LC-1000/ LC-2000 Loadout Manual

LC-1000/ LC-2000 Loadout Manual
LC-1000/ LC-2000
Loadout
Manual
SEquipment
Y S TCorporation
EMS
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All equipment is tested for proper operation before shipping from the factory.
Although no difficulty is typically expected, SYSTEMS cannot guarantee and will not
warrant that this product will function safely and as described, if equipment is
replaced by others, if additional equipment or software is installed, or if this
equipment is used for other purposes.
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WARRANTY
Systems Equipment Corporation, hereafter referred to as SYSTEMS, warrants its
products to be free from defects in material and workmanship under normal use and
service for a period of one (1) calendar year from date of shipment from the factory.
SYSTEMS' obligation shall be limited to repairing or replacing materials, parts, or
software determined, by SYSTEMS, to be defective in workmanship or suitability of
purpose. Notice of warranty claims must be submitted by the Buyer in writing to
SYSTEMS no later than fourteen (14) calendar days following the warranty's
expiration date.
All defective products must be returned to SYSTEMS for warranty service. All
transportation and insurance costs incurred are the responsibility of the Buyer. When
a defective product is so permanently installed that it cannot be readily removed and
returned, SYSTEMS will provide repair service at the site of installation. All
transportation and lodging expenses for on-site warranty service are the
responsibility of the Buyer. All non-warranty parts and labor will be billed to the
Buyer at the prevailing on-site service rate. All repaired or replaced parts are
warranted to be free from defects of material and workmanship for a period of ninety
(90) days from the date of installation or until the termination of the original
warranty, whichever is longer.
SYSTEMS assumes no liability for consequential damages of any kind and the Buyer,
by acceptance of delivery, releases and indemnifies SYSTEMS from any liability for
the consequence of use or misuse of any of the products provided by SYSTEMS or
used in conjunction with products provided by SYSTEMS.
The foregoing warranties constitute the entire warranty and are to be held expressly
in lieu of any other verbal, implied or assumed warranties, including those which
apply to the merchantability, fitness of purpose, or promptness of delivery of
products, or any other material obligation on the part of SYSTEMS.
TERMS and CONDITIONS
Shipping:
All equipment is FOB Waukon, IA USA
Payment
Schedule:
All prices quoted are in US dollars.
All checks submitted for payment are to be drawn on US
banks 1.5 % per month service charge on delinquent
accounts.
Taxes:
All taxes, levies, or duties that may result from this
transaction are the sole responsibility of the buyer.
Codes:
Certification to any applicable electrical or building codes or
other governing specification is the sole responsibility of the
buyer.
TABLE OF CONTENTS
Introduction ................................................................................................................................................... 1
Quick Start ..................................................................................................................................................... 3
Start Up Copyright Screen.............................................................................................................................. 5
Program Navigation....................................................................................................................................... 7
Main Operating Screen .................................................................................................................................. 9
HOT KEYS ................................................................................................................................................................................... 9
TRUCK .......................................................................................................................................................................................... 9
NET ............................................................................................................................................................................................... 9
GROSS........................................................................................................................................................................................... 9
DROPS ........................................................................................................................................................................................ 11
JOB .............................................................................................................................................................................................. 11
CUSTOMER................................................................................................................................................................................. 11
SILO / SCALE............................................................................................................................................................................. 11
MATERIAL.................................................................................................................................................................................. 11
WEIGH IN / WEIGH OUT OPTIONS ..................................................................................................................................... 11
Loading—Truck Scale ................................................................................................................................. 15
ALT-L AUTOMATIC LOADING ............................................................................................................................................... 15
Messages ................................................................................................................................................................................. 17
ALT-M MANUAL TICKET ........................................................................................................................................................ 19
Loading – Reverse Weigh Silo...................................................................................................................... 21
ALT-L AUTOMATIC LOADING ............................................................................................................................................... 21
Messages ................................................................................................................................................................................. 23
ALT-M MANUAL TICKET ........................................................................................................................................................ 25
Loading—Weigh Batcher ............................................................................................................................ 29
ALT-L AUTOMATIC LOADING ............................................................................................................................................... 29
Messages ................................................................................................................................................................................. 31
ALT-M MANUAL TICKET ........................................................................................................................................................ 33
Loading Pup Trucks—All Systems .............................................................................................................. 35
Low Silo Bypass ........................................................................................................................................... 37
Material Flow Errors .................................................................................................................................... 39
Aborted Loads .............................................................................................................................................. 41
F1-Lists................................................................................................................................................. 43
l
HELP ........................................................................................................................................................................................... 43
TRUCK LIST ............................................................................................................................................................................... 43
CUSTOMER LIST........................................................................................................................................................................ 43
JOB LIST ..................................................................................................................................................................................... 45
SILO CONTENTS ....................................................................................................................................................................... 45
MATERIAL LIST......................................................................................................................................................................... 45
CUSTOMER COMMENTS .......................................................................................................................................................... 45
TICKET LIST .............................................................................................................................................................................. 45
REPORT MENU ......................................................................................................................................................................... 47
UTILITY MENU .......................................................................................................................................................................... 47
ESC............................................................................................................................................................................................. 47
SYSTEM SHUTDOWN ................................................................................................................................................................ 47
F2-Context Sensitive List......................................................................................................................49
nF3-Ticket List ....................................................................................................................................... 51
m
CORRECTION TICKETS ............................................................................................................................................................ 51
CASH TICKETS .......................................................................................................................................................................... 51
HAND-GENERATED TICKETS ............................................................................................................................................... 53
DITTO TICKET .......................................................................................................................................................................... 53
FIND TICKET ............................................................................................................................................................................ 53
PRINT TICKET ........................................................................................................................................................................... 55
DISPLAY TICKET ...................................................................................................................................................................... 55
F4-Utility Menu ....................................................................................................................................57
o
UNRESOLVED TICKETS ........................................................................................................................................................... 57
WEIGH IN / OUT MODE ........................................................................................................................................................ 57
LOADOUT MODE..................................................................................................................................................................... 57
CHANGE POSTING DATE ....................................................................................................................................................... 57
SELECT COPY MODE ............................................................................................................................................................... 59
GATE CHECK ............................................................................................................................................................................ 59
SYSTEM SETUP .......................................................................................................................................................................... 59
Loading Setup......................................................................................................................................................................... 63
Ticket Setup............................................................................................................................................................................ 67
Software Setup ........................................................................................................................................................................ 69
FILE MAINTENANCE ............................................................................................................................................................... 75
Archiving Tickets.................................................................................................................................................................... 75
Erasing Lists .......................................................................................................................................................................... 75
REPORT MENU ......................................................................................................................................................................... 77
PRINT TRUCK LIST ................................................................................................................................................................... 77
PRINT JOB LIST ......................................................................................................................................................................... 77
PRINT CUSTOMER LIST ........................................................................................................................................................... 77
BACKUP TO DISKETTE ............................................................................................................................................................ 77
RESTORE FROM DISKETTE ..................................................................................................................................................... 79
TRAINING MODE / RESUME LOADOUT MODE ................................................................................................................ 79
EXIT PROGRAM ........................................................................................................................................................................ 81
ESC............................................................................................................................................................................................. 81
p F5-Unresolved Tickets............................................................................................................................83
q F6-Weigh In / Out or LoadOut..............................................................................................................85
r F7-System Shutdown ..............................................................................................................................89
s F8-Comments......................................................................................................................................... 91
t F9-Cash Sale........................................................................................................................................... 93
u F10-Fill / Empty Inventory Pictograph .................................................................................................. 95
F11-Copy Mode..................................................................................................................................... 97
F12-Tare a Truck .................................................................................................................................. 99

Hand-Generated Tickets............................................................................................................................. 101
Electronic Data Transfer—RedRover .........................................................................................................103
Sleep Mode..................................................................................................................................................105
Troubleshooting..........................................................................................................................................107
LC-1000/ LC-2000 Database Formats ......................................................................................................... 111
STRUCTURE FOR DATABASE: TICKET.DBF..................................................................................................................... 112
Explanation of fields in TICKET.DBF .............................................................................................................................. 113
STRUCTURE FOR DATABASE: TRUCK.DBF ...................................................................................................................... 118
Explanation of fields in TRUCK.DBF ............................................................................................................................... 118
STRUCTURE FOR DATABASE: JOB.DBF ............................................................................................................................. 120
Explanation of fields in JOB.DBF....................................................................................................................................... 120
STRUCTURE FOR DATABASE: CUSTOMER.DBF............................................................................................................. 122
Explanation of fields in CUSTOMER.DBF...................................................................................................................... 122
STRUCTURE FOR DATABASE: MIXES.DBF ....................................................................................................................... 123
Explanation of fields in MIXES.DBF................................................................................................................................ 123
STRUCTURE FOR DATABASE: SILOS.DBF ......................................................................................................................... 124
Explanation of fields in SILOS.DBF.................................................................................................................................. 124
STRUCTURE FOR DATABASE: SCALES.DBF ..................................................................................................................... 126
Explanation of fields in SCALES.DBF............................................................................................................................. 126
Index ...........................................................................................................................................................128
Jog Gate Addendum ............................................................................................................................................................. 131
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INTRODUCTION
An LC-2000 Material Loading Computer is a hardware/software system used to:
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Automatically load asphalt from a single silo onto trucks
Maintain silo inventory
Perform weigh-in/weigh-out (i.e., quarry) operations
Maintain ticket, job, customer, truck, and material databases
Transmit databases to/from another computer via a modem
An LC-1000 Material Loading Computer is an expanded version of the LC-2000 in that the
software and hardware are capable of supporting up to 4 silos.
Except for the number of silos, the operation of these programs is identical. Hereafter, the
software and hardware for either an LC-1000 or an LC-2000 will be referred to collectively as
the "LoadOut".
The primary databases maintained by the LoadOut are:
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Ticket
Job
Customer
Mixes
Silos
Truck
Scales
Comment
The LoadOut has several other databases it uses for its own purposes. In particular, the
Attributes database contains configuration data to customize the program for the customer's
individual needs.
The databases are in FoxPro 2.6 DBF format. Consequently, most accounting and spreadsheet
programs can directly read them. The set of units used for the internal databases is English
pounds (i.e., lbs.), dollars, and miles. Weighing indicators can be calibrated in any of several
different measurement units, but the program will always convert the measurement internally to
lbs. In addition, the operator may choose a third set of units for display and printing in which
case the program will convert from lbs. to the operator’s choice.
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Q U I C K S TA R T
To load a truck and generate a ticket, follow these steps:
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Enter a truck in the truck field by typing in a number or selecting it from the truck list
If the job should be different from the one shown in the job field, enter a job in the job field
by typing in a number or selecting it from the job list – because customers are tied to jobs,
the customer will automatically be selected
If the material in the silo is different from the one shown in the material field, type in the
material name or select another from the material list
The program will perform internal checks to verify that loading can proceed. When the
program is ready, (Alt-L)oad will be displayed in the bottom center of the screen.
Otherwise, this area will display a message indicating the problem that needs attention.
While holding down the a key, press the L key to begin the load.
When the load completes, the ticket is printed and saved to the internal ticket database, the
loading horn will sound if enabled, and the cursor will return to the truck field making the
program ready for the next load.
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Fig. 1 (above) Fig. 2 (below)
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S TA R T U P C O P Y R I G H T
SCREEN
When the program first starts, it performs several initialization and configuration procedures.
During this time, the copyright screen as shown in Fig. 1 will be displayed. If it is necessary to
adjust configuration parameters, press any alpha key while the copyright screen is displayed.
After a short delay, the configuration password screen will appear as shown in Fig. 2. If you are
authorized to make configuration changes, type the password where indicated. Refer to the
Software Setup section regarding configuration changes that can be made. After the changes
have been accepted, the program will restart and re-display the copyright screen.
SPECIAL NOTE
Pressing the aL keys while the copyright screen is displayed invokes an internal
version of the FIELDMOD utility (included in your installation directory) from which
Attribut.DBF can be modified.
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P R O G R A M N AV I G AT I O N
To move between fields on the main screen, use the w and y keys. When the cursor is
flashing in an input field, simply type in the truck, job, or material desired or press m. The m
key brings up the list associated with the field the cursor resides in. For example, if the cursor is
in the material field, pressing the m key brings up the materials list. A selection can then be
made from the list.
Many of the screens in the program require that you make a selection from the displayed list.
Use the following keystrokes to navigate through a list:
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Use w to move up one line
Use y to move down one line
Use {to move up one full screen
Use } to move down one full screen
Use g to go to the top of the list
Use d to go to the bottom of the list
Use e to accept the highlighted item
Use ^ to close the list without changing the current selection
In addition, many of the lists include options for adding, changing, deleting, etc., list entries.
These are indicated at the bottom of the list. For example, the truck list shows (N)ew Truck to
add a new truck. To add a truck, simply press N for the New Truck screen. From the Silos
list, you can also add materials by pressing the M key.
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Hot Keys
Truck Field
Gross Field
Net Field
Drops Field
Job Field
Fig.3a
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M A I N O P E R AT I N G S C R E E N
A typical Main Operating Screen is shown in Figures 3a, 3b, and 3c. The Main Operating Screen
is divided into ten distinct display areas:
Hot Keys
Hot keys along the top of the screen give the operator quick access to frequently used lists and
menu functions. For example, as the operator moves the cursor through the data entry fields,
the hot keys change to give the operator access to the underlying database associated with the
particular field.
Truck
The truck area allows the operator to type the name of a truck in the truck database. If the truck
exists, the remaining fields are automatically retrieved and entered. If the truck does not already
exit, the truck list opens with the closest spelling highlighted.
Net
In LoadOut mode, the NET field contains the net amount that will be loaded onto the truck.
This value comes from the truck database when a truck is selected. The operator can
temporarily change the NET for the current load by typing in a different value, as long as the
value does not exceed GROSS - TARE. With the cursor in the NET field, the operator can
change to GROSS mode by typing a G character.
In NET mode, the program will load the truck to the selected net weight. In GROSS mode, the
program will load the truck up to the indicated gross weight of the truck, irrespective of the
NET value.
Gross
The GROSS field contains the gross weight of the truck. This value comes from the truck
database when a truck is selected. The operator cannot change the value here (use the TRUCK
list to effect changes to GROSS). In LoadOut mode, the GROSS is the maximum weight the
program will load onto the truck. Lesser amounts can be loaded if the NET field is less than
GROSS. With the cursor in the GROSS field, the operator can change to NET mode by typing
an N character.
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Net Field
Drops Field
Job Field
Figures 3a & 3b
Weigh In / Weigh Out
Options
Customer Field
Silo/Scale Field
Material Field
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Drops
The DROPS field specifies the number of drops conducted to load the truck. This value also
comes from the truck database when a truck is selected. The operator can temporarily change
the value here for the current load (use the TRUCK list to effect permanent changes.)
Job
The JOB field specifies the job to which the load will be assigned. A job is always attached to a
customer. When an existing job is typed in, both the job and the customer fields are completed.
If the job does not exist in the database, the job list opens to the nearest spelling. The operator
can make a selection or enter a new job.
Customer
The CUSTOMER field specifies to whom the load will be billed. Since every job must specify a
customer, picking a job causes this field to be filled in automatically.
Silo / Scale
In LoadOut mode the silo is selected from the PLC via the console selector switch, if multiple
silos exist. If only one silo exists, the cursor will not stop at this screen location because there is
only one possible silo. Behind the scenes, the appropriate scale indicator will be selected
automatically because every silo is assigned to the appropriate scale by software.
In Weigh In/Weigh Out mode, the operator can choose a truck scale if multiple truck scales
exist – if only one truck scale exists, this field is bypassed.
Material
The material being loaded is displayed in this area. For a LoadOut system, the material
automatically reflects the material in the selected silo. Typing in a different material changes the
data in this field if the material already exists in the database. If the material does not exist, the
material list opens to allow the operator to add a material. In Weigh In/Weigh Out mode, this
field retains the value entered until the operator changes materials.
Weigh In / Weigh Out Options
This input area is only active when the system has a truck scale and the operator chooses Weigh
In/Weigh Out mode (see q key). Otherwise, this area is overlaid with cash ticket or silo
inventory information. The choices in this area consist of 3 mutually exclusive pairs:
Material received in or material delivered out
Cash transaction or credit transaction
Use tare on file or defer tare
When material is received into your inventory from a supplier, the ‘received’ option should be
selected – otherwise when the material is delivered out of your inventory to a customer, the
‘delivered’ option should be chosen.
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When the transaction is a cash transaction, the ‘cash’ option should be chosen – otherwise
choose a ‘credit’ transaction.
If the truck tare is known at the time of a transaction, choose ‘use tare’. Choosing ‘defer tare’
causes the ticket to be retained in an ‘unresolved’ database and will not be printed until a tare is
entered for the truck. The tare is entered by weighing the truck on the scale, using the tare from
the database, or manually entering a tare value. See the discussion for the key regarding
obtaining a truck tare.
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Fig. 4
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LOAD IN G— TRU C K S C A LE
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Enter the load information, starting with the Truck ID. Depending on which information
copy mode is used (see F11—Copy Mode), typing the Truck ID in the truck id field and
pressing ENTER may bring up Job and Customer information.
If the Job ID is not the desired job for this load, type the correct Job ID in the job field.
Next, make sure that the desired silo is selected to draw from (multiple silo systems only).
Verify that the material shown on the screen is the material to load onto the truck. Rejected
Material may not be loaded because it is a special category for those systems having a slat
conveyor reject gate.
Once all of the load information has been entered, the truck is on the scale, and other safety
conditions have been met, the bottom area of the screen shows (Alt-L)oad Truck and (AltM)anual Ticket. To execute a cash ticket, press F9 before loading (see the section Cash Tickets).
Alt-L Automatic Loading
Verify that conditions are safe to load.
Remove manual interlocks, such as opening the safety gate for the selected silo.
Comments are special records stored in a separate Comments database. They can be used to
flag special conditions that apply to certain customers (for example, credit limits). If a comment
exists for the selected customer, a window will pop up displaying the comment and prompt the
operator to press Y for yes to continue the load (see F8—Customer Comments). If N is
selected, the program returns to the main screen without loading the truck.
The system checks its safeties again and waits for a stable (no motion) weight from the weighing
indicator.
The silo gate opens and begins to drop the prescribed amount of material.
After the proper amount has dropped, the system closes the silo gate and waits for a stable
ending weight.
A brief message appears on the screen indicating that the program is learning new values for the
freefall and flow rate. In some cases, if circumstances prohibit learning new values (drop too
small, for example), the message indicates why the program has bypassed this step.
If the Horn After Batch (sec) setting in Loading Setup is greater than zero, the end-of-batch
horn blows.
On loads that require multiple drops—if the value for Automatic Loading Delay in Loading
Setup is greater than zero, that number of seconds is counted down and the next drop begins. If
the value is zero, the operator must press aL to begin each drop.
After the load is completed, if the Horn Load Complete (sec) value is greater than zero, the horn
blows.
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Typical ‘Before Load‘
Message Location
Fig 5 (above) Fig. 6 (below)
Typical ‘During Load’
Message Location
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The ticket is saved to the hard drive in the computer and ticket(s) are printed if printer(s) are
attached and enabled.
Pressing and holding a and pressing the A causes the system software to abort the load as
soon as it is able.
CAUTION
THIS IS NOT A SUBSTITUTE FOR A HARDWARE EMERGENCY STOP
BUTTON!
Use a properly wired hardware emergency stop to shut the silo gate in an emergency. Although
aA will cause the software to attempt to shut the gate, in case of damage to or failure of
system hardware, this might not happen fast enough to prevent bodily injury or property
damage. Please see the section on aborted loads for more detail.
Messages
If any system safety or incomplete information on the loading screen is preventing
the start of the load, messages will appear at the bottom of the screen. If any of the
system safeties is triggered during a drop, the system will attempt to close the silo
gate and a message will be displayed on the screen. The following table describes the
messages, their causes, and a possible remedy:
Message
BEFORE
LOADING:
Truck not defined
Job not defined
Can’t load rejected
material
Net too large
Too many drops
Waiting for truck
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Cause
Remedy
No Truck ID has been
entered
No Job ID has been entered
Material in selected silo is
Rejected Material
Net weight requested for
load is greater than the
truck’s maximum gross
weight minus the tare weight
for the truck
Net weight requested for the
load divided by the requested
number of drops is smaller
than the Smallest Drop
Weight safety setting
Weight on scale is less than
the Minimum Truck Weight
safety setting
Type Truck ID in Truck ID
field
Type Job ID in Job ID field
Change material in selected
silo
Reduce the net weight for
the load and/or increase the
maximum gross weight
allowed for the truck
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Decrease number of drops
Drive truck onto scale or
reduce Minimum Truck
Weight setting
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First Step of a
Manual Ticket
Fig. 7 (above) Fig. 8 (below)
Final Step of a
Manual Ticket
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Low Silo
DURING
LOADING:
Waiting for stable
weight
(informational
only—not an error)
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Low Silo Bindicator indicates Use the Low Silo Bypass or
a silo is almost empty
wait for more material
Weighing indicator shows
weight in motion
Wait for weight to stabilize,
reduce time system waits for
stable weight, check scale for
instability or increase
indicator filtering
Material flow error
Material stopped flowing
Fill silo, check silo gates,
(see section on
before the system expected it abort load or increase setting
material flow errors) to for the number of seconds for Seconds Before Material
in the Seconds Before
Flow Error
Material Flow Error setting
Truck moved off
Weight on scale dropped by Drive truck back onto scale
scale
a large amount
or abort load.
Alt-M Manual Ticket
If the load is too small to load accurately with the automatic system (for example, a pickup
truck), material can still be loaded if the operator controls the silo gate manually. In manual
mode, the program captures weights when instructed to do so by the operator. The operator
controls the hardware from the manual panel controls.
Pressing and holding a and pressing M prompts the operator to press the ENTER key to
take the starting weight for the drop. After a stable starting weight is captured, the operator is
prompted to load material onto the truck and press the ENTER key when done. A stable end
weight is taken and the operator is given the choice to either load more material onto the truck
or quit and generate a ticket. Using the arrow keys allows the different options to be selected.
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LOAD IN G – RE V ER SE W EI G H
SILO
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Enter the load information, starting with the Truck ID. Depending on which information
copy mode is used (see F11—Copy Mode), typing the Truck ID in the truck id field of the
screen and pressing ENTER may bring up Job and Customer information.
If the Job ID is not the desired job for this load, type the correct Job ID in the job field.
Next, make sure that the desired silo is selected to draw from (multiple silo systems only).
Verify that the material shown on the screen is the material to load onto the truck. Rejected
Material may not be loaded.
Once all of the load information has been entered and other safety conditions have been met,
the bottom area of the screen shows (Alt-L)oad Truck and (Alt-M)annual Ticket. To execute a
cash ticket, press F9 before loading (see the section Cash Tickets).
Alt-L Automatic Loading
Verify that conditions are safe to load.
Remove manual interlocks, such as opening the safety gate, for the selected silo.
If a comment exists for the selected customer, a window will pop up with the comment and
prompt the operator to press Y for yes to continue the load (see F8—Customer Comments). If
N is selected, the program returns to the main screen without loading the truck.
The system then waits for the gob hopper at the top of the silo to cycle open and closed. If the
loadout system is controlling the gob hopper, it will immediately cause it to open for the
prescribed amount of time, then close.
The system checks its safeties again and waits for a stable (no motion) weight from the weighing
indicator.
The silo gate opens and begins to drop the prescribed amount of material.
After the proper amount has dropped, the system closes the silo gate and waits for a stable
ending weight.
A brief message appears on the screen indicating that the program is learning new values for the
freefall and flow rate. In some cases, if circumstances prohibit learning new values (drop too
small, for example), the message indicates why the program has bypassed this step.
If the Horn After Batch (sec) value in Loading Setup is greater than zero, the end-of-batch horn
blows.
On loads that require multiple drops, if the value for Automatic Loading Delay in Loading Setup
is greater than zero, that number of seconds is counted down. The system waits for the gob
hopper at the top of the silo to cycle open and closed, then the next drop begins. If the value is
zero, the operator must press aL to begin each drop.
After the load is completed, if the Horn Load Complete (sec) value is greater than zero, the horn
blows.
The ticket is saved to the hard drive in the computer and ticket(s) are printed if printer(s) are
attached and enabled.
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Typical ‘Before Load‘
Message Location
Fig. 10 (above) Fig. 11 (below)
Typical ‘During Load’
Message Location
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C O M P U T E R
Pressing and holding a and pressing the A causes the system software to abort the load as
soon as it is able.
CAUTION
THIS IS NOT A SUBSTITUTE FOR A HARDWARE EMERGENCY STOP
BUTTON!
Use a properly wired hardware emergency stop to shut the silo gate in an emergency. Although
aA will cause the software to attempt to shut the gate, in case of damage to or failure of
system hardware, this might not happen fast enough to prevent bodily injury or property
damage. Please see the section on aborted loads for more detail.
Messages
If any system safety or incomplete information on the loading screen is preventing
the start of the load, messages will appear at the bottom of the screen. If any of the
system safeties is triggered during a drop, the system will attempt to close the silo
gate and a message will be displayed on the screen. The following table describes the
messages, their causes, and a possible remedy:
Message
Before loading
Truck not defined
Job not defined
Can’t load rejected
material
Net too large
Too many drops
Silo < Drop Size
SYSTEMS Equipment Corporation
Cause
Remedy
No Truck ID has been
entered
No Job ID has been entered
Material in selected silo is
Rejected Material
Net weight requested for
load is greater than the
truck’s maximum gross
weight minus the tare weight
for the truck
Net weight requested for the
load divided by the requested
number of drops is smaller
than the Smallest Drop
Weight safety setting
Silo doesn’t contain enough
material to make the current
drop.
Type Truck ID in Truck ID
field
Type Job ID in Job ID field
Change material in selected
silo
Reduce the net weight for
the load and/or increase the
maximum gross weight
allowed for the truck
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Decrease number of drops
Wait for gob hopper to add
enough material or reduce
the net weight for the load
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First Step of a
Manual Ticket
Fig. 12 (above) Fig. 13 (below)
Final Step of a
Manual Ticket
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Low Silo
During Loading
Waiting for stable
weight
(informational
only—not an error)
S I L O
Silo is below the Minimum
Silo Weight
L O A D O U T
C O M P U T E R
Use the Low Silo Bypass or
wait for more material
Weighing indicator shows
weight in motion
Wait for weight to stabilize,
reduce time system waits for
stable weight, check scale for
instability or increase
indicator filtering
Small Drop Size
The next drop requires more Wait for gob hopper to add
Options
material than the silo
enough material or reduce
contains
the net weight for the load
Material flow error
Material stopped flowing
Fill silo, check silo gates,
(see section on
before the system expected it abort load or increase setting
material flow errors) to for the number of seconds for Seconds Before Material
in the Seconds Before
Flow Error
Material Flow Error setting
Gob hopper opened Gob hopper opened while
The message is dismissed
unexpectedly
silo gate was open, causing
automatically, but to prevent
possible weighing inaccuracy inaccurate drops in the
future, reduce Maximum
Batch Weight setting,
increase the number of
drops, and/or increase the
time the gob hopper is
closed each cycle
Alt-M Manual Ticket
If the load is too small to load accurately with the automatic system (for example, a pickup
truck), material can still be loaded if the operator controls the silo gate manually. In manual
mode, the program captures weights when instructed to do so by the operator. The operator
controls the hardware from the manual panel controls. The operator should pay particular
attention to synchronizing manual drops with the gob hopper gates because dumping material
from the gob hopper while the silo gates are open will corrupt the weight readings.
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Pressing and holding a and then pressing M prompts the operator to press the ENTER
key to take the starting weight for the drop. If the system controls the gob hopper, it opens the
gob hopper at this time; otherwise, it waits for the gob hopper to open and close. After a stable
starting weight is captured, the operator is prompted to load material onto the truck and press
the ENTER key when done. In order to get an accurate weight it is crucial that the operator
closes the silo gates well before the gob hopper opens again. A stable end weight is taken and
the operator is given the choice to load more material onto the truck or quit and generate a
ticket. Using the arrow keys allows the different options to be selected.
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Fig. 14
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L O A D I N G — W E I G H B AT C H E R
•
•
•
Enter the load information, starting with the Truck ID. Depending on which information
copy mode is used (see F11—Copy Mode), typing the Truck ID in the truck id field of the
screen and pressing ENTER may bring up Job and Customer information.
If the Job ID is not the desired job for this load, type the correct Job ID in the job field.
Next, make sure that the desired silo is selected to draw from (multiple silo systems only).
Verify that the material shown on the screen is the one to load on the truck. Rejected
Material may not be loaded.
Once all of the load information has been entered and other safety conditions have been met,
the bottom area of the screen shows (Alt-L)oad Truck and (Alt-M)anual Ticket. To execute a
cash ticket, press F9 before loading (see the section Cash Tickets).
Alt-L Automatic Loading
Verify that conditions are safe to load.
Remove manual interlocks, such as opening the safety gate for the selected silo.
Press and hold a on the keyboard while pressing L.
If a comment exists for the selected customer, a window will pop up with the comment and
prompt the operator to press Y for yes to continue the load (see F8—Customer Comments). If
N is selected, the program returns to the main screen without loading the truck.
The system checks its safeties again and waits for a stable (no motion) weight from the weighing
indicator
The silo gate opens and begins to drop the prescribed amount of material.
After the proper amount has dropped, the system closes the silo gate and waits for a stable
weight.
Once the weight in the batcher has stabilized, the batcher begins to dump into the truck.
When material stops flowing out of the batcher, the system closes it and waits for a stable end
weight.
A brief message appears on the screen indicating that the program is learning new values for the
freefall and flow rate. In some cases, if circumstances prohibit learning new values (drop too
small, for example), the message indicates why the program has bypassed this step.
The horn blows if the Horn After Batch (sec) value in Loading Setup is greater than zero.
On loads that require multiple drops, if the value for Automatic Loading Delay in Loading Setup
is greater than zero, that number of seconds is counted down and the next drop is begun. If the
value is zero, the operator must press aL to begin each drop.
After the load is completed, if the Horn Load Complete (sec) value is greater than zero, the horn
blows.
The ticket is saved to the hard drive in the computer and ticket(s) are printed if printer(s) are
attached and enabled.
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Typical ‘Before Load‘
Message Location
Fig. 15 (above) Fig. 16 (below)
Typical ‘During Load’
Message Location
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Pressing and holding a and pressing the A causes the system software to abort the load as
soon as it is able. CAUTION: THIS IS NOT A SUBSTITUTE FOR A HARDWARE
EMERGENCY STOP BUTTON! Use a properly wired hardware emergency stop to shut
the silo or batcher gate in an emergency. Although aA will cause the software to attempt
to shut the gates, in case of damage to or failure of system hardware, this might not happen fast
enough to prevent bodily injury or property damage. Please see the section on aborted loads for
more detail.
Messages
If any system safety or incomplete information on the loading screen is preventing
the start of the load, messages will appear at the bottom of the screen. If any of the
system safeties is triggered during a drop, the system will attempt to close the silo
gate and a message will be displayed on the screen. The following table describes the
messages, their causes, and a possible remedy:
Message
Before loading
Truck not
defined
Job not defined
Can’t load
rejected material
Net too large
Too many drops
Batch too large
Low Silo
SYSTEMS Equipment Corporation
Cause
Remedy
No Truck ID has been entered
Type Truck ID in Truck ID
field
Type Job ID in Job ID field
Change material in selected
silo
Reduce the net weight for
the load and/or increase the
maximum gross weight
allowed for the truck
Decrease number of drops
No Job ID has been entered
Material in selected silo is
Rejected Material
Net weight requested for load
is greater than the truck’s
maximum gross weight minus
the tare weight for the truck
Net weight requested for the
load divided by the requested
number of drops is smaller
than the Smallest Drop Weight
safety setting
Net weight requested for the
load divided by the requested
number of drops is larger than
the Maximum Batch Weight
safety setting
Low Silo Bindicator indicating
a silo is almost empty
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Reduce the net weight for
the load and/or increase
number of drops
Use the Low Silo Bypass or
wait for more material
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First Step of a
Manual Ticket
Fig. 17 (above) Fig. 18 (below)
Final Step of a
Manual Ticket
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During Loading
Waiting for stable
weight
(informational
only—not an
error)
Material flow
error (see section
on material flow
errors)
Holding batcherpress any key to
dump
Batcher holds
[amount], dump
batcher manually
and press any key
to continue
S I L O
L O A D O U T
C O M P U T E R
Weighing indicator showing
weight in motion
Wait for weight to stabilize,
reduce time system waits for
stable weight, check scale for
instability or increase
indicator filtering
Material stopped flowing
Fill silo, check silo gates,
before the system expected it to abort load or increase setting
for the number of seconds in
for Seconds Before Material
the Seconds Before Material
Flow Error
Flow Error setting
aH has been pressed
Press any key to dump
during loading
batcher
Material still contained [stuck]
in batcher is greater than
MINBATCHERWEIGHT in
ATTRIBUT.DBF (default: 250
lbs.)
Get as much material as
possible out of the batcher
(bang batcher gates with the
manual button) then press
any key to get a tare weight
for this drop.
Alt-M Manual Ticket
If the load is too small to load accurately with the automatic system (for example, a pickup
truck), material can still be loaded if the operator controls the silo and batcher gates manually.
In manual mode, the program captures weights when instructed to do so by the operator. The
operator controls the hardware from the manual panel controls.
Pressing and holding a and pressing M prompts the operator to press the e key to
capture the full batcher weight for the drop. At this point, after manually opening the silo gate
to put the desired amount of material in the batcher, the operator should press e to capture
a stable starting batch weight. The operator is then prompted to press e to read the empty
batcher weight. At this point, the operator empties the batcher and presses e. A stable end
weight is taken and the operator is given the choice to load more material on the truck or quit
and generate a ticket. Using the arrow keys allows the different options to be selected.
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S I L O
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L O A D O U T
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LOAD IN G PU P T RU C KS —A LL
S YS T E M S
If a truck has a pup truck number entered, the data for the pup truck will automatically appear
on the main screen after the primary truck has been loaded. The operator can temporarily
change any of the pup truck information, except the truck number, directly from the main
screen. See the section F1-Lists regarding how to enter a pup truck number. Because the
system regards a truck and its pup truck as separate loads, separate tickets will be printed.
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Low Silo
Indication
Fig. 19 (above) Fig. 20 (below)
.
Low Silo Bypass
Indication
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L O W S I L O B Y PA S S
Some systems have bindicators that indicate when the level of material in a silo has gone too
low. This warning is usually to prevent load segregation, damage to the cone, or damage to the
lower part of the silo. If the intent of the operator is to empty the silo, the bindicators can be
disregarded and loading from the silo can continue.
When the program receives an indication of a low silo condition, it will not allow another drop
unless the operator acknowledges the condition. Fig. 19 shows the warning. Notice that the
aL option is inhibited. The operator can bypass the condition or perform manual loads.
If the operator wants the computer to control the drop, bypass is required. The manual ticket
option will allow the operator to keep the gate open to completely empty a silo. (See section on
loading for more information on manual tickets.)
To activate the Low Silo Bypass, press and hold a, then press B. The screen will show
that you have activated the bypass as seen in Fig. 20. If there is a low silo bypass horn, it will
sound until the end of the load or until the system is no longer bypassed. The aL
option is available again and you can load normally. To cancel Low Silo Bypass press
aB again.
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C O M P U T E R
Fig. 21 (above) Fig. 22 (below)
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C O M P U T E R
M AT E R I A L F L O W E R R O R S
When the system has opened the silo gate, it expects changing weight readings. If the weight is
not changing, or is changing in the wrong direction, a material flow error results.
Most commonly, material flow errors result from running out of material in the silo. Errors can
also happen because the system is trying to open the silo gate, but due to a hardware disconnect
or interlock in the manual system, it cannot. Often this is a result of the hardware Emergency
Stop button being engaged unintentionally (for example, someone accidentally leaned on it).
Another frequent cause is the Low Air Interlock.
Because sometimes gates react slowly, the operator can set the number of seconds that the
system detects no flow before causing a material flow error. This is described more detailed in
Loading Setup.
There are two or three recovery choices from a no-flow error depending on whether the system
is controlling multiple silos. They are:
•
•
•
Terminate the load—Saves and prints a ticket for the material on the truck unless the
amount is zero.
Continue loading from this silo—Prompts the operator to enter the number of additional
drops to perform. Entering zero drops terminates the load.
Continue loading from another silo [If more than one silo in the system]—Prompts the
operator to enter which material will print on the ticket and how many additional drops to
perform. Entering zero drops terminates the load.
NOTE
Changing the material to print on the ticket can cause a discrepancy between what the
LoadOut reports for material inventories and the inventories the plant computer
reports. This is because the LoadOut extracts its material report information from the
ticket database.
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C O M P U T E R
Fig. 23
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L O A D O U T
C O M P U T E R
A B O RT E D LOA D S
Pressing and holding a while pressing A during loading causes the system software to
abort the load as soon as it is able.
CAUTION
This is not a substitute for a hardware emergency stop button!
Use a properly wired hardware emergency stop button to shut the silo gate in an emergency.
Although aA will cause the software to attempt to shut the gate, in case of damage to or
failure of system hardware, this might not happen fast enough to prevent bodily injury or
property damage.
There are three recovery choices from an aborted load. They are:
•
•
•
Resume loading— Prompts the operator to enter the number of additional drops to
perform. Entering zero drops terminates the load.
Save data and print a ticket—Stores ticket information for the amount loaded to the ticket
database and prints a ticket if printers are attached and enabled.
Do not save data and do not print a ticket—Returns the operator to main screen without
storing ticket data or printing a ticket. To maintain accuracy, silo inventory is adjusted to
reflect material removed from the silo on systems so equipped.
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Fig. 1-1
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lF1-LISTS
From any location on the main screen, the list of databases may be accessed by pressing l.
The list appears as shown in Fig. 1-1. To make a selection from the list, use the w or y keys
to move through the list or simply type a highlighted key. The following items are available:
•
•
•
•
•
•
•
•
•
•
•
•
Help
Truck List
Customer List
Job List
Silo Contents
Material List
Customer Comments
Ticket List
Report Menu
Utility Menu
ESC
System Shutdown
Help
The Help screen displays a brief explanation of the function of each of the F-keys. If you forget
the function of any F-key, simply hit l twice from the main screen to bring up this list.
Truck List
The truck list shows the trucks already typed into the truck database along with the gross, net,
and tare weights, expressed in the selected set of units and the number of drops used for
loading. Permanent additions or modifications to the truck database are done here. The visible
fields in a truck record are:
truck number
gross weight
tare weight
net weight
drops
pup truck
To attach a pup truck entry to a primary truck, add the pup truck to the database first, then add,
or edit the primary truck entry. See the section Loading Pup Trucks.
Customer List
The customer list shows the list of customers entered into the database. A customer may be
attached to multiple jobs. When entering a new customer, you can also flag it as being as private
customer. This is useful is some accounting systems where customers are sorted by private (i.e.,
non-governmental) and non-private classifications.
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Fig. 1-1
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Job List
The job list shows the list of jobs entered into the database. Every job must have a customer
attached and every job must be unique. This means that job ‘HWY101’, for example, cannot be
attached to more than one customer.
Silo Contents
The silo contents list shows the silos available in the plant. From this screen you can change the
amount of material in the silo being displayed for silo inventory, adjust the values the program
uses for freefall and flow rate, and change the material designation.
NOTE
Freefall and flow rate values change throughout the day because the program continually
adjusts them as new information becomes available.
Material List
The material list displays the current list of materials entered into the system, the inventory on
hand for each material, and the price per unit.
Customer Comments
Customer comments provide a means of attaching information regarding customers. For
example, to add a comment that a particular customer is strictly COD, select the customer from
the list, and then press s to add the appropriate comment.
After you press aL to load but just before loading begins, the comment message box
appears to display the comment and give the operator the option to cancel or continue the load.
If the SYSTEMS Equipment RedRover utility is installed on a remote computer, comments
provide a means for your accounting department to inform the plant operator of special
customer conditions by sending comment records via a modem connection. See the section
Electronic Data Transfer – RedRover.
Ticket List
Choosing the ticket list pops up a window listing the tickets currently on file. Pressing the n
key from the main screen will also direct you to the ticket list. Refer to the section on the n
key for a description of the features available.
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Report Menu
The report menu option displays a sub-menu from which you can print or display the following
detailed reports:
truck report
customer report
job report
material report
load report
cash load report
private customer report
haul sheet
Utility menu
Choosing the utility menu pops up a menu listing common daily maintenance utilities. Pressing
the o key from the main screen will also direct you to the utility menu. Refer to the section on
the o key for a description of the features available.
ESC
Pressing the ESC key dismisses the list menu.
System Shutdown
Choosing system shutdown allows you to terminate the program. All operating parameters and
data are saved prior to program termination. Shutting down can also be done from the main
screen by pressing the r key. Refer to the section on the r key.
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L O A D O U T
C O M P U T E R
mF2-CONTEXT SENSITIVE
LIST
When the cursor is in the truck, job, or material field, pressing the m key pops up the list that
applies. For example, when the cursor is in the job field, pressing m brings up the job list.
This feature provides faster access to the lists that are routinely used throughout the day.
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L O A D O U T
C O M P U T E R
Ticket Types
Ticket Options
Fig. 3-1 (above) Fig. 3.2 (below)
Erroneous
Ticket
Correction
Information
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nF3-TICKET LIST
The ticket list shows all tickets generated since the list was last archived. See Fig. 3-1. From the
ticket list you can:
•
•
•
correct a ticket – change the job/customer, material, and/or truck on a ticket that was
incorrectly generated
ditto a ticket – copy the truck and job/customer from a ticket to the main screen
find tickets – locate all tickets with a specified
1) Ticket number (precludes all other criteria)
2) Start date
3) End date
4) Job
5) Customer
6) Truck
7) Material
•
•
reprint a ticket
display a ticket
Correction Tickets
To correct an erroneously generated ticket, select the ticket from the ticket list by highlighting it
with the w or y keys, and then press C. The screen shown is Fig. 3-2 appears. The upper
portion of the screen displays the information that exists on the erroneous ticket. You can enter
the information that should appear on the corrected ticket in the lower portion of the screen. In
the field highlighted by the cursor, simply type in the correct information or press the m key to
bring up the list that applies (from these lists you can add, change, etc., records as needed).
When the new information appears as it should, hold down the a key and press C.
Two tickets are generated and printed – one, which undoes the erroneous ticket by generating a
ticket where the net weight is subtracted, and a second ticket where the correct information is
applied. The original erroneous ticket will be marked with a “V” (for “void”) in the left-hand
column of the ticket list indicating it is now a void ticket. The undo ticket is marked with a “C”
(for “corrected”). The re-issued ticket is marked with an “R” (for “re-issued”).
No further changes can be made to the void or corrected ticket. If later an error is found in the
re-issued ticket, simply repeat the above procedure. When this happens, this re-issued ticket will
become a void ticket and two more tickets will be issued.
Cash Tickets
Cash tickets are marked with the “$” symbol in the left-hand column.
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Fig. 3-3 (above) Fig. 3-4 (below)
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Hand-Generated Tickets
Hand-generated tickets are marked with the “H” symbol in the left-hand column. See the
section Hand-Generated Tickets.
Ditto Ticket
The ditto feature allows you to copy the information shown on a particular ticket to the main
screen. This is useful when you need to load a truck using the same information used the last
time the truck was loaded. Simply highlight a ticket in the list and press the e key. If the
system is in LoadOut mode, the material is not copied because the material is obtained from
the currently selected silo.
In Weigh-In/Weigh-Out mode, the material is copied to the main screen.
Find Ticket
The F key allows you to search the ticket database for tickets of a specified nature. The screen
shown in Fig. 3-3 appears. You can find tickets using combinations of:
Ticket number (precludes any other criteria)
Posting start date
Posting end date
Job
Customer
Truck
Material
For example, to find all tickets issued between February 1, 1987, and August 5, 1987, to job
NEWJOB, enter 02/01/1987 in the Start Date field, enter 08/05/1987 in the End Date field,
and enter NEWJOB in the job field. To include all trucks, materials, etc., delete the data or type
ALL in the corresponding fields. When all criteria appear as they should, move to the <Find>
command button and press e.
If any tickets meeting the criterion are found, a screen similar to Fig. 3-4 appears. To print the
list for future reference, simply press the P key.
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Ticket Number
Being Displayed
Correction Ticket
Information
Fig. 3-5
Options
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Print Ticket
The print ticket option allows you to reprint a ticket. Simply highlight the desired ticket and
press the P key.
Display Ticket
To view a ticket as it would appear in the standard ticket format, highlight the desired ticket and
press the e key. A screen similar to Fig. 3-5 appears.
NOTE
When correction tickets are involved, you can use the Band F keys to move
backwards and forwards through the series to view all tickets in the correction sequence.
You can also reprint individual tickets by pressing the P key or print all the tickets in
the series by pressing the A key.
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Fig. 4-1 (above) Fig. 4-2 (below)
Copy Mode
Options
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oF4-UTILITY MENU
The day-to-day maintenance and configuration tasks are accomplished using the utility menu.
Press the o key to pop up the menu. Notice that several of the items have their own hot key,
shown in parentheses, such as Unresolved Tickets. Many of the items invoke additional submenus. See Fig. 4-1.
To make a selection from the menu, type the highlighted hot key shown or use the w or y
keys to highlight a selection, then press e.
Unresolved Tickets
If you have a truck scale, choosing unresolved tickets pops up a window listing the unresolved
tickets currently on file. An unresolved ticket occurs when gross information about a WeighIn/Weigh-Out ticket is captured but the truck tare weight is not yet known. Pressing the p
key from the main screen will also direct you to the unresolved ticket list. Refer to the section
on the p key for a description of the features available.
Weigh In / Out Mode
LoadOut Mode
Assuming you have a truck scale, these two menu items allow you to toggle between weigh
in/weigh out mode and loadout mode. You can also toggle modes by pressing q from the
main screen.
If you are in LoadOut mode, the words “Weigh In / Out Mode” appear indicating that you can
switch to LoadOut mode, and visa versa.
Change Posting Date
The posting date is useful when the date that should appear on the tickets is different from the
calendar date. For example, when an operator’s shift begins at 7:00 PM and the date printed on
your tickets should not change at midnight, set the posting date as required. Choosing the
“change posting date” option displays the same screen that appears when the program initializes.
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Gate Check
Options
Fig. 4-3 (above) Fig. 4-4 (below)
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Select Copy Mode
The copy mode designates how tickets are dittoed from the ticket list. The location of the copy
mode indicator is shown in Fig. 4-2. The copy mode may be set to
Manual
Ticket or
Truck
In TICKET mode, after you have made a truck selection, the program finds the last ticket in the
ticket list and fills in the job/customer information from that ticket (the material is also copied
when operating in Weigh-In/Weigh-Out mode). In TRUCK mode, the program locates the last
ticket on which this truck was used (which may not necessarily be the very last ticket) and fills in
the job/customer information from that ticket (the material is also copied when operating in
Weigh-In/Weigh-Out mode). Manual copy mode requires that you make the job/customer
selection without program assistance.
If individual trucks are hauling to different locations, use truck mode to let the program keep
track of these details for you. If all trucks are hauling to the same location and new trucks are
coming in to help with the haul, use ticket mode so that the new trucks get the correct
information.
Gate Check
Gate check is a maintenance feature that lets you open silo or weigh batcher gates from the
keyboard. It is important to note that this feature is not intended for truck loading – only as
verification that the electronic link between the computer and the silo gates is functional.
Choosing gate check displays a screen as shown in Fig. 4-3. If your system is not a weigh
batcher, the second line will not appear.
BE ABSOLUTELY CERTAIN THAT THERE IS NO MATERIAL IN THE SILO
AND/OR WEIGH BATCHER AND THAT NO PERSONNEL ARE IN THE
IMMEDIATE VICINITY BEFORE USING THIS FEATURE.
Press the indicated key to open a gate. If a gate fails to open but can be opened with a manual
panel button; the problem is most likely located at the fuse on the PLC output module.
System Setup
Choosing System Setup displays a sub-menu as shown in Fig. 4-4. Each of these options can
pop up other screen for data input.
Loading Setup – this option allows you to alter parameters such as gob hopper timing, silo
capacity, etc. See the discussion that follows for details.
Ticket Setup – this option allows you to change how your tickets are printed and what
information goes on them.
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Software Setup – this option affects how the program is configured. Since errors in these
parameters can cause your program to malfunction, a password is required to proceed. If you
need access to these parameters, you should contact your program supplier to obtain it.
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Parameters Depend
On Type of System
Fig. 4-5 (above) Fig. 4-6 (below)
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Loading Setup
Loading setup will invoke a series of screens, the order and content of which
depends on how your plant is set up.
Fig. 4-5 shows the first screen. This screen is for a system where the first silo uses a
truck scale. If a reverse weigh scale is used the second entry would be for minimum
silo weight and the third would be for smallest drop weight. For a weigh batching
system, the second line would be for maximum batch weight and the third for
smallest drop weight.
NOTE
The number and order of these screens depends on how many scales and silos your
system has. The smallest drop weight will be changed throughout the day because the
program continually adjusts this value as new information becomes available.
Fig. 4-6 is the next screen after all silos have been processed. The PLC has a timer
output for controlling a gob hopper. The first line in the list is the number of
seconds the PLC will turn on this output to hold the gob hopper open (call this time
T1). The second line is the number of seconds to hold the gob hopper closed (call
this time T2). The third line applies to reverse weigh silos. It is the amount of time
before the gob hopper opens that the program will terminate a drop to prevent the
gob hopper discharge from corrupting an accurate silo weight reading (call this time
T3). In essence, the program anticipates when the gob hopper is about open and
will terminate a drop prematurely (when the drop time exceeds T2 – T3) to prevent a
corrupted weight measurement. These parameters should be adjusted taking into
account your plant production rate (T2), the capacity of your gob hopper (T1), and
the amount of time required by your system for a weight reading to stabilize (T3).
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Fig. 4-7
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Fig. 4-7 shows the last screen in Loading Setup – the Common Parameters screen.
These parameters are explained below:
Use Metric Units – setting this parameter to “Y” enables displaying metric units
(either kgs or mgms, depending on the setting of “Display in Tons”). Setting this
parameter to “N” enables English units – either lbs. or tons
Display In Tons – used in conjunction with the preceding parameter, this
parameter determines whether major units (i.e., tons or mgms) are displayed or
whether minor units (i.e., lbs. or kgs) are displayed. The following table summarizes
how these two parameters interact:
Use Metric Units
N
Display In Tons
N
Lbs.
Y
Tons
Y
Kgs
Mgms
Horn Load Complete – setting this parameter to any value other than zero
determines how many seconds that the loading horn will sound after the last drop of
a load.
Horn After Batch - – setting this parameter to any value other than zero determines
how many seconds the loading horn will sound after each drop is completed,
excluding the last drop. Since the load complete horn is the same as the batch
complete horn, you may want to set this value to zero to avoid confusing the truck
driver.
Auto-Load Delay – this parameter determines how many seconds should elapse
after the end of a drop before the program automatically starts the next drop. The
purpose of this delay is to allow time for the truck to re-position before the next
drop commences. NOTE: To disable automatic drops, set this parameter to zero.
You will then need to manually start every drop by pressing the a L keystroke
combination.
Stability Delay – this time determines how long after shutting the silo gate the
program waits before looking for a stable weight from the indicator. The smaller
this value is, the faster (and potentially less accurately) the drop will complete. For
reverse weigh systems, this time is related to T3 discussed in Loading Setup; i.e., T3
should be set two or three seconds longer than the stability delay.
Delay Before Material Flow Alarm – this value determines the length of time used
by the program to determine when flow has stopped, typically due to an empty silo.
Bridged material may free itself. A value of 7 seconds is a good compromise
between long waits for empty silos and false material flow errors.
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Fig. 4-7 (above) Fig. 4-8 (below)
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Load Tolerance – this is a percentage value applied to the end of each load. If the
net load is short by more than this percentage value, the program pauses with an
option screen allowing you to complete the remainder of the load manually.
Free Fall Constant – this value determines how rapidly new information from each
drop is incorporated into what the program thinks the freefall is. Freefall is the
amount of weight the load increases after the command to shut is gate is given. The
freefall can change throughout the day due to temperature changes, amount of
material in the silo, distance from silo gate to truck bed, etc. The program adjusts
for these changes continually. The freefall constant determines how rapidly the
program adjusts. When the freefall constant is set at zero, no adjustments are made
(i.e., the freefall is fixed). Any value larger than zero, up to 50, applies that
percentage of the freefall from the most recent drop to the value held internally by
the program. If your system contains high vibration and you know the freefall fairly
accurately, use a lower value. If your system is stable and you would like the
program to adjust rapidly to changing conditions, use a larger value.
Flow Rate Constant – this value is similar to the freefall constant but applies to
updates the program makes to information it is collecting regarding the flow rate.
The flow rate is used to anticipate when to shut the gates. It is also used to pre-load
the PLC with a gate closure time so that if the LoadOut computer fails (a sudden
power outage, for example), the PLC can safely shut the gates without receiving a
command from the LoadOut computer. In most cases, the value you choose here
should track the value you’re using for the freefall.
Silo Inventory Prescale – for systems that receive measured pulses from the plant
computer, this value determines the increase in production each pulse represents.
For example, The SYSTEMS Equipment ADP-100 provides one pulse for each ton
produced at the point of A/C injection. The LoadOut increases the inventory in the
silo selected for filling each time a pulse arrives. Note reverse weigh silos do not
need an inventory pulse because the silo weight can be directly measured.
Ticket Setup
Fig. 4-8 shows the screen displayed when Ticket Setup is chosen.
Company Name – these three fields are used to enter information about your
company that will appear on printed tickets. Generally, your company’s address is
entered here.
Next Ticket Number – this field allows you to advance the ticket number. You
cannot reduce the ticket number unless you first archive all tickets in the current
ticket database. Refer to F4, File Maintenance, for instructions on how to archive
the ticket database.
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Fig. 4-9 (above) Fig. 4-10 (below)
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Default to cash tickets – this option allows you to remain in cash ticket mode
continually. If you set this option to “N”, you can enter cash mode for one ticket by
pressing the t key on the main screen. After the load is completed and the cash
ticket is printed, the program reverts to credit mode. Setting this option to “Y”
keeps the program in cash mode after each load completes.
Print Summary Results Only – in situations where only a single line summary
ticket is require rather than a full invoice ticket, set this option to “Y”.
Print Drops On Ticket – some states require that statistics for each drop be printed
on each full invoice ticket. Set this option to “Y” if you would like to enable this
feature.
Form Length In Inches – if your blank ticket paper for the standard ticket is not
5.5”, you can change the ticket length by entering the page length here. Standard
printer paper is 11” long yielding two tickets per sheet.
Number Of Copies – if you need multiple copies each time you print a ticket, enter
the desired number here. Note this number also applies to re-printed tickets.
Print Alternate Units – some States require both metric and English units on
tickets while other States prohibit multiple system of units. If you want both sets of
units printed, enter “Y” here. Entering “N” prints only your selected set of units.
See Loading Setup regarding how to select a set of units.
Use custom ticket format – if you use preprinted ticket sheets and have purchased
a custom ticket format file to your specifications, entering a “Y’ for this option will
instruct the program to use it. Otherwise entering a “N” here causes the internal
standard ticket format to be used.
Software Setup
Before you can modify any data in Software Setup, you must enter a password. The
purpose of the password is to prevent accidental entrance into this area where
erroneous entries can cause the program to malfunction. After passing the password
screen, a series of screens is displayed.
The first screen is shown in Fig. 4-9. If this computer is the only loadout computer,
or is the server in a Plant Local Area Network (i.e., the master computer), enter “Y”
to network master. The station number is a unique number identifying LC-x000
computers. If your computer is the master computer, enter “1”. Otherwise, enter a
number that uniquely identifies your computer. Note that the station number
appears on the ticket, i.e. “004325-1”. Because multiple computers can generate the
same ticket numbers, adding the station number to the ticket number allows your
accounting department to determine the computer that generated the ticket. If your
computer is the master, enter the number of computers in the network. If it’s the
only computer, enter “1”.
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Fig. 4-11 (above) Fig. 4-12 (below)
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Fig. 4-10 shows the scales setup screen. Enter the number of weighing indicators
used in your system. The LC-2000 system supports only one indicator – the LC1000 can support several. Every scale attached to the system will display a screen as
shown in Fig. 4-10 where the serial port parameters are entered. It is important that
these parameters be correct because an erroneous parameter here can cause the
program to malfunction.
Following the weighing indicator parameter screen is the silo parameter screen as
shown in Fig. 4-11. In this screen, the type of silo (i.e., TS for truck scale, WB for
weigh batcher, or BW for reverse weigh) and the weighing indicator attached to it are
specified. The drawing position parameter specifies the position, from left to right
that the silo inventory pictograph should appear on inventory sub-window.
Specifying a drawing position allows the pictographs to be drawn on the screen as
seen from the operator’s perspective. There will be one screen similar to Fig. 4-11
for every silo in the system.
The screen that follows, Fig. 4-12, contains several miscellaneous set-up parameters:
Print each drop – enter ‘Y’ if you’d like the gross, net, and tare weights for each
drop printed on standard tickets (not available for custom tickets)
Print overloaded tickets – if your location prohibits generating tickets for
overloaded trucks, choose ‘Y’ here.
Overload limit – this is the amount over the maximum gross weight of a truck in
which an overload condition is declared
Keystroke rate – this is the time interval at which the program temporarily stops
waiting for keystrokes to perform internal tasks. A value of 0.25 seconds is typical.
To make the keyboard more responsive, increase this value. Decreasing the value
causes the computer to capture weight reading more rapid at the expense of
keyboard response.
Background weight rate – this is the amount of time that the program requests
information from the indicator when not loading a truck.
Read silo rate – the program reads silo information from the PLC at this time
interval.
Watchdog time – this is the time in seconds of the longest possible drop before the
computer gives an error and closes the gate.
Minimum freefall time – this is the minimum amount of time the silo gates must
be open during a drop before the program will consider a new freefall value as valid.
Reject quantity – the accumulated amount of material that has been rejected
through the reject gate.
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Fig. 4-13
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Disconnect PLC – in case of a PLC failure, set this parameter to “Y” to cause the
program to ignore the PLC. Manual loading can proceed until the PLC is repaired.
The next screen, as shown in Fig. 4-13, has the communication parameters of the
PLC. These parameters are vital because if there are incorrect entries the computer
will have no control over the hardware. The initial question is about silo inventory.
If you don’t have a reverse weigh silo, and the plant computer has a tons-out pulse,
the computer can keep an approximate inventory of each silo. If you do have a
reverse weigh silo then the indicator will determine the silo inventory. The inventory
is displayed graphically on the main screen with a pictograph for each silo. The
other parameters on this screen determine the connection to the PLC and great care
should be taken before modifying them.
The next page of the setup accepts remote serial printer parameters. If a small sales
slip type printer is used then answer yes to this question. The printer described here
is not the ticket printer and would require an additional cable to the computer.
The next section asks for if there is a remote modem used for downloading the
databases (see the section Electronic Data Transfer – RedRover). The databases can
be copied to a different computer in a different location for accounting purposes
Silo information is entered in the next section of the setup. Each silo gets a page
that is used to input different things depending on what type of scale is being used.
This section is identical to the Loading Setup section. Please refer to that section for
the final screens in the software setup.
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Fig. 4-14
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File Maintenance
Choosing File Maintenance displays a sub-menu as shown in Fig. 4-14. The purpose of this
section is to provide an easy way to clean up old databases that won’t be needed anymore.
There is a danger of deleting useful lists, so great care must be taken when entering this section.
WARNING
ONCE YOU HAVE ERASED A LIST, YOU CANNOT GET IT BACK.
The ticket database is treated differently than the others because there is always a possibility of
needing to regenerate an old ticket. That is why the ticket list is archived instead of erased.
Older tickets are removed to a location on the LoadOut computer that the program will not
normally access.
An example of where erasing lists would be used is a portable asphalt plant that has just moved
to a different area with different customers, trucks, etc. Adding to the old lists would be
possible but the lists could be very large and there could be confusion between new and old
jobs, customers, and trucks.
Archiving Tickets
To archive tickets, press 1 from the File Maintenance menu. The next menu will
ask for a range of tickets to archive by date. Choose the date that would include all
of the tickets that are to be archived.
To retrieve a ticket from an archive, press 7 from the File Maintenance menu.
The program recovers all archived tickets and makes available all ticket list options.
See the F3-Ticket List section. When you are done working with the archived tickets
the program will reload the current working ticket database.
Erasing Lists
To erase a list, press the number of the list you wish to delete in the File
Maintenance menu. The program will then ask you to enter Y or N for deleting the
list. If you answer yes, the program will then ask you if you are sure you want to
delete the list. It asks twice because an erased list cannot be restored.
WARNING
DO NOT ERASE A LIST UNLESS YOU ARE SURE THAT YOU INTEND
TO LOSE ALL THE DATA IN THAT LIST.
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Fig. 4-15 (above) Fig. 4-16 (below)
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Report Menu
The report menu option displays a sub-menu from which you can print or display the following
detailed reports:
truck report
customer report
job report
material report
load report
cash load report
private customer report
haul sheet
The first four items that have reports are for the lists used by the program. The reports that are
generated show all tickets involving that item. Because the procedure is the same for these
reports, this manual will only show the example of the truck report.
After choosing the truck report, a menu will ask if a single truck or all of the trucks should be
included. Then it will ask for the date range of interest. With this information, the program will
either print the report or view the report on the screen.
The remaining items that are available for reports are handled differently since they cannot be
created about an individual truck, customer, job, or material. Therefore, the menu that appears
after selecting one of these reports asks only for the dates of interest. In addition, the option to
view the report on the screen is not available so printing is the only form of output.
Print Truck List
This option from the utility menu simply prints all the trucks that are on the truck list.
Print Job List
This option from the utility menu simply prints all the jobs that are on the job list.
Print Customer List
This option from the utility menu simply prints all the customers that are on the customer list.
Backup to Diskette
The backup option will take all of the databases and put them on a floppy disk for retrieval later.
If the time comes to get the data from the disk the Restore from Diskette option is used.
If the lists are too large to fit on one disk, the program will ask for another disk until all files are
saved. The person making the backup should label the disk or disks for future reference. If
multiple disks are needed the disk number should also be included on the label.
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Denotes
Training Mode
Fig. 4-17
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Backup to Diskette is very different from the File Maintenance menu. The backup will not
effect the lists in any way. It is simply a method to protect your data in case of a computer
problem. It is wise to periodically backup your data so that if something unforeseen happens,
the amount of time required getting the system back to normal in minimized.
Restore from Diskette
The restore option will ask for a diskette that has data from the Backup to Diskette option.
With the disk in the computer, this option will overwrite all data currently in the program with
the data that is on the diskette.
CAUTION
BECAUSE RESTORE FROM DISKETTE OVERWRITES DATA, THE
PROGRAM WILL LOSE ANY NEW DATA, INCLUDING TICKETS,
ENTERED SINCE THE BACKUP WAS RECORDED.
This option should only be used when there has been a major problem with all of the lists. Any
tickets generated after the backup will be lost along with trucks, customers, jobs, and materials.
Training Mode / Resume LoadOut Mode
The next option in the utility menu toggles between LoadOut Mode and Training Mode.
Training mode simulates LoadOut operations using an entirely different set of practice
databases—external hardware is disconnected. The computer will simulate the gates, silos,
trucks, and weighing indicators. This mode is used for training operators so they can get a feel
for how the program works before they control the real thing.
Because training mode has the exact feel of the program, it is necessary to put a message on the
screen warning that the program is in this mode. Fig. 4-16 shows how the main screen appears
in training mode.
All of the data in training mode is kept is a different location than the LoadOut data. There is
no way to transfer training data to the LoadOut. The truck, job, customer, and material lists
cannot be shared. The tickets that are generated in training mode are not useful for anything
other than practicing with the program.
To get out of training mode, use the Utility menu and choose the Resume Loadout Mode
option.
SYSTEMS Equipment Corporation
VER A60426
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SYSTEMS Equipment Corporation
S I L O
VER A60426
L O A D O U T
C O M P U T E R
Page 80
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S I L O
L O A D O U T
C O M P U T E R
Exit Program
This option is the same as the System Shutdown Option in the Lists Menu. Choosing Exit
Program allows you to terminate the program. All operating parameters and data are saved prior
to program termination. The exception is any parametric data entered in training mode that
would affect the actual running mode – this data is discarded. Shutting down can also be done
from the main screen by pressing the r key twice. Refer to the section on the r key.
ESC
Pressing the ESC key dismisses the utility menu.
SYSTEMS Equipment Corporation
VER A60426
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L C - 1 0 0 0
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S I L O
L O A D O U T
C O M P U T E R
Fig. 5-1
SYSTEMS Equipment Corporation
VER A60426
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p
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S I L O
L O A D O U T
C O M P U T E R
F 5 - U N R E S O LV E D T I C K E T S
LC-1000 / LC-2000 systems with truck scales can also perform weigh-in/weigh-out (i.e., quarry)
operations. If a truck arrives loaded and the tare weight is unknown, a partial ticket can be
generated for which all information is known except the tare weight (and consequently the net
weight). Refer to the Defer Tare option in Weigh-In / Weigh–Out. These partially resolved
tickets are saved in a database awaiting further processing.
To view the list of unresolved tickets, press p from the main screen, press N from the utility
menu, or use the w or y keys to highlight the row and press e . The unresolved ticket
screen appears as shown in Fig. 5-1. Note that in the ticket number column, either the word
“bought” or “sold” appears rather than a ticket number. This is because no tickets have been
generated yet. You can highlight an unresolved ticket from this screen and press e to copy
it to the main screen. Unresolved tickets do not take part in any summary calculations.
When a tare weight is captured using the F12 key from the main screen, the updated tare is used
to compute the net weight for any unresolved tickets where this truck appears. These tickets are
then moved to the main ticket database and printed. The load date and time that appear on the
ticket is the date and time the ticket was entered into the unresolved database (the date and time
the material crossed the scale). The ticket numbers assigned will be the next available ticket
numbers although the original unresolved ticket might have been started many days earlier.
SYSTEMS Equipment Corporation
VER A60426
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S I L O
L O A D O U T
C O M P U T E R
Fig.6-1
SYSTEMS Equipment Corporation
VER A60426
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q
S I L O
L O A D O U T
C O M P U T E R
F6-WEIGH IN / OUT OR
LOAD O U T
For configurations with truck scales, the q key toggles between Weigh In/Weigh Out mode
and LoadOut mode. The mode the program is currently executing in is shown below the onscreen scale read-out. The caption will be a green bar and read “LoadOut” when operating in
loadout mode – the caption will be red and read “Weigh In / Weigh Out” when operating in
weigh-in / weigh-out mode. To switch modes, simply press the q key.
Weigh In/Weigh Out mode is for quarry type operations. It is capable of using the truck scale
to weigh, ticket and inventory all materials coming into and out of the plant.
There are three pairs of choices when a loaded truck drives onto the scale. Each choice can be
one or the other, NOT BOTH. The operator must tell the system:
•
•
•
Is the load being RECEIVED into the yard or DELIVERED to a customer?
Is the transaction a CASH SALE or purchase or is it a CREDIT SALE or purchase?
Should a ticket be generated now that will USE TARE on file, or should the system DEFER
TARE until the truck comes back empty?
Ideally, a transaction where the plant is receiving material will happen in these steps:
•
•
•
•
•
•
•
•
•
•
•
A loaded truck drives onto the scale
Enter the truck ID, job ID and material being received
Choose a1 Received and whether the purchase is cash or credit
Choose a6 Defer Tare
aG to Generate Ticket
The system records all of the information in the unresolved database, but does not yet print
a ticket
The horn blows if present and if the Horn Load Complete (sec) setting is greater than zero
(see Loading Setup for more details)
The truck drives off of the scale and dumps material on the pile
The empty truck drives back onto the scale
Press  to get a tare weight for the truck (see  Tare for more details)
The unresolved ticket is resolved, stored into the ticket database, and a ticket is printed if
printer(s) are connected and enabled. The unresolved ticket is deleted.
The tare need not be deferred if there is a recent, accurate tare on file for the truck. If the USE
TARE option is selected, a ticket is printed immediately after pressing aG.
SYSTEMS Equipment Corporation
VER A60426
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SYSTEMS Equipment Corporation
S I L O
VER A60426
L O A D O U T
C O M P U T E R
Page 86
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S I L O
L O A D O U T
C O M P U T E R
A transaction where the plant is delivering material should happen in these steps:
•
•
•
•
•
•
•
•
•
•
•
An empty truck drives onto the scale
Enter the truck ID
Press  to get a tare weight for the truck (see  Tare for more details)
The truck drives off of the scale and is loaded with material from the pile
The loaded truck drives back onto the scale
Enter the truck ID, job ID and material being received
Choose a4 Delivered and whether the sale is cash or credit
Choose a3 Use Tare
aG to Generate Ticket
Information is stored to the database and a ticket is printed if printer(s) are connected and
enabled
The horn blows if present and if the Horn Load Complete (sec) setting is greater than zero
(see Loading Setup for more details)
NOTE
The material list holds inventory information for each of the materials (see material list
for more information). In order to retain compatibility with the LoadOut system,
negative amounts represent material inventory (stockpile) and positive amounts
represent amounts shipped.
SYSTEMS Equipment Corporation
VER A60426
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S I L O
L O A D O U T
C O M P U T E R
.Fig. 7-1
SYSTEMS Equipment Corporation
VER A60426
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r
S I L O
L O A D O U T
C O M P U T E R
F 7 - S YS T E M S H U T D O W N
To exit the program, press the r key. In the event that you accidentally pressed the r key
during daily operation, another screen appears asking you to verify your choice. The default
option on this screen is “Yes”. You can select this option by pressing e. Pressing r will
also select “Yes” so simply pressing the r key twice in succession is a fast and convenient way
to exit the program.
SYSTEMS Equipment Corporation
VER A60426
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S I L O
L O A D O U T
C O M P U T E R
Denotes Comments
for This Customer
Fig. 8-1 (above) Fig. 8-2 (below)
Options for
Customer Comments
SYSTEMS Equipment Corporation
VER A60426
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S I L O
s
L O A D O U T
C O M P U T E R
F8-COMMENTS
Comments are informational records attached to the customers you choose. For example, if a
particular customer should always pay in cash, you can add a comment to alert the LoadOut
operator to this fact. When a comment record is attached to a customer, a flashing asterisk
appears to the right of the customer number as shown in Fig. 8-1. After the customer field has
been completed on the main screen, you can view, edit, add, or delete the comment by pressing
s or use l -Customer Comments, as shown in Fig. 8-2.
If a comment record exists for the selected customer, a red alert message appears on the screen
after you press a L to begin loading the truck. At this point, you can choose to continue
loading or cancel the load. Comments are a very useful way for your accounting department,
using RedRover from a distant location, to warn the operator of special conditions. See the
section Electronic Data Transfer – RedRover.
SYSTEMS Equipment Corporation
VER A60426
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S I L O
L O A D O U T
C O M P U T E R
Cash Ticket Inputs
Fig. 9-1
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VER A60426
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S I L O
t
L O A D O U T
C O M P U T E R
F9-CASH SALE
The LoadOut can be configured to always run in cash mode or to execute an occasional cash
sale (see o, (S)ystem Setup, (T)icket Setup, Default to cash tickets). In either case,
pressing t brings up the price/tax window as shown in Fig. 9-1 from which you can
modify the price per unit and tax rate. Prices are stored internally in units of dollars per
pound. If the operator switches to a different set of units, prices are automatically converted
to reflect the new set of units.
If you use cash tickets only occasionally, you can cancel the cash ticket before the load starts by
pressing t again. Otherwise, continue with the normal load process. Once the load has
completed, the program will return to credit ticket mode.
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S I L O
L O A D O U T
C O M P U T E R
Silo Inventory
Pictographs
Fig. 10-1 (above) Fig. 10-2 (below)
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S I L O
L O A D O U T
C O M P U T E R
u F10-FILL / EMPTY
I N V E N T O RY P I C T O G R A P H
For truck scale and weigh batching silos, you can reset the silo inventory pictograph to either
filled or empty by pressing u. If the operator needs to frequently switch the silo that is filling,
or small calibration errors exist, etc., the count of material inventory in a silo can become slightly
inaccurate during the course of a day. At a known point, such as an empty silo or a high silo
alarm, this option can be used to adjust the pictograph quickly and easily.
To make a selection from the list of displayed choices, use the w or y keys to move through
the list. The following are the available choices:
•
[Selected Silo] has been emptied. This choice sets the amount in the silo inventory
pictograph for the selected silo to zero.
•
[Selected Silo] has been filled. This choice sets the amount in the silo inventory pictograph
for the selected silo to the silo capacity entered in loading setup.
This feature is not necessary for a reverse weigh silo because the program can directly determine
the amount of material in the silo by simply reading the silo weight.
SYSTEMS Equipment Corporation
VER A60426
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S I L O
L O A D O U T
C O M P U T E R
Copy Mode
Options
Fig. 11-1
SYSTEMS Equipment Corporation
VER A60426
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S I L O
L O A D O U T
C O M P U T E R
 F 1 1 - C O P Y M O D E
The copy mode controls how the program automatically completes the main screen when the
operator enters a truck number.
From any location on the main screen, the operator may change the information copy mode by
pressing  . To make a selection from the list of choices, use the w or y keys to move
through the list. The chosen copy mode appears at the bottom right corner of the main screen
(i.e., TRUCK, TICKET, or MANUAL).
The following are the available copy modes:
•
Manually enter every field—this choice requires that operator type in the job/customer
information for every load. In Weigh In/Weigh Out mode, the material description must be
changed manually, if necessary. In LoadOut mode, the material description is taken from
the selected silo.
•
Copy job/customer information from the last TICKET—this choice automatically uses
the job/customer information from the last ticket in the ticket database. In this mode, the
operator only has to type the job/customer information if the current load is going to a
different job. The material description will be copied from the ticket when operating in
Weigh In/Weigh Out mode. In LoadOut mode, the material description is taken from the
selected silo.
•
Copy job/customer information from the last load for this TRUCK—this choice
automatically uses the job/customer information from the last ticket for this truck (it is
possible that the last ticket for this truck may not be the same as the last ticket in the ticket
database). In this mode, the operator only has to type the job/customer information if the
truck is going to a different job. The material description will be copied from the ticket
when operating in Weigh In/Weigh Out mode. In LoadOut mode, the material description
is taken from the selected silo.
SYSTEMS Equipment Corporation
VER A60426
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S I L O
L O A D O U T
C O M P U T E R
Truck Tare
Options
Fig. 12-1
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S I L O
L O A D O U T
C O M P U T E R
 F 1 2 - TA R E A T R U C K
If the system has a truck scale, the operator may tare a truck from any location on the main
screen, by pressing  . If no truck has been entered in the truck area, the truck list will come
up to allow selection of a truck to tare. Once a truck is selected, a list of choices is displayed.
To make a selection from the list, use the w or y keys to move through the list or simply
type a highlighted key. The following items are available:
• Read Scale Tare
This choice reads the current weight on the indicator, stores it to the database as the selected
truck’s tare weight, and resolves unresolved Weigh In/Weigh Out tickets for that truck. The
load horn is sounded to alert the driver that the tare has been taken.
• Use Database Tare
This choice resolves unresolved Weigh In/Weigh Out tickets for a truck using the tare weight
stored in the database.
• Manually Enter Tare
This choice allows the operator to type in the weight to be stored as the truck’s tare in the
database and resolve unresolved Weigh In/Weigh Out tickets for that truck.
• Cancel
Return to the main screen.
SYSTEMS Equipment Corporation
VER A60426
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SYSTEMS Equipment Corporation
S I L O
VER A60426
L O A D O U T
C O M P U T E R
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S I L O
L O A D O U T
C O M P U T E R
H A N D - G E N E R AT E D T I C K E T S
Tickets may be added to the ticket database when the net weight information cannot be
obtained from your LoadOut system. This is most useful, for example, when your weighing
indicator is damaged and the weight information is obtained from an independent scale. With
hand-generated tickets, you can use this independent weight information to keep your ticket
database consolidated.
To enter a hand-generated ticket, fill out the main screen as you normal would prior to loading a
truck. When the information has been entered, hold down the a key and press P. The
ticket information will be added and printed. A message “Hand Generated Ticket” will be
clearly printed on the ticket. Reprinted tickets will also print this message. The ticket will
appear in the ticket database with “H” on the left-hand side of the display.
This feature should only be used when absolutely necessary to keep your ticket database
organized.
SYSTEMS Equipment Corporation
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SYSTEMS Equipment Corporation
S I L O
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L O A D O U T
C O M P U T E R
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S I L O
L O A D O U T
C O M P U T E R
E L E C T R O N I C DATA
T R A N S F E R — R E D R OV E R
RedRover is a program (purchased separately) that transfers data between a remote location and
a LC-x000 computer. In order to use RedRover, an MS-DOS-compatible ISA modem must be
installed in both the LC-x000 computer and the remote computer, and RedRover must be
installed on the remote computer.
From the remote computer, RedRover can access the LC-x000 databases and perform the
following functions:
•
•
•
•
•
•
retrieve tickets from an LC-x000 computer for any combination of start date, end date,
truck, job, customer, and material (editing the ticket database is not supported). Once
retrieved, these tickets can be incorporated into your company’s accounting system
electronically
edit the truck database
edit the job database
edit the customer database
edit the materials database
edit the comments database
RedRover allows your accounting department to electronically retrieve tickets into your
accounting system, eliminating most of the manual re-typing that would otherwise be required.
RedRover also allows database editing from a central accounting location, freeing the operator to
run the plant.
SYSTEMS Equipment Corporation
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SYSTEMS Equipment Corporation
S I L O
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C O M P U T E R
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S I L O
L O A D O U T
C O M P U T E R
SLEEP MODE
If an MS-DOS-compatible ISA modem is installed in the LC-x000 computer and a remote
computer has RedRover installed, you may leave the computer LC-x000 running unattended
(overnight, for example) so that it’s databases may be accessed. In order to prevent phosphor
screen burning, the LC-x000 computer may be put in a “sleep” mode. In sleep mode, the
program ignores all external hardware and monitors only an installed modem and the keyboard.
When in sleep mode, the program clears the screen to a blue background and periodically scrolls
a simple message across the screen, indicating it is “sleeping”.
To enter sleep mode, press and hold a, then press S. To wake up a sleeping LC-x000
computer, hold down the a key, then press the S key again.
SYSTEMS Equipment Corporation
VER A60426
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SYSTEMS Equipment Corporation
VER A60426
D2-06B
110/220VAC
7
6
5
4
CB
7
6
5
4
CA
Module 2
3
2
1
0
NC
3
2
1
0
20-28VDC
8mA
4
5
6
7
0
1
2
3
CA
7
6
5
4
CB
7
6
5
4
4
5
6
7
24
VDC
Module 3
3
2
1
0
NC
3
2
1
0
20-28VDC
8mA
D2-16ND3-2
B
A
IN
0
1
2
3
7
6
5
4
CB
7
6
5
4
CA
4
5
6
7
110
VAC
Module 4
D2-16NA
3
2
1
0
NC
3
2
1
0
80-132VAC
10-20mA
50/60Hz
D2-16NA
B
A
IN
0
1
2
3
0
1
2
3
7
6
Module 5
D2-08TR
3
2
5
7
6
5
4
5
6
7
RELAY
Module 6
D2-08TR
3
2
1
C
1
C
5-240VAC
1A 50/60Hz
5-30VDC
5mA-1A
D2-08TR
OUT
L0
L4
C
4
5
6
7
RELAY
L0
L4
C
5-240VAC
1A 50/60Hz
5-30VDC
5mA-1A
D2-08TR
OUT
L O A D O U T
Module 1
D2-240 CPU
PORT 2
PORT 1
CH4
0
1
2
3
D2-16ND3-2
B
A
24
VDC
S I L O
0-
+
24VDC OUT
_
0.2A
G
85-264VAC
50/60 Hz
CH3
CH2
CH1
TERM
RUN
RUN
CPU
IN
Output 50
Light should be
lit when system
trying to open
silo 1
L C - 2 0 0 0
0+
0G
0N
0H
CPU
DL240
PWR
BATT
CPU Light
Normally
OFF
Koyo
205
CPU
Run Light
Normally
ON
Input 4A0
Light should
be lit when
gob hopper
opens
/
Direct
Logic
Power Light
Normally
ON
A/B Switch
Should be on
“A” to view
status of first
eight inputs
L C - 1 0 0 0
C O M P U T E R
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S I L O
L O A D O U T
C O M P U T E R
TRO UB L ES H O OT IN G
The following is a list, in no particular order, of things that might come up and things to try
before you call your dealer for service.
Symptom
No picture on monitor
Before loadout program
starts, screen has
message: “n lost
allocation units in n
chains. Convert lost
chains to files?”
SYSTEMS Equipment Corporation
Problem
• Computer/monitor not
plugged in
• Computer/monitor not
turned on
• Cable disconnected between
computer and monitor
•
Loadout has been shut
down improperly
Suggested Remedy
• Plug computer/monitor in
•
Turn computer/monitor on
•
Check cabling between
devices (15 pin VGA cable,
may have in-line extensions)
Respond with Y for yes. To
prevent from happening in
future:
Always shut down loadout
with F7
Use an uninterruptible
power source (ups). If on a
generator, don’t turn on the
loadout until generator is up
to power
•
•
•
Loadout has experienced a
power sag or surge
VER A60426
•
Page 107
Input X0
Light should be lit
when gob hopper
open
SYSTEMS Equipment Corporation
VER A60426
G
LG
C0
X0
X1
X2
X3
C1
X4
X5
X0-X7: INPUT
90-120V~7-15mA
50-60Hz
Koyo
05
X6
X7
C2
Y0
Y1
Y2
Y3
Y4
Y5
C3
Y0-Y5: OUTPUT
6-240V~2.0A 50-60Hz
6-27V - 2.0A
D0-05AR
RX2
TX2
RX1
TX1
CPU
RUN
PWR
CPU Light
Normally OFF
Run Light
Normally ON
L C - 2 0 0 0
AC(L) AC(N)
95-240V~
30VA 50-60Hz
LOGIC
Direct
Y0 Y1 Y2 Y3 Y4 Y5
OUTPUT
Power Light
Normally
ON
/
X0 X1 X2 X3 X4 X5 X6 X7
INPUT
Output Y0
Light should be lit when
system trying to open silo 1
L C - 1 0 0 0
S I L O
L O A D O U T
C O M P U T E R
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L C - 1 0 0 0
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S I L O
Loadout program starts
and gives message
beginning “The weighing
indicator has not
responded…”
•
Loadout program starts
and gives message
beginning “The silo PLC
is not responding…”
•
Computer cannot establish
communications with
weighing indicator
•
Computer cannot establish
communications with PLC
[usually SYSTEMS 1190
enclosure (LC-1000) or DL05 (LC-2000)]
•
•
•
•
•
System says (Alt-L)oad,
operator presses
aL, gates won’t
open, system gives
message: “Material Flow
Error”
1. Gate check utility does not
open gate
• Manual hardware
emergency stop button
engaged
• Manual system interlock
not made
•
•
SYSTEMS Equipment Corporation
PLC wiring not
connected to silo gate
solenoid
No panel power at PLC
output
VER A60426
L O A D O U T
C O M P U T E R
Check weighing indicator
power
Check cabling between
indicator and computer
(usually SYSTEMS 1011 or
1311 cable—9 or 25 pin
serial cable at computer end)
Check PLC power.
SYSTEMS 1190 enclosure
has a power switch on door
AND a fuse inside. PLC
CPU’s also have power light.
Check PLC cabling
(SYSTEMS 1336 cable—9
pin serial cable at computer
end, RJ-12 (phone) jack at
PLC end—goes into PLC
port 2)
Check that PLC is in RUN
mode (RUN light on CPU
should be ON)
Check that PLC does not
have a CPU error (CPU light
on CPU should be OFF)
•
Disengage e-stop
•
Check manual system
interlocks, i.e.: low air, safety
gates, gob hopper/batcher
limit switches
Check interconnect wiring
•
•
PLC has two sets of Hot,
Neutral and Ground—one
to supply it and one to
control hardware. Make sure
the second set is hooked up
to panel (control) power
Page 109
L C - 1 0 0 0
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S I L O
•
PLC output burned out
•
•
System says (Alt-L)oad,
operator presses
aL, gates won’t
open, system gives
message: “Waiting for
Gob Hopper” and never
moves on
(reverse weigh only)
System does not respond
to typed commands
Printer is not printing
tickets
SYSTEMS Equipment Corporation
2. Gate check utility does open
gate
• Freefall is larger than
desired drop size
• Manual hardware emergency
stop button engaged
• PLC wiring not connected
to gob hopper open signal;
PLC input burned out
•
•
•
•
Keyboard disconnected
•
•
Printer cable disconnected
•
VER A60426
L O A D O U T
C O M P U T E R
Select Draw From silo 1, do
gate check, watch PLC
output indicator light for silo
1 [50 in 1190 enclosure (LC1000); Y0 on DL-05 PLC
(LC-2000)]
Replace PLC Output
Module or Module Fuse
Use fewer drops or ticket
this load manually
Disengage e-stop
Check interconnect wiring to
PLC input [4A0 in 1190
enclosure (LC-1000); X0 on
DL-05 PLC (LC-2000)];
verify PLC indicator light
lights
Turn computer power off
(just this once!) plug
keyboard back into
computer
Check printer cable (parallel
printer cable—25-pin at
computer end, 50 contact
Centronics at printer end)
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L C - 1 0 0 0 / L C - 2 0 0 0 DATA B A S E
F O R M AT S
This document describes the fields in the databases used by an LC-x000 Material Loading
Computer System. These databases are generated using Microsoft FoxPro 2.6 for MS-DOS in a
dBase IV format. As such, they are directly readable by Microsoft Excel, Lotus 1-2-3, and other
spreadsheet or database programs. This list of databases does not include all databases used by
the program.
The order of the fields listed below may not occur in the actual database in the order shown. As
improvements are made to the program, the order, size, and characteristics of these fields may
change. Any analysis program you may develop should NOT rely on field order.
Notes regarding algebraic signs: Material sold to customers is defined as being positive in sign
and adds to the material inventory as positive. The net amount shown on the ticket will be
positive. In addition, gross and tare weights are positive. Material bought from customers is
defined as being negative in sign and adds to the material inventory as a negative number. In
other words, if your material inventory is negative, it represents the net amount you have on
hand. If the material inventory is positive, it represent the net amount sold to customers.
If a correction is made to a ticket, two additional tickets are issued - one undo ticket to correct
the material inventory and another redo ticket to issue out the correction. The algebraic sign
maintained in the ticket database uses the following convention for gross, tare, and net weights:
Inventory Ticket:
Undo Ticket:
Redo Ticket:
Loadout
Positive
Negative
Positive
Weigh Out
Positive
Negative
Positive
Weigh In
Negative
Positive
Negative
In order to maintain a consistent numeric system, the program will assign the same sign to the
gross and tare weights that it assigns to the net weight as shown in the table above. This is so
that correction tickets, sales taxes, shipping charges, etc. are correctly computed. Obviously it is
not possible to have negative weights - the algebraic sign simply serves to indicate the direction
material is moving and to maintain accurate computations. For computational purposes:
Net Weight = Gross Weight – Tare Weight
The absolute value of the net is the amount of inventory change and the sign indicates the
direction material is moving (i.e., positive when sold to a customer and negative when bought
from a customer).
SYSTEMS Equipment Corporation
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Structure for database: TICKET.DBF
A ticket record contains all information necessary to reconstruct the event at the time the ticket
was generated. Therefore, jobs, customers, trucks, materials, etc. can be deleted from their
respective databases without destroying the information needed to describe the ticket.
Field
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Field Name
TICKET
MIX
MIXDSCRPT1
MIXDSCRPT2
NET
PRICE
JOB_NUM
CUST_NUM
TRUCK
PUPTRUCK
LOADDATE
LOADTIME
POSTDATE
LINK_FORW
LINK_BACK
JOB_L1
JOB_L2
JOB_L3
JOB_L4
ZONE
ZONECHARGE
TAX_RATE
DISTANCE
PER_MILE
PER_LOAD
PER_LB
CUST_R1
CUST_R2
CUST_R3
CUST_R4
COMMENT
MIX_NUM
MAX_GROSS
GROSS
TARE
MEASURTARE
DROPS
TRKCOMMENT
PUPMAXGROS
PUPGROSS
SYSTEMS Equipment Corporation
Type
Width
Character
8
Character
20
Character
8
Character
8
Numeric
18
Numeric
18
Character
10
Character
10
Character
8
Character
8
Date
8
Character
5
Date
8
Character
8
Character
8
Character
35
Character
35
Character
35
Character
35
Character
10
Numeric
18
Numeric
18
Numeric
18
Numeric
18
Numeric
18
Numeric
18
Character
35
Character
35
Character
35
Character
35
Logical
1
Numeric
2
Numeric
18
Numeric
18
Numeric
18
Logical
1
Numeric
2
Character
35
Numeric
18
Numeric
18
VER A60426
Decimals
4
8
8
8
8
8
8
8
8
8
4
8
8
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Field Field Name
41
PUPTARE
42
PUPMEASTAR
43
PUPDROPS
44
CHANGEDATE
45
CHANGETIME
46
CT
47
CTL
48
CASH
49
TAX
50
TOTAL
51
WEIGHMASTR
52
RESOLVED
53
MANUALLOAD
54
TODAYSNET
55
JTD
56
TODAYLOADS
57
COMPOSE
58
TICKCOMNT1
59
TICKCOMNT2
60
TICKCOMNT3
61
TICKCOMNT4
** Total **
Type
Width
Numeric
18
Logical
1
Numeric
2
Date
8
Character
5
Logical
1
Numeric
3
Logical
1
Numeric
18
Numeric
18
Character
32
Character
8
Logical
1
Numeric
18
Numeric
18
Numeric
3
Logical
1
Character
35
Character
35
Character
35
Character
35
979
L O A D O U T
C O M P U T E R
Decimals
4
8
8
8
8
Explanation of fields
fields in TICKET.DBF
Field
Field name
Type
Width Dec Start
End
1
TICKET
Character
8
1
8
A unique value field of the form NNNNNN-S where NNNNNN is a 6-digit ticket number and
S is the station number from which the ticket was generated.
2
MIX
Character
20
9
28
The name of the mix or material that was used when this ticket was created
3
MIXDSCRPT1
Character
An optional additional mix descriptive field.
8
29
36
4
MIXDSCRPT2
Character
An optional additional mix descriptive field.
8
37
44
5
NET
Numeric
The net weight expressed in lbs. on this ticket.
18
4
45
62
6
PRICE
Numeric
18
8
The price, in dollars per lb., for the material on this ticket.
63
80
SYSTEMS Equipment Corporation
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7
JOB_NUM
Character
The job this material was sent to or came from.
10
L O A D O U T
81
90
8
CUST_NUM
Character
10
The customer to bill or pay for the material on this ticket.
91
100
9
TRUCK
Character
8
The truck the material on this ticket was hauled on.
101
108
10 PUPTRUCK
Character
8
The number of drops used to load pup truck, if applicable.
109
116
11 LOADDATE
Date
The date this ticket was generated.
8
117
124
12 LOADTIME
Character
The time of day this ticket was generated.
5
125
129
C O M P U T E R
13 POSTDATE
Date
8
130
137
The date on which this ticket should be posted to the owner’s accounts. This field may differ
from LOADDATE.
14 LINK_FORW
Character
8
138
145
If this ticket is involved in a correction ticket sequence, this field contains the ticket number of
the next ticket in the sequence. If this field is empty, this ticket is the final correction ticket.
15 LINK_BACK
Character
8
146
153
If this ticket is involved in a correction ticket sequence, this field contains the ticket number of
the previous ticket in the sequence. If this field is empty, this ticket is the original ticket from
which the correction sequence begins.
16 JOB_L1
Character
35
154
188
17 JOB_L2
Character
35
189
223
18 JOB_L3
Character
35
224
258
19 JOB_L4
Character
35
259
293
These fields are the free-form job fields used for operator description of the job on this ticket.
20 ZONE
Character
The zone in which this job lies.
294
303
21 ZONECHARGE
Numeric
18
8
304
The charge, in dollars, for hauling the load on this ticket to ZONE.
321
22 TAX_RATE
Numeric
The tax rate to be applied to this ticket.
18
8
322
339
23 DISTANCE
Numeric
The distance, in miles, to this job.
18
8
340
357
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24 PER_MILE
Numeric
18
8
358
The shipping charge, in dollars per mile, which applies to this ticket.
375
25 PER_LOAD
Numeric
18
8
376
The shipping charge, in dollars per load, which applies to this ticket.
393
26 PER_LB
Numeric
18
8
394
The shipping charge, in dollars per lb., which applies to this ticket.
411
C O M P U T E R
27 CUST_R1
Character
35
412
446
28 CUST_R2
Character
35
447
481
29 CUST_R3
Character
35
482
516
30 CUST_R4
Character
35
517
551
These fields are the free-form customer fields used for operator description of the customer on
this ticket.
31 COMMENT
Logical
1
552
552
This field contains ‘T’ if the customer on this ticket has a credit comment.
32 MIX_NUM
Numeric
2
553
554
The number of the mix on this ticket. Used internally by the LC-x000 program and has no
significance to the operator.
33 MAX_GROSS
Numeric
18
8
555
572
The maximum gross weight, in lbs., for the truck specified on this ticket.
34 GROSS
Numeric
18
The gross weight, in lbs., of the load on this truck.
8
573
590
35 TARE
Numeric
18
The tare weight, in lbs., of the truck on this ticket.
4
591
608
36 MEASURTARE
Logical
1
609
609
This field equals 'T' if the tare is measured by a scale - equals 'F' if entered by hand.
37 DROPS
Numeric
The number of drops used to load this truck.
2
610
611
38 TRKCOMMENT
Character
35
612
646
An optional field to store additional information about the truck. This information is not used
unless it is printed on a custom ticket or custom report.
39 PUPMAXGROS
Numeric
18
8
647
664
If a pup truck is involved in this ticket, the maximum allowable gross, in lbs, for the pup truck.
40 PUPGROSS
Numeric
18
The truck the material on this ticket was hauled on.
SYSTEMS Equipment Corporation
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682
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41 PUPTARE
Numeric
18
8
683
700
If a pup truck was used, the tare weight, in lbs., of the pup truck on this ticket.
42 PUPMEASURTAR Logical
1
701
701
This field equals 'T' if the ticket used a pup truck and the pup truck tare is measured by a scale equals 'F' if entered by hand.
43 PUPDROPS
Numeric
2
The truck the material on this ticket was hauled on.
702
703
44 CHANGEDATE
Date
8
704
711
45 CHANGETIME
Character
5
712
716
If this ticket is involved in a correction sequence, these fields specify the date and time the
correction was made.
46 CT
Logical
1
717
717
A correction ticket flag. This field will be set to ‘T’ if this ticket is involved in a correction ticket.
47 CTL
Numeric
Used internally for correction tickets.
3
718
720
48 CASH
Logical
1
721
This field will be set equal to ‘T’ if this ticket was a cash ticket.
721
49 TAX
Numeric
18
8
722
739
50 TOTAL
Numeric
18
8
740
757
These fields are maintained for historical reasons. Use ‘PRICE’ and ‘TAX_RATE’ along with
shipping charge fields to compute the value of the material on this ticket.
51 WEIGHMASTR
Character
32
758
789
The operator who generated the ticket. If this is a correction ticket, it will contain the name of
the operator who created the correction.
52 RESOLVED
Character
8
790
797
A field used internally to track Weigh In/Weigh Out (quarry operation) tickets where the gross
weight is known before the truck has been tared.
53 MANUALLOAD
Logical
1
798
If this ticket was generated manually, this field will contain ‘T’.
798
54 TODAYSNET
Numeric
18
8
799
816
Stores a temporary job summary for the current day. This field is used to avoid recomputing
summaries repeatedly – not useful otherwise.
55 JTD
Numeric
18
8
817
834
Stores a temporary job summary for tickets remaining in the database. This field is used to
avoid recomputing summaries repeatedly – not useful otherwise.
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56 TODAYSLOADS
Numeric
3
0
835
837
Stores a temporary load count for the current day. This field is used to avoid recomputing
summaries repeatedly – not useful otherwise.
57 COMPOSE
A flag used internally.
Logical
1
838
838
58 TICKCOMNT1
Character
20
839
859
This field can be used by accounting personnel for ticket specific information. Currently not
used by loadout software.
59 TICKCOMNT2
Character
20
860
880
This field can be used by accounting personnel for ticket specific information. Currently not
used by loadout software.
60 TICKCOMNT3
Character
20
881
901
This field can be used by accounting personnel for ticket specific information. Currently not
used by loadout software.
61 TICKCOMNT4
Character
20
902
922
This field can be used by accounting personnel for ticket specific information. Currently not
used by loadout software.
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The following is an explanation of other databases used by the program. This list is not a
complete list of all databases used. Many of the fields are important only in the operation of the
program and have no meaning to the operator. An explanation is given only for those fields
pertinent to the operator.
Structure for database: TRUCK.DBF
Field
1
2
3
4
5
6
7
8
9
10
11
12
13
Field name
NUMBER
PUP_TRUCK
NET
LJOB
DROPS
LCUST
LTICKET
GROSS
LAST
TARE
TARE_DATE
TARE_TIME
MEASURTARE
Type
Character
Character
Numeric
Character
Numeric
Character
Character
Numeric
Logical
Numeric
Date
Character
Logical
Width
8
8
18
10
1
10
8
18
1
18
8
5
1
Dec
4
4
4
Start
1
9
17
35
45
46
56
64
82
83
101
109
114
End
8
16
34
44
45
55
63
81
82
100
108
113
114
Explanation of fields in TRUCK.DBF
Field
Field name
Type
Width Dec Start
End
1
NUMBER
Character
8
1
8
The truck number, which appears on the ticket when this truck is loaded.
2
PUP_TRUCK
Character
8
9
Optional field used to specify a pup truck being pulled by this truck.
16
3
NET
Numeric
The net weight, in lbs., to load onto this truck.
17
34
35
45
44
45
18
4
4
LJOB
Character
10
5
DROPS
Numeric
1
The number of drops to use when loading this truck.
6
LCUST
Character
10
46
55
7
LTICKET
Character
8
56
63
8
GROSS
Numeric
18
4
64
81
The maximum gross weight, in lbs., this truck can be legally loaded to.
9
10
LAST
TARE
SYSTEMS Equipment Corporation
Logical
Numeric
1
18
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82
83
82
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The current tare weight, in lbs.
11 TARE_DATE
Date
The date of the last tare for this truck.
8
101
108
12 TARE_TIME
Character
The time of day this truck was tared.
5
109
113
13 MEASURTARE
Logical
1
114
114
Indicates if the tare weight was measured by instruments or entered manually.
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Structure for database: JOB.DBF
Field
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Field name
JOB_NUM
CUST_NUM
ZONE
ZONECHARG
E
TAX_RATE
DISTANCE
PER_MILE
PER_LOAD
PER_LB
L1
L2
L3
L4
LAST
JOB_EXTRA
Type
Character
Character
Character
Numeric
Width
10
10
10
18
Dec
Numeric
Numeric
Numeric
Numeric
Numeric
Character
Character
Character
Character
Logical
Character
18
18
18
18
18
35
35
35
35
1
64
8
8
8
8
8
8
Start
1
11
21
31
End
10
20
30
48
49
67
85
103
121
139
174
209
244
279
280
66
84
102
120
138
173
208
243
278
279
343
Explanation of fields in JOB.DBF
Field
Field name
1
JOB_NUM
The job name.
Type
Width Dec Start
Character
10
1
End
10
2
CUST_NUM
Character
10
11
20
This field ties the job to a customer in CUSTOMER.DBF. Every job must have a customer
attached.
3
ZONE
Character
See the ticket database explanation of this field.
10
21
30
4
ZONECHARGE
Numeric
See the ticket database explanation of this field.
18
8
31
48
5
TAX_RATE
Numeric
See the ticket database explanation of this field.
18
8
49
66
6
DISTANCE
Numeric
See the ticket database explanation of this field.
18
8
67
84
7
PER_MILE
Numeric
See the ticket database explanation of this field.
18
8
85
102
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8
PER_LOAD
Numeric
See the ticket database explanation of this field.
18
8
103
120
9
PER_LB
Numeric
See the ticket database explanation of this field.
18
8
121
138
10 L1
Character
35
11 L2
Character
35
12 L3
Character
35
13 L4
Character
35
See the ticket database explanation of these fields.
139
174
209
244
173
208
243
278
14 LAST
15 JOB_EXTRA
For internal use.
279
280
279
343
SYSTEMS Equipment Corporation
Logical
Character
VER A60426
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64
C O M P U T E R
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Structure for database: CUSTOMER.DBF
Field
1
2
3
4
5
6
7
Field name
R1
R2
R3
R4
LAST
CUST_NUM
CUST_EXTRA
Type
Character
Character
Character
Character
Logical
Character
Character
Width
35
35
35
35
1
10
64
Dec
Start
1
36
71
106
141
142
152
End
35
70
105
140
141
151
215
Explanation of fields in CUSTOMER.DBF
Field
Field name
Type
Width Dec Start
1
R1
Character
35
2
R2
Character
35
3
R3
Character
35
4
R4
Character
35
See the ticket database explanation of these fields.
1
36
71
106
End
35
70
105
140
5
LAST
Logical
1
141
141
6
CUST_NUM
Character
10
142
151
The customer name, which is tied to a job or series of jobs. When a job is chosen, the customer
the job is attached to is automatically selected and will appear on the ticket along with the
selected job.
7
CUST_EXTRA
For internal use.
SYSTEMS Equipment Corporation
Character
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152
215
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Structure for database: MIXES.DBF
Field
1
2
3
4
5
6
Field name
MIX
INVENTOR
Y
LLOADS
LAST
MIX_NUM
PRICE
Type
Character
Numeric
Width
20
18
Numeric
Logical
Numeric
Numeric
5
1
2
18
Dec
4
Start
1
21
End
20
38
8
39
44
45
47
43
44
46
64
Explanation
Explanation of fields in MIXES.DBF
Field
Field name
Type
Width Dec Start
1
MIX
Character
The name of the mix appearing on a ticket.
20
1
End
20
2
INVENTORY
Numeric
18
4
21
38
This field keeps a running inventory of material shipped or received. Material sold is considered
a positive number and material bought is considered negative. Thus if more material of this type
is bought than is sold, this field will be contain a negative number.
3
LLOADS
4
LAST
5
MIX_NUM
Used internally.
Numeric
Logical
Numeric
5
1
2
39
44
45
43
44
46
6
PRICE
Numeric
18
8
47
64
The price assigned to this material. In many cases, the operator will assign zero to this field at
the plant site, then apply the company’s price when the tickets are posted to the accounting
books at the home office.
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Structure for database: SILOS.DBF
Field
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Field name
SILO
MIX
QUANTITY
LOWSILO
SCALE_ID
FREEFALL
FULLFLOWRT
APPARENTFF
SILOTYPE
CAPACITY
MINIMUM
MAXIMUM
SDW
NAME
POSITION
FLORATECNT
DRIBBLEWT
Type
Numeric
Character
Numeric
Logical
Numeric
Numeric
Numeric
Numeric
Character
Numeric
Numeric
Numeric
Numeric
Character
Character
Numeric
Numeric
Width
1
20
18
1
1
18
18
18
2
18
18
18
18
8
8
3
18
Dec
Start
1
2
22
40
41
42
60
78
96
98
116
134
152
170
178
186
189
8
8
8
8
8
8
8
8
8
End
1
21
39
40
41
59
77
95
97
115
133
151
169
177
185
188
206
Explanation of fields in SILOS.DBF
Field
Field name
Type
Width Dec Start
End
1
SILO
Numeric
Identifies the silo to the program.
1
1
1
2
MIX
Character
The material currently loaded in this silo.
20
2
21
8
22
39
4
LOWSILO
Logical
1
This field contain ‘T’ if this silo is in a ‘low silo’ condition.
40
40
5
SCALE_ID
Numeric
1
41
6
FREEFALL
Numeric
18
8
42
The freefall weigh, in lbs., to apply when loading from this silo.
41
59
7
FULLFLOWRT
Numeric
18
8
8
APPARENTFF
Numeric
18
8
9
SILOTYPE
Character
2
Contains ‘TS’, “WB’, or ‘BW’, depending on the type of silo.
60
78
96
77
95
97
98
115
3
QUANTITY
Numeric
18
The current amount of material, in lbs., in this silo.
10
CAPACITY
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18
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The maximum material capacity, in lbs., for this silo.
11 MINIMUM
Numeric
18
8
The significance of this field depends on the type of silo.
116
133
12 MAXIMUM
Numeric
18
8
134
151
If silo is a weigh batcher, this field specifies the maximum capacity, in lbs., of the batch hopper.
13 SDW
Numeric
18
The smallest drop weight, in lbs., possible for this silo.
8
152
169
14 NAME
Character
8
170
177
15 POSITION
Character
8
178
185
POSITION specifies where to draw the silo on the inventory graph – used to show silo(s) from
the operator’s perspective.
16 FLORATECNT
Character
17 DRIBBLEWT
Numeric
These fields are for future use.
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18
186
189
188
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Structure for database: SCALES.DBF
Field
1
2
3
4
5
6
7
8
9
10
11
12
13
Field name
SCALE_ID
SCALE_TYPE
BRAND
MODEL
PORT
RATE
IRQ
ADDRESS
PARITY
DATABITS
STOPBITS
FLOWCTRL
CHANNEL
Type
Numeric
Character
Character
Character
Character
Character
Character
Character
Character
Character
Character
Character
Character
Width
1
2
2
5
4
6
4
4
4
4
4
4
8
Dec
Start
1
2
4
6
11
15
21
25
29
33
37
41
45
End
1
3
5
10
14
20
24
28
32
36
40
44
53
Explanation of fields in SCALES.DBF
Field
Field name
Type
Width Dec Start
1
SCALE_ID
Numeric
1
1
SCALE_ID uniquely identifies the scale head / weighing indicator.
End
1
2
SCALE_TYPE
Character
2
2
3
Identifies the type of scale. Acceptable entries are “TS” (i.e., truck scale), “WB” (weigh batcher),
and “BW” (back weigh or reverse weigh).
3
BRAND
Character
2
4
5
This entry identifies the manufacturer of the scale head / weighing indicator. The program uses
this entry to select the correct communications format.
4
MODEL
Character
5
6
10
This entry identifies the manufacturer’s model number of the scale head / weighing indicator.
The program uses this entry to select the correct communications format.
5
PORT
Character
4
11
14
This field specifies the MS-DOS serial port. Valid entries are “COM1”, “COM2”, “COM3”,
and “COM4”.
6
RATE
Character
This field specifies the serial port baud rate.
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15
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7
IRQ
Character
4
21
24
This field specifies the MS-DOS hardware interrupt number used by this serial port. Each
indicator is assigned a unique interrupt. Non-standard IRQs may be assigned if the serial port
hardware is configured appropriately.
8
ADDRESS
Character
4
25
28
This field specifies the MS-DOS serial port address this indicator communicates through. Valid
entries are “03F8”, “02F8”, “03E8”, and “02E8”.
9
PARITY
Character
4
29
32
Specifies the parity used by the serial port. Valid entries are “E”, “O”, and “N”.
10
DATABITS
Character
4
33
36
Specifies the number of data bits encoded into each serial port character. This field is usually set
at either “7” or “8”.
12
FLOWCTRL
Character
4
41
44
Specifies what type of flow control to use. This field is usually blank (i.e., no flow control).
13
CHANNEL
Character
8
45
53
This field specifies a channel number if a Rice Lake 810 indicator is installed. Depending on the
number of RL 810 channels installed, this field is set to “1”, “2”, “3”, or “4”. Ignore this field if
no Rice Lake 810 indicators are present.
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INDEX
A
Abort a Load ......................................................................................................... 17, 23, 31, 41
Accounting Programs................................................................................................................ 1
Archiving Tickets.................................................................................................................... 75
Attribute Database ................................................................................................................ 1, 5
Auto-Load ............................................................................................................................... 65
B
Backup to Diskette............................................................................................................ 77, 79
Batcher .............................................................................................................. See Gob Hopper
C
Cash Sale................................................................................................................................. 94
Cash Ticket ................................................................................................................. 11, 69, 94
Change Posting Date............................................................................................................... 57
Communication....................................................................................................................... 73
Company Information............................................................................................................. 67
Configuration .................................................................................................................. 1, 5, 57
Copy Mode.............................................................................................................................. 98
Correction Tickets....................................................................................................... 51, 53, 55
Customer Comments................................................................................. 15, 21, 29, 43, 45, 92
D
Diskette ............................................................................................................................. 77, 79
Display Ticket......................................................................................................................... 55
Ditto Ticket ................................................................................................................. 51, 53, 59
E
Empty the Silo......................................................................................................................... 37
English Units........................................................................................................................... 65
Erasing Lists............................................................................................................................ 75
Error .................................................................................................. 19, 25, 33, 39, 51, 71, 110
Exit Program ..................................................................................................................... 81, 90
F
F10-Fill / Empty Inventory Graph .......................................................................................... 96
F11-Copy Mode ...................................................................................................................... 98
F12-Tare a Truck .................................................................................................................. 100
F1-Lists ................................................................................................................................... 43
F2 Hot Key.............................................................................................................................. 49
F3-Ticket List.......................................................................................................................... 51
F4-Utility Menu ...................................................................................................................... 57
F5-Unresolved Tickets............................................................................................................ 83
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F6-Weigh In / Out or LoadOut ............................................................................................... 85
F7-System Shutdown .............................................................................................................. 90
F8-Comments.......................................................................................................................... 92
F9-Cash Sale ........................................................................................................................... 94
File Format................................................................................................................................ 1
File Maintenance......................................................................................................... 67, 75, 79
Find Ticket .............................................................................................................................. 53
Floppy Disk............................................................................................................................. 77
Flow Rate ................................................................................................................................ 67
Free Fall .................................................................................................................................. 67
G
Gate Check.............................................................................................................................. 59
Gob Hopper............................................................................... 21, 23, 25, 27, 59, 63, 110, 111
H
Hardware......................................................................... 1, 17, 23, 31, 39, 41, 73, 79, 110, 111
Horns....................................................................................... 3, 15, 21, 29, 37, 65, 85, 88, 100
I
Incorrect Ticket....................................................................................................................... 51
L
LC-1000 .................................................................................................................................... 1
LC-2000 .................................................................................................................................... 1
Loading – Reverse Weigh Silo ............................................................................................... 21
Loading – Truck Scale ............................................................................................................ 15
Loading – Weigh Batcher ....................................................................................................... 29
Loading Setup ....................................................................................................... 59, 63, 65, 73
LoadOut Mode .................................................................................................................. 57, 79
Low Silo Bypass ................................................................................................... 19, 25, 31, 37
M
Main Operating Screen ............................................................................................................. 9
Manual Ticket ............................................................................................................. 19, 25, 33
Material Flow Error ................................................................................ 19, 25, 33, 39, 65, 110
Metric Units ............................................................................................................................ 65
Modem ................................................................................................................................ 1, 73
Moving Between Fields ............................................................................................................ 7
P
Password ....................................................................................................................... 5, 61, 69
Posting Date ............................................................................................................................ 57
Print Ticket.............................................................................................................................. 55
Printer.......................................................................................... 17, 21, 29, 69, 73, 85, 88, 111
Program Navigation .................................................................................................................. 7
Pup Trucks .............................................................................................................................. 35
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Q
Quarry ........................................................................................................................... 1, 83, 85
Quick Start ................................................................................................................................ 3
R
RedRover .................................................................................................... 45, 73, 92, 104, 106
Report Menu ..................................................................................................................... 47, 77
Restore from Diskette ............................................................................................................. 79
Reverse Weigh ........................................................................................ 21, 63, 67, 71, 73, 111
S
Search Ticket Database........................................................................................................... 53
Select Copy Mode................................................................................................................... 59
Silo Inventory.......................................................................................................................... 67
Sleep Mode ........................................................................................................................... 106
Software Setup .............................................................................................................. 5, 61, 69
State Requirements ................................................................................................................. 69
System Parameters .......................................................................... 5, 47, 59, 61, 65, 71, 73, 81
System Setup........................................................................................................................... 59
System Shutdown.................................................................................................. 43, 47, 81, 90
T
Tare a Truck .......................................................................................................................... 100
Ticket Number ............................................................................................................ 67, 69, 83
Ticket Setup ...................................................................................................................... 59, 67
Training Mode ........................................................................................................................ 79
Troubleshooting .................................................................................................................... 108
Truck Scale ........................................................................... 11, 15, 57, 63, 71, 83, 85, 96, 100
U
Units........................................................................................................................ 1, 43, 65, 69
Unresolved Tickets ........................................................................................................... 57, 83
Utility Menu............................................................................................................................ 57
W
Weigh Batcher ............................................................................................................ 29, 63, 96
Weigh In / Out Mode ........................................................................................................ 57, 85
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Jog Gate Addendum
This addendum addresses the jog gate (also known as a dribble gate) feature available in program
versions 2000-B27 and later. This feature controls a pair of gates where, during the beginning of
a drop, both gates are opened to speed up a load and, as the drop nears completion, the
secondary gate is closed to provide a more-controlled material flow. On silos with only one gate
air cylinder, the jog gate is the main gate. This feature is available only for truck scales and
reverse weigh silos and is not available for weigh batching silos.
Idealized Flow Rate
Close Secondary Gate
Dribble Weight
Tons/Sec
Close Jog Gate
Freefall
Time, seconds
The figure above shows an idealized flowrate (not to be confused with total drop weight) using a
jog and secondary gate. With both gates open, maximum flow develops. At some point before
closing the jog gate, the secondary gate must be closed so that smooth, uniform flow can
develop before closing the jog gate. The point at which the secondary gate is closed is set by a
silo parameter named “Dribble Weight”.
The value of this parameter is accessible from the main screen by pressing F1 for lists, then
selecting (S)ilo Contents (the Silo Maintenance screen will appear), then pressing (A)djust
Freefall and Flowrate. The Change Freefall … screen will appear where the last entry allows you
to modify the dribble weight.
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If the dribble weight is set very large (ie, larger than the drop size) the program will not allow the
secondary gate to open during the drop. If the dribble weight is set to 0, both gates will open
and close together as though there was a single control signal controlling both gates. To
properly use this feature, you need to pick a value that balances fast loading with accurate
loading depending on the difference in gate size, the speed of the gates, etc. Start with a value of
4 tons (or equivalent) and adjust it up or down until drops are accurate while being as fast as
possible – your emphasis should be on accuracy, however. Once a workable value has been
determined, leave it there. For small drops, the program can determine when or when not to
use the secondary gate. If you have found an appropriate dribble weight, then change the value
manually to 0 without adjusting the freefall upwards, the actual freefall will be much larger. The
program will overload until it has adjusted the freefall to account for the changed conditions.
If you have program update diskettes, install the update now.
Start the LoadOut program. Your databases will automatically be updated but, by default, the
feature will be disabled. Terminate the program. At the MS-DOS prompt run the FIELDMOD
utility from the command line by typing FIELDMOD. A list of databases will appear. Use the
down-arrow key until SILOS.DBF is highlighted, then press the ENTER key to begin editing
the database.
Use the TAB key to locate the parameter named “Has_dribgt”, then change the parameter from
“F” to “T”. Press the ENTER key, then the ESCAPE key continually until the utility program
is terminated.
Restart the LoadOut program. Follow the procedure above by pressing F1 to set the dribble
weight value to 4 tons (or its equivalent in the system of units you are using). You may need to
experiment to find the proper value the works best with your hardware.
LC-1000 LoadOuts can control up to 4 silos. Each silo jog gate has an independent PLC output
for opening the jog or main gate. These terminal numbers are 50, 51, 52, and 53, respectively,
inside the 1190 PLC enclosure. The secondary gate, however, has only one output from the
PLC, terminal 56 inside the 1190 PLC enclosure, and must be wired through your draw-from
selector switch to properly route the signal to the appropriate secondary air cylinder solenoid.
LC-2000 LoadOuts can control only one silo. The jog or main gate control output is terminal
Y0 on the DL-05 PLC. The secondary gate control output is terminal Y2 on the DL-05 PLC.
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