OPEN button To automatically discharge the mixer from an external input ensure that the AUTO discharge button is on GREEN and energize the remote MIXER DISCHARGE ENABLE input This can be connected to a bucket sensor to allow discharge only when safe If the normal operation starts Demand Stations not from Batch Link computer then appropriate This control can also be used to take a mixer off line when desired The three keys controlling the batching action RUN STOP and ABORT are duplicated on the MIXER SCREEN allowing the cycle to be controled from this screen More detail is available on this screen with batch number and mixer times provided in the top left corner and the demand number of batch in mixer shown beneath the mixer 2 2 Run batch 2 231 From DEMAND button In precast block or paver plants operation is normally set up on the DEMAND screen This is selected by pressing the DEMAND button at the bottom of most screens The SET UP FORMULA SIZE TO RUN screen appears For Batch Link Order Entry operation please refer to Batch Link Manual SET UP FORMULA SIZE TO RUM the BATCHTRON MIXER DEMAND SCREENS have REM OFF 9 CALL buttons allow control of the MIXER from DEMAND FORMULA BATCH SIZE 100 100 100 100 BATCHES TOTAL QTY E PATCH 0 READY 3816 BATCH 0 0 0 0 STATIONS local to the casting station or buc
33. e 0 2 0 e o 0 AE Hus s mixer is reached RE WET FIN i RUN RUN FFILLEFILLAFILLEFILLEFILLA FILLY FILL ps sos Jos fas a FILL ss WET E BATCH SCREEN MENU This screen can be reached by pressing the water or admix areas on the batching screen The water and admix columns show the TARGET amounts and then the ACTUAL amounts below BATCH IN MIXER MIXING TIME TIME LEFT DISCHARGE LEFT Al The buttons under the WAT1 symbol will feed water when pressed and indicate feeding in auto mode by turning BLUE PREWET is related to the fast water valve and FINAL WET to the slow water valve The CLR button will clear the actual value when pressed only if mixer shows empty The FILL and DIS buttons under the admix symbols fill and discharge the sight glasses when pressed If admixes are fed directly only the FILL buttons are active The MIXER TOLERANCE ERROR RESET button will turn RED when a liquid tolerance error is founded AUTOMATIC mode The button has to be pressed in order to reset the alarm and the screen will automatically jump to Batching screen BatchTron Ver 1 0 FILLA FILLA FILLE FILL HEAT WATER At any time individual pushbuttons can be used to manually operate mixer motor hydraulic pump flop gates and discharge doors The conveyors can also be controlled by their respective AUTO STOP RUN button sets In the case of
34. e useful in determining problems with the displays for these functions 6 0 APPENDIX 6 1 Passwords The default passwords should be given to supervisory personnel only they are intended to prevent unauthorized persons from altering the setup data SETUP PASSWORD 9625 FORMULA PASSWORD 1515 GENERAL RESE T 9999 CLEAR FORMULA MEMORY 9152 INGREDIEN TS 1616 RADARTRON CALIBRATION 1919 SETENGLISH ME TRIC 1111 DEMANDS 1818 BatchTron 1 Ver 1 0 34
35. ed weights unless compensated BatchTron allows both manual and automatic entry of moisture values Once entered both the weight of aggregate and the water value are automatically corrected as a result You will notice that the aggregate target weights on the batch screen will be higher than they were before compensation To enter manual Moisture values select the field for aggregate 1 to 6 using the E and buttons Enter the moisture value with decimal point followed by ENTER To initiate automatic moisture compensation from sensor such as the RadarTron 1400C press the AUTO button picture iaie enti sis of sensor for the appropriate aggregate bin which will turn green when activated Typically one or two aggregates will use automatic sensors and_ the others will have manual moisture OJO Ou 99 9 OOJO 9 ASO ou MOISTURE SENSORS BIN 1 MENU EIAS These screens are reached by the MENU button and appropriate PASSWORD Highlight the selected entry area using the and buttons or simply touch the entry area This also brings up the keypad For more information on these screens see Section 3 3 BatchTron 1 Ver 1 0 BIN 7 Ew ON GREEN BIN 2 OFF RED entry If an automatic sensor is faulty turn it off by pressing AUTO a second time and enter the manual value on the keyboard 2 2 7 Radartron calibration screen This screen is reached by the MEN
36. eding wet cast buckets 223 Alarm screen SYSIEM ALARM If after a few seconds the alarm message OVER ZERO BAND appears on the red SYSTEM ALARM screen one of the scales is off zero Press the RESET button and note the scale readings If one is over the zero check band check to ensure that no material is sticking in the scale hopper and press the ZERO button for the appropriate scale When the scale indicates zero press the RUN button again If cannot zero out of range Other alarm messages will appear if the feed time exceeds the timeout value the weight tolerance for an ingredient is exceeded the admixes do not fill properly the scales do not discharge within the allotted time or equivalent faults in the mixing cycle Note the message and press the RESET button to return to the batch screen If more than one alarm is active 2 2 4 Ingredient trimming If you need to alter the amount of one or more ingredients access the FORMULA ENTRY screen via the MENU button and PASSWORD use the short cut method touch anywhere above the hopper feed gates Use the E and buttons to locate the ingredient to be changed or touch the entry area Enter the new value press the STORE button and the formula wil be permanently modified When you return to the BATCH screen the modified formula will be used on the next batch In order to view a formula enter the formula number press Enter followed by V
37. er of bins per scale must be ZERO OTHER TYPE NO SCALE NUMBER OF INGREDIENTS TYPE WATER aDMIXES The number of bins per scale or number of ingredients per mixer for OTHER TYPE Water and Admixes wil prevent more ingredients than used in the plant to be added in SCALE 1 TO 5 SETTING or LIQUID large enough to allow for normal buildup SCALE PURGE TIME SEC the time for which the discharge continues after the zero check band is reached This time allows the remainder of the material to be discharged SCALE UNITS press LB or KG to set the measurement units for the scales Note If both unit systems are used like in this example the actual unit system will be set in a special screen see 3 9 After either the scale capacity or units are changed power must be turned off and on again for the change to take effect DO NOT ATTEMPT CALIBRATE SCALES BEFORE THIS HAS BEEN DONE BatchTron Ill Ver 1 0 17 SETTINGS PER MIXER screens 3 5 Scale 1 to 5 Settings Note ingredients must be entered before this screen can be used For each bin enter the number of the ingredient that it holds SCALE 1 SETTINGS DRIBBLE PREACT TOL MIN 106 OPEN MOISTURE overshoots the target Count the number of jogs and reduce the dribble to achieve approximately 5 jogs PREACT sometimes called Free Fall it is the amount prior to the target weight at which the feeder will cut
38. for example a meter with an output of 25 per pulse is entered as 25 The units of measurement per each mixer must be entered as a number Possible selections are given on the screen Example if tenths of gallons is required enter 21 The LIQUID SETTINGS for each mixer are PREACT TOL as for ingredients LIQUID SETTINGS MIXER 1 Admix WATER is used for 4 WATER correction of NAME PREACT TOL DRIBBLE T 68 ADMISES the water target due to the NAME S amount of the free water in the admix This is a value from 096 for pure reagent to 100 for pure water Note ingredients must be NOTE VALUES FOR PREACT AND DRIBBLE ARE IN PULSES entered before this screen can be used For each bin enter the number of the ingredient that it holds followed by ENTER This can be changed at any time to map the ingredients to the bins Materials will feed in the numerical order shown in the table The BatchTron Ill Ver 1 0 21 3 8 J ogging Change Passwords JOGGING PASSWORDS JOGGING PASSWORDS SG 1 Sc 2 SCREEN 2 ALARMS BATCH SCREEN This screen allows selection of jogging or continuous feeds Normally clam gates and butterfly valves are jogged to simulate slow feed while motor driven feeders such as belts and screws are not These settings are made during installation of the system and should not be changed afterwards
39. hich turn yellow when the illustrated positions are reached In between these positions no indication is given but the manual RAISE and LOWER buttons light to show operation 2 3 2 Slump Meter The slump meter screen is available only with the slump meter option It provides a low cost method of controlling the water to get consistent slump in wet cast concrete The reading is a measure of mixer motor power As water is added to the dry material the power reading will increase until a zero slump mix is attained the reading will then drop sharply as more water is added This indicates an INCREASE in actual slump BatchTron Ver 1 0 11 The curve shows mixer motor power To operate correctly the water start delay must be long enough to allow most or all of the dry material to enter the mixer in order to raise the power to a high value The water will then flow until the power decreases to the set value The FAST and SLOW water turn on and run to set value FAST water then turns off and SLOW water runs to the final set value After a programmed mixing time the mix is ready When setting the SLUMP METER for the first time add water by pressing the FAST and SLOW buttons until the desired slump is obtained Note the MOTOR POWER reading Set the SLOW point at a little above this value Retain this value in FORMULA memory by pressing STORE AUTO MOTOR POWER 83 4 Set Point Once the c
40. imers start at the start of aggregate discharge delaying the discharge of other ingredients accordingly Admix 6 is usually reserved for super plasticizer which is timed from the end of the water feed SLUMP NUM RD PWR DN RDNGS NUM SAI MISCELLANEOUS SETTINGS this box is a general purpose NGS PLES MMIX2 FINAL WET MIN T MMIX2 FINAL WET MAX T MOIST WATER LIMIT CALC gt MIXING i MIXER DISCH TIME D 1 55 ES 60 i D ADMIXES 120 8 5 1 0 5 0 0 3 5 8 0 8 neoomnn loses 1 69606906006 69609006 1 entry area for values customized to individual applications It will typically include conveyor runout times and PREWET OF FINAL WET the point at which PREWET water cuts off expressed as a percentage of the FINAL WET value This setting is duplicated on the MICROMIX screen 3 6 1 MASTERMIX SLUMPMETER SETTINGS DRY MIX TIME Is the time in seconds after discharge into mixer has started before the measurement of the moisture of dry material in the mixer commences MIXER RPM Is the rotation speed of the mixer in rpm QUALITY FACTOR Is a parameter to indicate in MAS TERMIX how fast it tracks the change in the moisture This value can run from 1 to 10 The bigger this value
41. ket filling positions They allow the delivery of a pre 100 0 HH nan nud chosen mix design and batch size whenever the holding bin is empty or a bucket is in place for filling In REMote batches are requested from the DEMAND ARF START OPERATION pori Press 5 before proceeding STATION In OFF batches are requested from the BATCHTRON SCREEN In CALL batches will be requested even though the bin level is not low This allows the station to accelerate occasional batches to speed production of large castings MIXER CLEANOUT where provided allows local control of mixer functions and locks out automatic operation during cleaning and maintenance Pressing the CLEAN OUT button will block control of mixer motor discharge open close scale discharge open close as well as other functions when BatchTron Ver 1 0 SIMULATE EJ The SET UP FORMULA SIZE TO RUN screen allows a formula and batch size to be set up for each user location in the plant These DEMAND STATIONS can use the same or different formulas or batch sizes Each time a station calls for a batch the chosen formula and batch size will be made and delivered DEMANDS The DEMAND column represents the destination or DEMAND STATIONS Use the E and buttons to locate the cursor at the DEMAND STATION to be edited and press ENTER The cursor moves to the FORMULA column which you want to run
42. ll restart If the message TIME OUT is displayed the cable from screen to PLC is probably disconnected Refer to the OMRON manual for more details 5 4 1 Screen device checks The SYSTEM MENU screen allows functional checks of Buzzer LED LCD Backlight Screen data memory Touch switches Battery voltage The screen SYSTEM MENU can be displayed by lightly pressing any two corners of the screen at the same time If there are symbols at some corners first press a clear corner and then any other corner or access a different screen the ADMIXES screen is a good choice This stops the operation of the unit and the RUN LED goes OFF SYS TEM MENU Quit Transmit Mode Maintenance Mode Expansion Mode QUIT returns you to the operating screen TRANSMIT MODE is for use in transferring Screen programs This should not be accessed MAINTENANCE MODE wil allow you to check operation of the touch screen EXPANSION MODE should not be accessed it allows access the programming console function Relevant sub menus are selected from the screens BatchTron 1 Ver 1 0 29 From the SYSTEM MENU select MAINTENANCE MODE to display the menu MAIN TEN AN CE MODE MENU Memory Init Memory S witch Settings Calender Chek Select I O Check for the MODE MENU MODE MENU I F Check Device Check Select Device Check for the DEVICE CHECK MENU DEMCE CHE
43. mounting pin located at the bottom rear of the module until the module can rotate upward Pull it free of the rail 5 6 Screen Unit Backlight Turn the power off and disconnect the terminal block wiring and the communications cable If a memory unit or interface unit is mounted remove them Loosen four screws at corners on the rear face of the N T631 and remove the rear case From this point on be careful not to touch any electronic parts or printed circuit boards inside the unit otherwise static damage may occur Disengage two backlight connectors at the top and bottom and pull out the touch panel cable Loosen two mounting screws and remove the backlight Be sure to use a magnetized Phillips screwdriver so that screws do not fall into unit Remove immediately if they do Fit new backlights note that top one is different than the bottom one Each backlight has three projections Slot these into slits on the unit and tighten the screws while lightly holding the backlight with fingers Make sure that the cable does not come out of the backlight Re engage backlight connectors at top and bottom Replacing the Battery The Screen unit has the same type of lithium battery for memory back up as the PLC The battery type 3G2A9 BATO08 is good for 5 years at an ambient temperature of 25 C 80 F Higher ambience will reduce this time Replacement is warned by the RUN LED showing orange during operation or red when
44. n semi auto mode the screen will prompt INPUT MOISTURE VALUE when the wet reading is ready Press over it and it will open numeric keypad Input the wet moisture value press enter and close the keypad When a calibration is in progress the mixer will not discharge and will not add any admixtures The calibration process will finish when the calibration screen is closed In either Auto or Semi auto calibration mode the calibration parameters should first be stored The screen should then be closed to continue with the mixing cycle 3 0 SYSTEM SETUP Some screens are only used for initially plant set up Because this data is critical to correct plant operation setup screens are password protected To prevent these settings being inadvertently changed we recommend that setup password only be given to supervisory personnel DATA ENTRY MENU MENUS AVAILABLE ARE FORMULAS INGREDIENTS SETUP PARAMETERS ENTER PASSWORD ion 9 5 J6 6 3 FI Pressing the MENU button displays the DATA ENTRY MENU screen 3 1 Passwords Several passwords can be entered to access the different functions shown on this screen Other passwords may be added from time to time See APPENDIX 6 1 for list of passwords FORMULAS allows the formula screen to be accessed and ingredient values to be entered modified or copied to another formula INGREDIENTS Allows the ingredient screen to be accessed
45. nd other equipment Scale Tron Inc cannot be held responsible for the consequences of poor maintenance The calibration procedure is given in Section 4 11 A scale reading of the capacity value a fixed negative number or a reading which does not change when the scale is loaded indicates a failure of a load cell cables transmitter or PLC input module Locate the transmitter for the affected scale and jumper the OUTPUT and COM terminals together with a short piece of wire The scale reading should change to a small negative number If this does not occur the PLC module is probably faulty If this occurs correctly jumper the SIG and SIG terminals together The reading should change to a small negative number if not showing this already Both conditions indicate a faulty load cell connection a faulty load cell or a mechanical fault on the load cell mount You could try adjusting the OFFSET switch and pot to re zero the display If successful the scale zero has been altered either by some mechanical work being done an overstressed load cell or an electrical problem Monitor it closely while running If the reading does not change turn the OFFSET switch to each extreme position If the display stil remains unchanged the transmitter is probably at fault BatchTron 1 Ver 1 0 28 5 2 Output failure If a motor or valve fails to operate first check the fuses bottom front of cabinet if one is blown its indicator will be
46. ng giving the highest accuracy at the fastest possible batching speed for the conditions ROM lt gt STOP 2 0 Operational Screens 2 1 Control Screens BatchTron lll has the capability for 250 different screens although only a few of these are used Some screens control plant functions while some allow data entry Scrolling through the screens is done with the arrow buttons in the bottom corners The MENU button provides access to the setup screens which require a password before they can be altered as does the formula screen Shortcuts are provided from the main screen to other areas pressing anywhere in the top bin area will access the MENU screen while pressing the water or admix areas will access the water admix screen Other shortcuts will be provided when appropriate The screen arrangement is customized to your plant Thus some screens will differ from the description or may not appear Some custom BatchTron Ver 1 0 CURRENT BATCH FOR MIXER BATCH BATCH SIZE 100 a 0 0 0 0 WATER in WATER he ADMIZ i adir 0 MIXER 1 MIXER 2 ALL AUTO Before turning on any equipment ensure that nobody is working on or around the plant machinery Ensure that all personnel are aware that equipment will start automatically and warn them before you start Post warning notices on conveyors and mixers Check the mixer in particular and ensure that the main power switch is open before all
47. orrect slump values are obtained for different mixes they can be entered in the FORMULA screen Each formula can have a different slump value which wil be retrieved and executed automatically NOTE 1 Super plasticizer is normally added AFTER the water has been added which will make the slump much greater Adjust the initial slump for 2 5cm and add enough super plasticizer to attain the desired final slump value 2 The FAST water cutting point is automatically processed by the PLC program when the power is going down Since the slump meter measures motor power the correct setting will change if the batch size changes Be aware and adjust the set point accordingly 2 33 MicroMix screen is available only with the MicroMix option It provides a low cost alternative to the MasterMix or equivalent water control system and is suitable when a short mixer cycle time is not of major importance run for 30 to 60 seconds and the FINAL water for 45 to 90 seconds If FINAL exceeds 90 seconds increase PRE WET value ifless than 45 seconds decrease PRE WET value When the time is correct note PRE WET setting if it is less than 85 seconds decrease the final wet flow rate by increasing the pressure regulator setting conical valve on the water valve assembly turn the adjusting screw clockwise If the time is PRE WET MOIS TURE REMOTE DIAL WATER LIMIT When the mixer cycle
48. owing access Keep the large red emergency STOP button in the depressed state until you are ready to start At any time during operation when you want to stop the equipment or if you think that someone is in danger press the STOP button All plant equipment controlled by the BatchTron will stop but when you restart it will continue from where it left off When you sure that it is safe turn on the POWER circuit breaker The batching graphic screen will appear The batching screen shows a diagram of the batch plant Along the top are aggregate bins and cement silos On top of each bin is marked the name of the ingredient Two rows of data are displayed The TARG row displays target weights and the ACT row displays actual values during and after each material feed The bin bottoms are actuator buttons which feed material into the scales These are active time that this screen is displayed Caution pressing these FEED buttons will feed material To prevent accidental feeding when the system is not in use press the red emergency stop button on the console Below the feed buttons are the scale hoppers each has a weight display a Zero button in the box and a discharge button hopper bottom The Zero button will zero the scale reading to compensate for drift material buildup and equipment maintenance Similar to the FEED buttons the DISCHARGE button will open the scale discharge gate Use caution
49. pear the screens and the correct area will be brought up automatically in the formulas screen Values that are self tune such as Dribble Preact will be recalculated automatically when the operator changes the system units 3 10 Scale Inspect Routine assis 1200 SETTLINS 880 800 n ACTUAL 12120 The operator can access this screen by touching a button in the SCALES SETTING menu screen The inspector can watch the target actual maximum and minimum tolerance settling and jogging events for each ingredient in part when they feed into the chosen input scale 3 11 Second language screens This feature is optional and will bring up all the screens in the second language by use of the language button on the batching screen DESEADO ACTUALES BANDA FLEX MEZCL 2 LOTE ACTUAL PARA MEZCL 0 LOTE 0 a TAMANO LOTE 100 E E ui I I ORMU ADMIX Mi 3 FORMULA pog MENU BatchTron 1 Ver 1 0 23 4 0 INSTALLATION AND SETUP 4 1 Power Connection The BatchTron can be powered from 110 volt or optionally 22 240 volt power 50 or 60Hz Connect the LINE input to the L1 terminal the NEUTRAL input to the L2 terminal and POWER GROUND to the green yellow ground terminal Route the wires through the cable duct to the bottom of the cabinet and make an opening where appropriate If using 220 240 volt power check the jumpers on the 24 volt or 12 volt power supply to en
50. r Setup Values JOG GATE OPEN TIMES SECONDS Use the E and buttons to locate each of the functions or touch the entry area to relocate the cursor Enter the desired values on the keypad folowed by ENTER The C button clears a wrong entry This parameter is only used on clamshell gates and butterfly valves which are jogged to simulate slow feed Motor driven devices such as conveyor belts and screw feeders must not be jogged enter 0 for these ingredients The jogging process closes the gate for 1 second and opens it for the time entered in seconds and tenths You should enter a time which allows an amount to fall with each jog which is equal TIMERS FOR MIXER CYCLE 1 STANDARD MIXER DELAYS MIXER MEXER2 MEXERS gt T T MISCELLANEOUS SETTINGS CALL TIMES IN SECONDS SPARE AGG SC VIBR OFF TIME AGG SC VIBR ON TIME SC VIBR OFF TIME MIXING TIME MIXER to the tolerance for the CE UM TIME DISCH PREWET XWATER METERED TIME ingredient FINAL WET DELAY ALL SPA NOTE Typical values for 2 hou aggregate clam gates are 0 5 ARE OUT FLEX BELT 2 2 to 0 8 sec INER 2 FULL DELAY 9 2 OPPER FULL DELAY RUNOUT INCL BELT MIX 2 1 ADMIXES AGGREGATE MOISTURE TIMEOUT ALARMS AGGREGATE FEEDS MENT 1 WATER ADMIX FILL SCALE DISCHARGE ADX WTR TIMEOUT oS oss 1 NOTE 11 delays after Mixer full delay ex
51. rmation from the D iagnostic Screen will be useful in reporting a problem to ScaleTron Inc The screen shows rows of lights numbered 0 to 15 Each row is labeled on the left as HO to H5 H13 to H14 Combine the light number with the row DIAGNOSTIC SCREEN D X UMS 1 1021 Ln ran rca FE a 111 ps T ton oma 1n 105 pan 1 mne Pag gd i PAY 9 vere lel PA ES vx TER Co 0u on ER Se i Am me ven 6 ALOG CHANELS 01 232 SCALE1 02 233 SCALE2 03 234 SCALE3 04 235 SCALEA S SCALES 6 SLUMPMETER aei d 7 rea p Ay eR og Im 55 peas Se 5 a mi ima ag qme pep pn Pa Pp OT me a ER aD Mis e pm ex pe x Wi Ren B 7 RADARTRON1 THIS IS THE FINAL REGULAR SCREEN 33 8 RADARTRON2 S MIXTRONi ejeje gt 222222229 LE LY 10 MINTRON PRESS MENU FOR SETUP SCREENS number to identify the light fully For example light number 12 in the second row H1 is number H1 12 During diagnosis we wil ask you to locate certain lights and tell us whether they are on or off The bottom ANALOG row shows the values being received from the scales and moisture or slump sensors These ar
52. run in the SIMULATE mode This mode is useful for training or fault finding purposes Note for this mode the red E STOP button on the console must be depressed to prevent actual plant equipment such as aggregate feeds and conveyors from running The system will run through batch and mixing sequences just as if real batches were being made Operators can be taught the different functions this way Since PLC outputs BatchTron Ver 1 0 live these be checked for correct sequencing in the case of an equipment failure SIMULATE mode is cancelled by pressing the SIMULATE button once again 2 2 2 From Batch Link Order Entry operation Please refer to Batch Link Manual for this kind of operation NOTES Starting the Demand selects the first line KBD of the SET UP FORMULA SIZE TO RUN screen When all is ready and you have ensured that no personnel are working on the equipment turn the large red emergency STOP button on the console to the right to energize the external equipment Initiate the batch The RUN button should turn GREEN and the target weights should appear on the screen If the STOP button is still RED the pre start conditions have not been met These differ from one system to another but check that the scale discharge gates are closed and any other input enabling conditions are met such as BIN LOW PROBE when feeding dry cast to a holding hopper or a BUCKET IN PLACE signal when fe
53. st correctly verify the communication by monitoring the COM1 and COM2 lamps on the PLC One should be pulsing continuously the display port and the other should pulse during normal print If it does not or the printer still does not print check the cables and connections for open circuit 5 8 Modem operation Using the modem Scale Tron service personnel can check the contents of the PLC check your setup data upload this data and correct it if necessary We can also view the system while it runs and locate faults which are holding up operation If necessary we can modify the program to overcome problems and download new updated software To operate the modem the modem cable must be plugged into a phone jack and the modem power must be on Verify that the POWER lamp on the modem is lit Open the control panel and locate the cable labeled MODEM in the rear area of the cabinet Disconnect the PRINTER cable and replace it with MODEM cable remember to switch it back after you are finished Locate the PLC main module labeled CPU 44 Under the RUN and COM1 COM2 lamps is a door Open it and switch DIP switch number 4 to the PERIPHERAL BY SETUP position ON to the left if it is not already ON You are now ready to start modem communication Call Scale Tron and ask for further instructions Please have a good description of your problem before calling us BatchTron 1 Ver 1 0 5 9 Diagnostics Screen Info
54. starts in AUTO the PREWET water runs to set value which is defined as a percentage of the FINAL WET set value Water then turns off for a programmable delay and then the FINAL WET turns on and runs to the set value After an equal programmed delay the mix is ready PREWET and FINAL WET buttons can be used for manual water feed To set up the first batch add water manually by pressing these buttons until the moisture in the mix is correct Note the Moisture value on the screen and set the FINAL WET indication to this value by using its T or 4 buttons Pressing STORE enters this value into the formula in use The PRE WET value is a fixed percentage of the FINAL WET value After the moisture has been set correctly monitor the PREWET and FINAL lamps and time the addition of water in each case Ideally the PRE WET water should BatchTron Ver 1 0 Moisture system MOISTURE 80 50 FINAL WET of the arrow buttons more than 90 seconds increase the flow rate turn screw counter clockwise The graph shows two curves The blue curve is the direct moisture reading and the white curve is average moisture The two curves are used in setting up the system by observing the mixing action Although this curve will eventually scroll off the Screen it can be viewed by use immediately under the graph The water limit feature allow the system to set a maximum value for the water added to mix therefore cutting the water if the
55. sure that they are set for the correct voltage to change cut both jumpers with wire cutters and solder together in the 240V position The PLC and some models of power supply handle both supply voltages without change 4 2 Input and output connection Inputs are either 24 volt dc 110 or 240 VAC as discussed at the time if the order Outputs are controlled via relays which are normally connected to the line voltage 110 to 240 volts The fuse holders include neon blown fuse indicators which operate on 110 240 volt power they wil not illuminate on 24 volt power These are replaced by 24 volt LED indicators for 24 V operation Inputs should be connected to the PLC terminal strips according to the schematic diagram supplied Route the wires through the cable ducts provided to the bottom of the cabinet and make openings where appropriate Leave a loop of wire at least 6 long beneath the PLC terminal strip to allow the terminal strip to be removed for service BatchTron 1 Ver 1 0 24 4 3 Special inputs Several inputs are provided for central mix applications as follows BATCH START duplicates the RUN button to start a batch but does not restart it after an alarm This input can be connected to a remote push button or to a bin level indicator in a concrete holding hopper to reorder concrete when the bin level is low This will give a slow batch delivery since the batch is only started when the bin is low SCAL
56. t see summing unit instructions Increase the amount of test weights used as the correct adjustment is approached Offset Locate the load cell transmitter for the scale to be calibrated inside the BatchTron cabinet These transmitters are green circuit boards marked 1410 While monitoring the display turn the OFFSET rotary switch to the position which gives the lowest positive reading Note Do not press the ZERO control on the touch screen prior to this adjustment If it has been pressed turn the power off and on again to reset the system Using a small screwdriver turn the transmitter ZERO control to obtain a zero reading on the display If necessary turn the OFFSET switch to its next position Caution if the OFFSET switch is turned too high a negative reading will be obtained which will not vary when the ZERO control is turned Reduce the OFFSET setting until a positive reading is obtained Span Load the scale with test weights Using the total weight of test weights added move the SPAN jumper to obtain the closest reading and turn the SPAN control until the correct reading is obtained If necessary move the SPAN jumper to its next position Remove the weights and verify that the reading returns to zero within the required accuracy normally an error of a few LB or kg is acceptable If not within desired limits repeat the offset and span adjustments unti the desired accuracy is obtained Remove the lifting
57. the high voltage and 24 Vdc circuit apply power and turn on the circuit breaker inside the front panel and the POWER keyswitch on the front panel If the breaker trips now or during testing there is a short circuit in the added wiring Successful operation is shown by the appearance of the batching graphic screen If the screen does not illuminate check the 24 volt power supply Its output should be between 22 and 28 volts DC If an error message is displayed proceed to section 5 4 To verify the output connections to valves and motor starters press the manual buttons on the various graphic screens while monitoring the appropriate devices If one or more do not operate check the LED indicators on the PLC output module then check the fuses Use a voltmeter if necessary to verify that the output is energized when the button is pressed and proceed to FAULT FINDING Remember that there is a 10 second warning alarm delay before the mixer motor is energized During this time the graphic symbol flashes To verify input connections from motor starters and position switches operate each switch in turn and monitor the appropriate symbols on the graphic screen which should darken For the few inputs which do not have a symbol monitor the LED indicator on the PLC input module It is essentia to have all inputs connected they are interlocked with the internal sequence and wil prevent proper automatic operation proceeding if not present
58. the warning using the following procedure Ensure that the unit has been powered for at least 5 minutes to charge the capacitor and then turn off the power This gives 5 minutes to replace the battery before the memory is lost PLC module replacement If the PLC output indicators are not illuminating or the display indicates communication problems a PLC fault is indicated Verify that the power indicator on the PLC power supply is illuminated If not check the incoming power voltage and the power connections If the RUN indicator is not illuminated check the connection of the plug in modules These units all plug together in an end to end manner and locking tabs on the top and bottom of each unit lock them in place Verify that all units are tightly plugged together and the locking tabs are pushed towards the rear panel Slider uU Loc Ps de dus PL ne a If a module is faulty remove the wiring connector by opening the gray locking tabs on each end of the connector and pulling the connector out of the module body Unlock the orange locking tabs at the top and bottom of each side of the faulty module by pulling them forward Then carefully pry the modules apart sideways until the connectors part If locking brackets are fitted at each end of the PLC on the DIN rail loosen one end BatchTron Ver 1 0 31 Finally release the module from the DIN rail by levering down the yellow
59. vided The load cell transmitter units model 1410 wil supply excitation for up to 4 350 ohm load cells only per scale for a greater number of load cells the optional EXCITATION SUPPLY must be used 4 6 Printer BatchLink connection The printer or BatchLink cable plugs into the RS 232 communication port adjacent to the PLC See Schematics for details BatchTron 1 Ver 1 0 25 4 7 Modem connection To operate the modem the modem cable must be plugged into a phone jack and the modem power must be on Verify that the POWER lamp on the modem is lit The Modem cable usually plugs into the Peripheral communication port adjacent to the PLC See Schematic for details Locate the PLC main module labeled CPU 44 Under the RUN and COM1 COM2 lamps is a door Open it and switch DIP switch number 4 to the ON SETUP position ON to the left if is not already ON 4 8 Moisture sensor connection Up to twelve moisture sensors such as the Radartron 1400C can be connected to the BatchTron lll See Schematic for connection details 4 9 Wiring verification WARNING before applying power verify with a test meter that there is no connection between the mains power circuits and the 24 volt dc circuits Any connection between these circuits will destroy all internal electronics This damage is not covered by warranty After verifying that the power jumpers are in the correct position and that there are no connections between
60. with the FINAL WET cycle Both must be complete before discharge can commence MIXER DISCHARGE TIME the time for which the mixer discharge door is open in automatic mode If discharge takes place manually the door must be held open for at least this time in order to cancel the automatic mixer cycle Observe the MIXER FULL symbol on the batch screen it is extinguished when the mixer cycle is complete TIMEOUT ALARMS These timers will create an alarm and stop the batching process if any feed time exceeds the set value It warns of material bridging or empty bins etc Enter values that are double the expected feed time for each ingredient WATER ADMIX FILL will create an alarm if the feed time exceeds the set value SCALE DISCHARGE scale discharge timeout will initiate an alarm if the time is exceeded during scale discharge Allow double the normal scale discharge time INGREDIENTS DISCHARGE DELAYS normally the aggregate is discharged first followed by cement and water Some admixes need to be discharged with the aggregate MASTERMIX SLUMPMETER SEITINGS sensor signal and the more stable the result will be and hence will increase the stability signal STAB LTS Is the target accuracy of the water amount in liters Increasing this value will decrease the stabilization time but will decrease the accuracy TIMERS FOR MIXER CYCLE 2 LIGHTWEIGHT MIXER DELAYS while others should discharge later These t
Download Pdf Manuals
Related Search