SYSDYNE batching system operator`s manual

SYSDYNE batching system operator`s manual
SYSDYNE
Trailblazer/Scout
Concrete Batching Computer
S Y S T E M S
OPERATOR’S MANUAL
System & Operations .................................................................................................. 4
Introduction .................................................................................................................. 4
Installation Instructions............................................................................................. 6
Hardware List ................................................................................................................ 6
System Hardware Structure ...................................................................................... 7
Hardware Specifications ............................................................................................ 7
Installation Procedure ................................................................................................ 8
Software Upgrade ......................................................................................................... 9
Operating Guide.......................................................................................................... 10
Starting the System ................................................................................................. 10
Preliminary Set-Up Steps ........................................................................................ 11
Enter a mix design ................................................................................................... 17
Starting an Automatic Batch ................................................................................... 18
Batching Cycle Details ................................................................................................. 24
Description of fields and features ................................................................................. 27
Job.................................................................................................................................... 32
Scheduler.................................................................................................................... 32
Job Maintain ................................................................................................................ 32
Job Edit ....................................................................................................................... 33
Mix.................................................................................................................................... 37
Mix Design .................................................................................................................. 37
Parameters ................................................................................................................. 37
Materials ..................................................................................................................... 38
Material .......................................................................................................................... 39
Material Type .............................................................................................................. 39
Weight material........................................................................................................... 39
Mater Material ............................................................................................................. 43
Utilities............................................................................................................................ 46
Scale List .................................................................................................................... 46
Scale Setting ............................................................................................................... 46
Horn List ..................................................................................................................... 48
Horn Setting: ...................................................................................................... 48
Hoist List ..................................................................................................................... 48
Hoist Setting ....................................................................................................... 48
Mixer List .................................................................................................................... 48
Mixer Setting .............................................................................................................. 48
Operation Parameters ................................................................................................. 49
Printer Setup............................................................................................................... 50
Diagnose ..................................................................................................................... 50
Dos Data ..................................................................................................................... 51
Charge ............................................................................................................................ 52
Truck Charge: This is the mixer truck charging profile. Each truck will have its individual
charge rate and may be updated after every batch. ..................................................... 52
Scale Discharge Sequence ........................................................................................... 52
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Customer ....................................................................................................................... 54
Ticket............................................................................................................................... 56
Report ............................................................................................................................. 59
Quote................................................................................................................................. 71
Calculator ................................................................................................................... 71
Dispatch Interface ............................................................................................................. 72
Accounting Interface......................................................................................................... 73
Auto Seek’N Feed............................................................................................................. 74
3
System & Operations
Introduction
The term “Trailblazer” will reference to Trailblazer and Scout systems for similar situations and
functions. The Trailblazer batching computer system combines state of the art microprocessor
technology, advanced electronic circuitry together with intelligent programming to achieve
highly efficient and accurate automatic batching control. As a result, improved plant
production is attained with reduction of plant equipment wear. The computer programs have
been designed to be versatile and flexible in order to accommodate different plant
configurations. The system, with many features and extensive processing power is however,
simple to operate.
The Trailblazer batching systems retain a large collection of data related to job, mix design,
delivery ticket, batch recordation, customer, inventory and truck data which are organized and
orderly maintained in the internal hard disk. This database can be rapidly retrieved to produce
many useful management reports.
The Trailblazer system configuration is based on the latest IBM1 PC compatible computer, high
resolution monitor for information display, full sized keyboard and a mouse pointing device for
command and data entry. The software operates under MS-Windows2.
The Trailblazer systems include a manual operation panel allowing the operator to manually
perform all the plant operating functions. Carefully designed interlocks are incorporated to
disable certain switches and push buttons on the manual operator’s panel during the
automatic batching cycle to ensure that there is no manual interference on the automatic
operation.
The monitor information display is always formulated to guide the operators though the
various stages of the operation. Specific keyboard keys and mouse “clicks,” which can be used
to issue commands, are easily identified on the monitor screen display. It is therefore
unnecessary for the operator to memorize a myriad of commands. Functions which can be
activated at a specific stage are shown on a self-explanatory screen menu. Each step on the
automatic batching process is also clearly identified and the current system status is always
annunciated on the monitor screen. The computer also prompts the operator with on screen
messages whenever there is special action to be taken.
The CPU sends signals to and receives signals from the plant devices such as valves,
solenoids, motor starters, limit switches, meters and scale sensing devices through connection
terminals and interfacing electronics located in a factory fabricated wall junction box.
The specifications for standard output signal drive capacity and the input device requirements
are listed in Hardware Specifications. SYSDYNE CORP. must be consulted should there be any
deviation from the specifications.
With the IBM3 PC compatible hardware platform and MS Windows, Trailblazer batching system
reads and writes the same kind of data storage devices widely used in today’s office computer
systems. This makes it possible to exchange information with the office computer systems.
Delivery ticket, batch, and material inventory information can be readily transferred to other
accounting computer system electronically.
1IBM is the trademark of International Business Machines Corporations. 2MS DOS is the trademark of MICROSOFT.
4
Throughout this manual the terms screen, window or screen window, menu, cursor, field, is
repeated again and again. The operator’s understanding of these terms is important.
SCREEN refers to the TV-like monitor display.
SCREEN WINDOW OR WINDOW refers to a small portion of the screen blocked out for
displaying some special message, usually superimposed over the original screen display.
MENU means a list of items displayed on the SCREEN or in a WINDOW.
CURSOR refers to either the white arrow controlled by the mouse.
POINT and CLICK refers to moving the cursor via the mouse and clicking on the desired object.
FIELD refers to a piece of data in a record or a space on the screen where certain data is to be
located.
Users are reminded that since the system relies on the different sensors on the plant to derive
different appropriate control signals, it is most important that all sensing devices are
periodically inspected and calibrated.
3IBM is the trademark of International Business Machines Corporation.
5
Installation Instructions
Hardware List
Check for the following items before starting installation. You must have all those items
shipped to you in order to complete the installation:
PC with power cable.
Monitor, with power cable.
Speakers
Mouse type pointing device
Full size keyboard
Printer, with power cable
Parallel printer cable
Wall Junction Box, (J Box).
Wall Junction Box Key
Manual panel
Manual panel security key
Manual panel cables, C1 and C2
Transceiver cable (combination scale and analog/digital cable).
Transceiver
Transceiver power cord
Sysdyne “Black Box,” Analog Input Module.
RS485 conversion dongle.
Sysdyne Corp and the shipping agent must be notified immediately if any items are missing or
damaged during shipment.
6
System Hardware Structure
SCALE
GOLDBOX
INDICATOR
SCALE
INDICATOR
PRINTER
BLACK-BOX
WALL J-BOX
RS485
CONVERTOR
COMPUTER
KEYBORAD
MONITOR
MOUSE
Hardware Specifications
Dimensions: Wall junction box: 30”×24”×8” (Scout measures 16 x 20 x 12)
Computer room environment: The computer room ambient temperature should be
maintained within a range of 55 to 95 degree F. Continuously operating at high temperatures
or starting the system from extreme cold conditions without adequately warming the room
may cause the computer to fail. Extremely dusty conditions should also be minimized.
Power requirements: Line voltage of 115VAC, 60Hz, 15 Amps of stable power source, not
shared by any other plant equipment. Power fluctuation and interruption must be corrected by
installing either a constant voltage transformer or an uninterruptible power supply.
Wall Junction box: All plant wiring connections are to be terminated at the wall junction box,
except those from the scale indicator or moisture probe.
Scale inputs: Load cell indicators providing a 0-10 VDC continuous analog output.
7
NOTE: Each of the load cell indicators uses a 9-pin connector to connect to a
Black Box analog channel. PIN-2 is positive, PIN-3 is negative, PIN-4 is ground
(option).
Meter material counts inputs: Metering device count inputs must be 115 VAC at NOT MORE
THAN 15 (fifteen) counts (ON-OFF cycles), per second. ON-OFF cycles cannot be less than 60
milliseconds.
Output drive capacity: Each output signal from the computer is 115 VAC with 1 amp load
capacity. Motors must not be connected to the computer directly.
Installation Procedure
Locating the SYSDYNE computer: The PC system should be placed at a convenient location
allowing the operator clear sight of mixer truck during the loading process, all the while
operating the keyboard and mouse. The manual operations panel should be situated next to
the computer for convenience. Avoid locating the monitor under direct sunlight or next to the
radio base station.
Installing the Wall Junction Box: The wall junction box should be installed at an easily
accessible location in the batch room preferably less than 10ft. away from the computer.
Cables from J-Box to CPU are 15ft. in length. The operator should be able to see inside of the
wall junction box when the box door is open in order for him to do simple troubleshooting
tasks.
Power to the system: AC power is to be brought in from a stable AC dedicated line through
a 20-amp circuit output breaker, from the load center of the plant power system. Punch a hole
at a suitable spot on the side of the wall junction box and bring the AC power line through the
hole and connect them to the terminals marked “L1”, “L2”, on the power terminal strip at the
bottom of the wall junction box. Wiring between wall junction box and source must be in
applicable conduits to meet the local electrical installation code.
Note: It is very important the Sysdyne junction box be properly grounded.
Connecting Plant Control Wires: All plant control wires, for the devices controlled by the
batch computer, are connected either directly to the terminals or through a pre-assembled
cable to the terminals inside the wall junction box. Carefully connect each plant wire to the
appropriate device and terminal. After the connections have been made, you can use the
manual operator’s manual panel to operate each plant device to ensure that every connection
is correct. You must do so before proceeding to set up and check out the automatic mode
operation.
In general, all solenoids or starters should have one conductor terminated at the output
terminals in the wall junction box and the other conductor terminated at the L2 terminals in
the wall junction box. A starter or solenoid is activated by the system supplying 115VAC at the
output terminal of the particular device.
Each output terminal in the wall junction box is fused and has a neon indicator light to show
the presence of voltage. 1A fuses are installed from the factory. If your starters or solenoids
require larger fuses, you can replace them with 2A fuses. NEVER connect a motor directly to
the terminal.
8
Admixtures and Water Meters: Admixtures and water, which are typically measured by
metering devices, must have the meter return signals properly connected to the designated
input terminal. The switched power source for meters and limit switches should originate from
terminal “3L1.”
Each metering device must be calibrated to the batch computer after the system has been
completely set up.
Admixture Bottles: If admixture bottles are used, each bottle must have its own liquid level
control amplifiers to cut the discharge signal when the bottle is empty and to cut the fill signal
when the bottle has either reached the desired target or has filled to capacity. The system is
set up such that the bottles for admixtures #1, #2, and #3 are discharged from the same
signal and at the same time, as bottles for #4, #5 and #6 admixtures. The bottle empty signal
from each bottle should be wired as follows.
Admixtures #1, #2, and #3 zero outputs are wired in series to TFS 11. Admixtures #4, #5,
and #6 wired series to TFS 12 (refer to wiring manual for locations of TFS board).
A series circuit will generate 115VAC signal on TFS 11 when bottles #1, #2, and #3 are empty
and likewise on TFS 12 when bottles #4, #5, and #6 are empty.
Admixtures Flow Rates: Admixture flow must be adjusted such that the meter counting rate
shall not exceed fifteen (15) counts per second for reliable operation. Unreliable counting may
result in improper admixture dosages and seriously affect the quality of the concrete produced.
Connecting the Computer: Securely mount or position each component of the system.
Avoid excessive dusty areas especially for the computer and printer. Connect the remaining
components of the batching system with the factory provided cables. Proceed to check out all
the operations.
Software Upgrade
You can download the latest version of batching program on our web site:
http://www.sysdynecorp.com
9
Operating Guide
The following chapter is intended to show a first time user, step by step, how to start up the
system, how to batch a load of concrete using the operator’s manual panel, how to set up the
simplest material tables and mix designs and finally how to batch a load in the automatic
mode. The advanced features of the Trailblazer series batching computers allow the operator
to pre-enter jobs, set up different truck charging sequences, set up projects, etc. the operator
is encouraged to experiment with these features after batching a few loads with the simplest
setting.
Starting the System
The batching computer system, once installed, requires no special starting procedure.
To start the system, simply turn the spring loaded power selector switch on the operator’s
manual panel to the ON position and release the switch. This will allow you to start devices
necessary in the batching process, (i.e., air compressors, aeration, etc…). Turn on the PC,
monitor, printer, analog input module and power to the J-box transceiver unit, (it is highly
recommended that you use a battery back up / constant voltage transformer for the protection
of your electronic equipment. Doing so, will allow you to turn on several components at
once). Wait a few seconds for the Windows User Logon Menu to appear. Double click on
your company name. Once the Windows Desktop appears double click on the SYSDYNE
Batching icon. A small window will appear requiring a user name. Put the name of your
company or the word admin, both company name and admin must be in lower case
characters. The Batch menu will appear.
NOTE:Click the license button to change the license of your program.
The on-screen TABS located at the top of screen allows the user to select and initiate different
functions of the program. The steps to select and initiate a function are:
Move the cursor, using the mouse to the menu item you wish to enter. Once the cursor is on
the menu item click the left mouse button.
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To go into the Batch menu, simply click on the Batch icon on the lower left side of the current
screen.
Before attempting to use any of the functions in the batch program, the operator should first
try to become familiar with the manual panel operation. Batching a few loads using the
manual panel will help speed up the familiarization process. In addition, manual mode
batching may be necessary when an equipment malfunction prevents the use of the automatic
cycle.
Material set-up
Before the system can be used to batch in automatic mode, the materials table and at least
one mix design must be properly set up. A mix design is the formula, which specifies the name
and the quantity required of each material per cubic yard mix. The material tables are set up
to provide various batching control and information processing parameters including the
information relating the material names used in a mix design formula to the actual bin gate
solenoids, meter valves or pumps on the plant. Example: if sand is stored in material bin #1
and if the computer is to batch one cubic yard of a mix contains 1600 lbs. of sand per cubic
yard, the computer will look up the material tables to find the name SAND under which Bin #1
solenoid to batch out 1600 lbs. of material.
Preliminary Set-Up Steps
Click on the Material Tab
Looking at the small “pull-down” menu labeled Material Type, insure it has “Weighed”
displayed.
Weighed Materials set-up
First, double click anywhere on the first line of the Material menu. A small window will
appear with the Name field highlighted in blue. Type in the name of the first
weighed material, (1-6 are reserved for aggregates and 7-10 are reserved for
cements). When name is typed in hit the TAB key on the keyboard. The cursor will be in the
Bin ID field. Continue using the TAB key until all data requested has been entered.
Name: This is name of the particular aggregate you are currently setting the details
for. The name you type here will be used by the program to reference this material in
other menus.
Bin ID: This is the gate number assigned to this material (Bins 1-6 are reserved for
aggregates and 7-10 are reserved for cements).
Auto Cut Off: This is “autopilot” of the weighing side of the program. Checking this
box will allow the program to automatically adjust the freefall compensation value.
Type (Pull down menu): Tell the program what category of material you are setting
up. This value is used for timing purposes, i.e., when to discharge admixtures, water,
etc…
Fast Cut off: When more than one gate is used for the same material with the same
material name this value will represent the amount “short” of the desired target in
which to shut all other gates that have like material and are being used in multi gate
weighing cycles.
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NOTE: The first gate (bin gate name) listed will be the final weigh up gate. It is not
necessary to set up details for all subsequent materials of the same name as the data
will not be used.
Tolerance: This represents the percentage of the total weight error or deviation
allowed acceptable of the desired target weight.
Slow Cut Off: This is the value the program will use to compensate for freefalling
material. If using AUTO CUT OFF this number will not adjust, however the value is
constantly updating within the program. If AUTO CUT OFF is not being used, then this
value will be assumed and fixed.
Scale Settling Time: This is the amount of time in seconds to allow the scale to
settle between jogs.
Auto Jog: Putting a check in this box enable the auto jog feature.
Spec. Gravity: This value represents the density of the material that you are detailing.
Jog Open Time: This is the amount of time in seconds; an electrical of 115VAC+/signal is applied to the solenoid valve connected to the cylinder of this bin. Basically
this is the amount of time for jogging but, due to the differences in hose sizes,
cylinders, solenoids, bin gate characteristics the definition had to be exacted.
Inventory Unit, (Pull down window): Select the unit of measure for the batching of
this material.
Jog Close Time: This represents the amount of time in seconds, between JOG OPEN
signals.
Alarm Level: Put the weight at which you wish the program to notify you of the onhand amount of this material. The value here is the inventory weight.
Min. Flow Rate: Reserved for future use.
Alarm On: Checking this box will enable the Alarm Level feature to function.
Man Batch: This feature can be used to inventory materials that are to be used in the
batching process but are not electrically connected to the batch computer. When used,
the precise amount of material needed in a specified mix will appear on the batch
screen but will not generate any kind of output.
Aeration Off: This is the amount of weight in weighing units the aeration will cut off
prior to the desired target weight.
Moisture: Putting a moisture percentage value in this field will cause the program to
adjust the water and sand based on this fixed value. This value will remain until
changed by the operator.
Auto: If this box is checked and the MAX MOISTURE field mentioned below is setup,
the program will then look for an input signal from a moisture gauging device.
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NOTE: The input signal from the moisture gauge must be of a 9-10VDC
calibration. There is no on-screen calibration in this program. The program algorithm
is analog input volts x 2 = moisture % displayed.
Auto Moisture:
Delay Sec.: This feature is used when an “under the bin gate” moisture gauge
is used. This represents the amount of time in seconds the program delay its
moisture sampling once the gate opens.
Min Weight: This feature is used when an “under the bin gate” moisture
gauge is used. This represents the amount of weight in weighing units the
program will disregard before starting to measure moisture content.
Min Moisture: This is the minimum amount of moisture the program will
accept to update the moisture value. If the minimum is not reached then the
previous batch value will be used.
Max Moisture: This is the maximum amount of moisture the program will
accept to update the moisture value. If the moisture amount surpasses this
value then the previous batch value will be used.
NOTE: If for some reason you wish to disable the auto moisture compensation feature
this value must be set to zero.
Max. Amt. In Mix: This is the maximum allowable weight in weighing units per yard
or meter that may be used in creating a mix design without receiving a warning
message of “Exceeds Max Allowable Amount in Mix,” message. If you encounter this
message you must either reduce the weight of the material or acknowledge the
overage.
Absorption:
Show Balance: Using this feature will cause the program to display the current
balance of this material to be displayed on the portion of the batch screen used to
represent this product.
Repeat this procedure for all weighed materials to be used by the batching program.
Metered Materials Setup:
Click on the Material tab
Looking at the small “pull-down” menu labeled Material Type, insure it has “Metered”
displayed.
First, double click anywhere on the first line of the Material menu. A small window will
appear with the Name field highlighted in blue. Type the name of the admixture to be
metered. When name is typed in hit the TAB key on the keyboard. The cursor will be in the
Pump ID field. Continue using the TAB key until all data requested has been entered.
13
Name: This is name of the particular admixture you are currently setting the details
for. The name you type here will be used by the program to reference this material in
other menus.
Pump ID: This is the pump number assigned to this material (Pumps 1-6 are
reserved for admixtures and 15 and 16 are reserved for waters).
Cut Off: In event the metered material continues to overrun its target by the same
amount every batch cycle the feature allows the program to automatically compensate
for the overage.
Type: (Pull down menu): Tell the program what category of material you are setting
up. This value is used for timing purposes, i.e., when to discharge admixtures, water,
etc…:
Tolerance: This represents the percentage of the total volume error or deviation
allowed acceptable of the desired target amount.
Max AMT In Mix: This is the maximum allowable volume in metering units per yard
or meter that may be used in creating a mix design without receiving a warning
message of “Exceeds Max Allowable Amount in Mix,” message. If you encounter this
message you must either reduce the volume of the material or acknowledge the
overage.
Batch Start: This field requires a single or double digit integer used to represent any
number of timed situations during the batching/discharging cycle:
1. The start of any weighed material.
2. The start of any fine aggregate weighing.
3. The completion of scale #2.
4. The completion of scale #3.
5. The completion of scale #2 weighing.
6. The completion of scale #3 weighing.
7. The completion of scale #4 weighing.
8. The batching of any weighed material. (The program does not check for the
completion of any weighed material before allowing weighed material in the
scale to be discharge.)
9. Scale discharge complete.
10. Scale 1 discharge complete.
11. Scale 2 discharge complete.
12. Scale 3 discharge complete.
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14. Scale 4 discharge complete.
Unit: This is the unit of measure for this material to be batched in. This setting may
differ from the inventory unit.
Batch Delay: This is the amount of time in seconds, the bottle or direct feed material
will be delayed once the Batch Start setting has been met.
Meter Rate: This is the value in batch units per pulse.
Discharge Start: Uses the same coded integers as listed above.
Metric Batch Unit: This field is the metric liquid measurement. Example: milliliters
or liters, (mls or lts).
Discharge Start: This is the amount of time in seconds; the discharge of this material
will be delayed, once Discharge Start setting has been met.
Spec. Gravity: This value represents the density of the material that you are detailing.
Min Flow Rate: Reserved for future use.
Inventory Unit: This setting is used for entering the incoming material volume as
stated on the bill of laden. Typically aggregates are delivered to your plant in tons
and cements can be either tons or pounds. You decide.
Man Batch: This feature can be used to inventory materials that are to be used in the
batching process but are not electrically connected to the batch computer. When used,
the precise amount of material needed in a specified mix will appear on the batch
screen but will not generate any kind of output.
Alarm Level: Checking this box will enable the Alarm Level feature to function. This
is feature uses an Inventory Unit amount to warn the operator of a low material
level.
Bottle: Placing a check in this box will cause the computer to verify a “bottle empty
signal” prior to every batch and also automatically enable a bottle discharge signal.
ALARM ON: If you want to be made aware of a diminishing quantity of this product
then set the Alarm Level to your desired setting.
Show Balance: Using this feature will cause the program to display the current
balance of this material to be displayed on the portion of the batch screen used to
represent this product.
Repeat this procedure for all metered materials to be used by the batching program.
Check the value set for the Meter Rate to see if it represents correctly the meter transmitter
rate for this particular metered material. For example, if the meter transmitter generates one
pulse for every 5 ounces of admixture flowing through the admixture meter, then the Meter
Rate should be set to 5. If one pulse represents 1/2 an ounce then the Meter Rate should be
set to .5.
15
Note: IT IS VERY IMPORTANT THAT THE CORRECT METER RATE IS ENTERED
OTHERWISE, AN ERRONEOUS DOSAGE MAY RESULT.
CAUTION, CAUTION, CAUTION
AFTER THE SYSTEM HAS BEEN INSTALLED AND THE SET UP HAS BEEN COMPLETED,
TRAIL LOADS MUST BE BATCHED IN THE AUTO MODE. VERIFY IF:
All material names and bin numbers are correctly designated, i.e., all materials are batched
from the correct bins.
All admixture dispensing
batched from the correct
can produce steady and
dispensed amounts agree
systems are functioning properly. That all metered materials are
systems, at a reasonable flow rate such that the meter transmitter
reliable pulses to be registered by the computer and the actual
with the quantities registered on the screen and recordation.
16
Enter a mix design
A mix design must be present in the mix design file before it can be used to batch a load of
concrete. A mix design or formula specifies the amount of each material per yard to be
batched into one load. The mix design is based on a one cubic yard mix or cubic meter mix. In
actual operation, the quantity of any material required in a load is derived by multiplying the
quantity specified in the mix design by the yardage of the load.
The following procedure can be used to enter a mix design:
From any screen point and click on the Mix tab. The monitor will display the mix screen.
The first line of the Mix Design menu will be highlighted in blue. Point and click in the first
empty field under the Code column. Enter a Code or abbreviated name / number your choice.
The code can be alphanumeric, (use letters, numbers or a combination thereof).
Point and click on the on the next empty field under the Project column. Project is used for
rare occasions when the contractor wants assurance that only certain mixes to be batched on
his or her Project. Placing a Project name in association with same Project name in the
Job menu this will cause the program to only allow the associated mixes to be entered in the
Job menu.
Point and click on the next empty field under the Description heading. In this field you will
type the explanation of the Code. This Description will be printed on the delivery ticket.
Now you
screen).
appear.
batched.
will need to move to the Materials menu (located on the right hand side of the same
Point and click on the empty field under the Material column. A pull-down menu will
Select the first aggregate you want to be loaded in the weigh hopper when
This also applies to cementitous materials.
Point and click on the empty field under the Amount column and enter the weight, per yard
or per meter, (depending on the unit of measure you will be using). The weight should be in
pounds or kilograms.
NOTE: The weight or dosage is to be the net individual amount and not the accumulated in a
batch. For those materials that require moisture compensation, the required dry weight should
be entered into the mix design. The compensation is usually done at the time of batching.
Point and click on the next empty field under the By% column. This field is only used for
admixture dosing. If you are not entering an Admixture simply skip this step. With this
feature you have the choice of dosing the admixture “per yard / meter” or by “100 weight of
cement.” If you want to dose by the yard / meter then select “N” from the pull-down menu.
The Unit column will automatically default the weighing units set in the Material Detail menu.
Continue steps e, f and g until all materials for this mix design have been entered.
17
Now go to the Parameters menu just above the Materials menu on the same screen. In this
menu there are two columns: Parameter and Value. They will be explained as follows:
Unit: Your choice of YDS or M3.
Price 1: General Price per yard or meter of concrete.
Price 2: Special price per yard or meter of concrete.
Price 3: And yet a really special price for a yard or meter of concrete.
Not Tax Of: This is the amount of a yard or meter of concrete delivered that is not
taxable.
Tax: Select either Y for yes if this product is taxable or N for no if it is not.
Max Drop Size: This is the maximum yardage or meter of this mix design that either
weigh batcher can manage.
Mixing Time: This is the maximum amount of mixing time for this mix.
Once all the data for the mix design has been entered point and click on the Save
button.
Starting an Automatic Batch
The weighed materials batching into the same scale are to be batched one at a time in the
order they appear in the mix design.
18
The Batch screen display is for entering or modifying the information required to batch a load
in auto mode or Semi-Auto mode. It contains the information from a selected Job (selected
from the Scheduler) or information from the last batch. To be able to pull up the last batch
information a simple key entry makes repeating the same batch an easy task. It should be
noted that the first time after the system is restarted, the last batch information no longer
exists.
Qty_Sold: Upon reaching the Batch Edit screen the cursor will be blinking on the
Qty_Sold field. This is the quantity sold. If the job is selected from an existing job,
this field will automatically fill in the amount specified in that particular job. If no job
exists then fill in this field with the amount of yards or meters. Example: for five yards
type 5 and press the TAB key. For whole numbers only, it is not necessary to enter the
decimal point or zero beyond the decimal point. If you want 5 ¾ for an existing job;
the Mix field will be automatically filled with the mix code stated for that job. This field
is the same as the Product Code in the Job menu.
Truck: This is the number assigned to the truck that is to be loaded. If you have
assigned this truck number to a Job then this field will automatically be filled in. This
truck number will also determine the load rate and discharge sequence. If no truck
number has been assigned to this job or you do not fill in this field, the load rate is
then determined by a default load rate in the Utils menu.
Mix Description: This is the description of the mix design you have selected in the
Mix field.
Unit: This field will default to the weigh unit selected in the mix design menu.
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Project: Project together with Mix code determines which mix design is to be used.
There must be a mix design in the Mix field with both a matching Mix code and
Project code.
Note: Assigning a Project name to an existing Mix allows you to use a discount for
specific customers. Enter a discounted price into the Price field with the appropriate
Project name and you will not have to re-input the discount in the future for that
particular project.
Driver: This is the name of the truck driver. If a driver name has been assigned to the
TRUCK number then this field will automatically be filled in.
Qty_In_Truck: Quantity in Truck. This is the amount of concrete left over from a
previous batch that can be resold. The batch size is located as: BATCH SIZE=
(QTY_SOLD-QTY_IN_TK).
Job#: This is the JOB number assigned to this load. The basic system will store up to
100 jobs.
Truck Weight: For future use.
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2nd Water: 2nd Water specifies the amount of hot water as a percentage of the total
quantity of water. This allows the blending of two waters according to a fixed ratio.
This field is a GLOBAL type field meaning that all batches are affected. When the
systems power is turned on the value of 2nd Water is reset to zero. The value of 2nd
WATER is the amount of 2nd water used in terms of the percentage of the total amount
of water required. If a negative value is entered it will be taken as zero. If the entered
value is over 100, it will be taken as 100.
2nd Water will be effective only if the mix design calls for both waters and if the
individual amount after Trim is not zero or less than zero. The computer calculates the
total amount of water used by adding up all the individual quantities called for in the
mix design, and adjusting with the Trim and Water Adjust amounts. The total is
reduced by the two waters batched and then computed based on the percentage of
2nd Water. Assume that the 2nd Water is hot water and the mix design calls for more
than one hot or cold water, the individual amount to cold or hot water will be in the
same ratio as their original amounts of the same water type in the mix design. For
example, if there are two cold waters, “A” and “B”, and if the calculation calls for a
total of 35 gallons of cold water, and if it is specified in the original formula that the
cold water is to be 30 from “A” and 20 from “B”, then the actual target will be:
“A” cold water=20/ (20+30) ×35 gallons = 14 gallons
“B” cold water=30/ (20+30) ×35gallons = 21 gallons
Cases where no redistribution of water will take place are:
No water present in the mix design.
The total amount of both waters after trim is zero or negative.
Note: In order to make the process simple and flexible, enter the hot and cold water
material into all the winter mix design as follows:
Set the quantity of cold water to be the total amount required less one (1). Before
starting a batch, change the value of hot water to whatever percentage is required. A
“0” means no hot water is used, a 100 means all water used is hot.
Water Adjust: This is amount of water in gallons or liters to be added or subtracted
from the upcoming batch. To subtract water per yard from the batch use the negative,
(-) symbol. Use the (+) or just the number to increase the water amount per yard.
This is a GLOBAL type field, meaning that this field retains the value you insert for this
load and all subsequent loads thereafter until you remove the value or restart the
system. When using this field water is in gallons added per yard using positive
numbers. For example, to add 3 gallons per yard, enter 3. To add a 1 ½ talons a yard
enter 1.5, and so on. To subtract water from the load enter a minus (-) sign first then
enter the amount you wish to take out per yard.
Before the actual batching start, the computer checks to make sure that all admixture
bottles and materials weigh bins are empty. If any scale or bottle is not empty, the
computer will give the operator a warning and he is supposed to confirm if this NOT
EMPTY condition is acceptable, (by overriding, refer to the description below),
otherwise the automatic cycle will not proceed.
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# Of Drop: The calculated drop size is derived as follows: Calculated drop size =
batch size and # of drops. However, the actual drop size for batching may be different
depending on the value of the parameter of Drop Repeat Mode (found in Utils in the
Operation Parameters menu); the computer automatically corrects the error
condition by increasing the # of drop until the actual drop size is smaller or equal to
the maximum drop size.
Batch Size: Batch Size defines the amount of material to be batched, and is
calculated as follows: Batch Size = (Qty Sold) – (Qty In Truck).
Tolerance Check: A check in this feature (Tolerance Check), activates the tolerance
checking program which will halt the batching process whenever over batching
quantity exceeds the tolerance limits. The operator is required to acknowledge his
acceptance of the condition in order for the system to continue batching. Any input
other than a “check” will allow the system to automatically accept the tolerance error
and continue batching.
Print: A “check” to Print specifies that the system is to print the ticket for this batch.
No ticket prints for any other input.
Trim: A “check” in this feature is used to access the trim utility which allows the
operator to adjust the amount of any material called for in a mix design without
actually changing the mix design record in the file. When the Trim icon is pressed,
Mix and Project fields will be checked. There must be valid mix design in the file
before TRIM screen can be displayed; otherwise, only a mix design list will be
displayed. In which case, the operator must select the correct one from the list.
Once the Trim screen appears, trim amount can be entered by pointing and clicking
on the appropriate material and actual change made under the Trim column. Any
amount entered with or without a “+” sign is interpreted as a positive value which will
be added to the original design displayed on the left to derive the net amount on the
right. Any amount with a “-” sign means that the amount is to be subtracted from the
original design quantity. The Net amount field will be immediately updated as soon as
the ENTER key is pressed or if the cursor had been moved out of the field. Remember
all trims are done per yard and the trim values will remain until the operator changes
the fields otherwise. If you choose no longer to trim this mix then simply uncheck the
Trim box on the Batch Edit menu.
Any material with zero or negative value net amount as a result of trim adjustment
will not be batched.
Once alterations to the trim menu are complete, point and click on the OK icon to
return to the Batch Edit screen.
AX ByPass: These are the exact names of the admixtures which are to be bypassed,
(not dispensed even if specified in the mix design) during the automatic batch cycle.
These are GLOBAL fields.
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The buttons at the bottom of the Batch Edit menu are:
Start: If the batching cycle is initiated by clicking on Start and no errors are detected,
batching cycle will start without the verification step.
Verify: If a batching cycle is initiated by clicking on Verify and no error has been detected,
then the Verify screen will appear with JOB#, MIX#, batch size, and total number of drops
displayed on the top section. The lower section of the screen is used to show all the names of
the materials to be batched, from which bin a material is to be drawn, and the target
quantities.
The information on the screen should be verified. Should any other error be found using the
mouse, left click on the "NO" icon to return to the Batch Edit screen to make corrections.
After the verification, move the cursor to Start Batch? Click YES to start the batching cycle.
Pre-start load: A batch may be pre-started even when the current load is still being batched.
The pre-started load feature allows the start batching of the next load immediately after the
current load has been fully discharged. Only one pre-started load can be initiated at a time.
Any attempt to initiate more than one pre-started load causes the system to display an error
message, “Too Many Pre-started Batches,” on bottom of the screen.
Once a pre-started load has been initiated, the Next load indicator at the bottom of the
screen will show the truck number of the pre-started load. The indicator will revert to the
normal display of “time of Next Scheduled Load” after batching of the pre-started load starts.
Point and click on LAST DROP (F5) or pressing function key F5 may be used to cancel a prestarted load.
Demo: If the batching cycle is initiated by clicking this button then the batch will
automatically begin batching in demonstration mode. No gates or valves will be activated and
no inputs will be considered.
Manual: Selecting this feature will cause the batch screen to appear as though it is ready to
do an automatic batch; however, no automatic outputs will occur. Simply point and click on
the appropriate bins, silos, bottles and water as needed to complete the batch. The batch
may be manually or automatically discharge.
Semi-Auto: This feature is much the same as a Manual batch however, the program will
automatically meter in the liquid materials.
Test: Used only in New York for state testing. Consult factory for further details.
Once the automatic cycle is allowed to proceed, the first material for each in the mix design
should start to feed into the scales and the metered materials should start to flow, (into
bottles, if used). The computer continuously monitors the scale weight reading and the meter
counts. Immediately after the batching cycle starts, the system initializes all the batching
parameters, including calculating the size for each group, target weight and tolerance limit for
each material. Any error condition detected may prevent the cycle from continuing.
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If the message Over/bounce is displayed next to any material being batched, it means that
the material has been over batched and has actually exceeded the tolerance limit. In which
case, the batching process of that material stops and the operator is required to check if the
“over” condition is acceptable. If it is not acceptable, the operator may have to switch out of
the AUTO mode, correct the problem and finish the load manually. If the “over” condition is
acceptable then the operator may click on the OVRD icon or strike the F2 key to continue to
the next material.
After all the materials have been batched, the computer displays a status message under the
individual amounts of each material weighed or metered in this batch. The bottled admixtures
will display FINISH, the admixture discharge icon will display DISCH_W, (discharge
waiting). The weighed materials will display FINISH in each bin used. The weigh hopper will
display WAIT_DISCH, (Waiting for discharge).
Discharge from the weighed hoppers can begin at this time, either manually or automatically.
For manual discharge operation the operator must use the appropriate Open/Close discharge
switches. For auto discharge mode the F10 key must be pressed or point and click on the
DISCH (F10) icon. To stop auto discharge press the F10 key again or point and click on the
DISCH (F10) icon.
The F10 key toggles discharge start and discharge stop. The status of the key will be
displayed in the lower center portion of the screen. Upon beginning discharge the weigh scales
will display current loading rates. The aggregate portion will display the truck loading rate per
second.
To adjust the rate up press the “+” key and to slow the rate discharge press the “-” key. There
are several factors involved with the discharge rate settings. In the Scale Discharge
Sequence menu, the amount of aggregate going into the truck before the cement begins will
determine proportionally the rate of discharge for the cement.
In the Truck Charge menu the truck loading rate determines the overall initial discharge rate.
If no truck number is used when setting up the batch then the computer will use the Default
Disch. Rate found in the Operation Parameters menu.
Once the material has been fully and completely discharged weigh batchers will display
FINISH and if the HORN feature is used the horn will sound after the appropriate time delay
set in the Utils menus. The next batch may be initialized.
The Trailblazer batching computers communicate with the operator through the use of
numerous user-friendly menu screens. The operator is given messages on the screen showing
the status of the system and action commands which may be taken. The following chapters
are devoted to the explanation of the items on these screens. These chapters are organized in
the similar order their tabs appear on the screen.
Batching Cycle Details
In general, the batching process for a weighed material is as follows:
Open the material feed to let the material flowing into the scale weighing hopper.
The system monitors the scale weighing continuously. When the scale weight reaches or
exceeds the preliminary cut-off weight, the system immediately shuts off the feed and
initializes a time delay allowing the scale to settle.
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After the scale setting time delay expired, scale weight will be rechecked to see if it
is
within tolerance limits. If the weight has not reached the lower tolerance limit, the
job
mode is initiated.
In Jog Mode, the feed gate is opened for a preset job open time, normally a fraction of a
second to allow a “bite” of material to drop down. If the final scale weight has reached the
lower tolerance limit but not exceeded the upper tolerance limit, the weight is accepted and
recorded as the weight batched. The inventory records will then be updated. Should the final
weight exceed the upper tolerance limit, the system will display the OVER/BOUNCE message.
If it is set up to check the tolerance, the next material will not be started until the operator
acknowledges and accepts the over weight condition. The system will repeat this batching
process until all materials called for in the mix design have been batched.
Auto/manual addition: For the systems with AUTO/MANUAL ADDITION feature, all the manual
batch switches are enabled when all of the required materials have been completely batched.
Manual addition of any material (which must be properly set up in the material tables) will be
displayed on the screen accumulatively and identified on recordation the batch. Should the
computer detect a gate open or a meter running and cannot find the corresponding material
setup tables, or the manual addition of different material cause the total number of materials
to exceed 16, the system will disable the manual switches to prevent further manual addition
for this load.
Any manually batched amount will be added to the accumulative weight, but the net weight
will be printed separately under the caption “M” on the automatic batch recordation.
LOADS REQUIRING MULTIPLE DROPS WILL NOT BE ALLOWED TO USE THIS FEATURE.
Once the discharge process has been initiated, and any scale has discharged to be on the preset discharge tare weight, the manual batch switches are disabled, no more manual addition is
allowed.
As soon as all the materials have been batched, the scale hopper can be discharged.
The automatic discharge sequence is initiated by hitting the F10 key or left clicking on the
DISCH (F10) icon.
PRE-DISCHARGE LOAD: If the F10 key is pressed before all the materials have been
completely batched, it would be memorized and as soon as all materials have been completely
batched, the automatic discharge sequence starts. Should the load have multiple drops, the
discharge or the first drop requires initiation (pressing the F10 key) and all the following drops
will discharge automatically as soon as the batch is completed.
A number of different discharge sequences (the order or timing according to which different
scales, admixtures, and water are discharged into the truck or mixer) can be set up. The
discharge will follow the preset scale discharge sequence, opening each discharge gate
accordingly. If discharge rate control is specified in the setup the discharge gate will be pulsed
to open and close keeping the discharge flow rate to those specified. Metered material may
start discharging if bottles are used.
Any discharge gate may be forced to close by manually pressing and holding the manual
discharge CLOSE switch or pressing and holding the manual OPEN switch to force the gate
fully open. Each scale is discharged until the scale weight is below its allowed discharge tare
weight to make sure that the scale is empty. Then the system checks to ensure that all
metered materials are in. Once all materials are finished, the current batching cycle is
considered completed. The batching of the next drop starts automatically if there is one or if
25
the next load has been pre-started, otherwise, the system resets itself and stays in the
AUTO/READY idling mode.
In the case where a plant is equipped with a mixer, the mixer timer starts counting down after
all materials are in the mixer. Discharging from the mixer is prohibited until the mixing time
expires. After a mixer tilted to the full discharge position or in the case of a stationary mixer
with discharge gate, the discharge gate opens to the full open position; a discharge open timer
starts counting down. Mixer returns to the home position or mixer gate closes automatically
upon the expiration of the discharge open timer, after the mixer has returned to the home
position or the mixer discharge gate closes and the limit switch has been activated, the
system initiates the mixer down/gate close delay. When the mixer down/gate close delay
expires, the mixer discharging cycle is completed, and the mixer is ready to accept the next
drop for mixing.
26
Description of fields and features
The main screen is laid out in such a way as to give you the effect of layers of windows
separated by tabs. The screen contains 10 tabs, including the current one, indicated by
darker font or characters. The tabs are labeled as such:
Batch
Job
Mix
Material
Utilities
Charge
Customer
Ticket
Report
Quote
The first or current tab is the Batch tab. This is pretty much the main screen. This screen
gives you all the information of the goings on of the batch plant as setup with the system. On
a standard Trailblazer you will typically find 6 virtual admixture bottles, 6 virtual aggregate
bins, 4 virtual cement silos, two virtual water icons, two admix discharge icons, cement
aeration virtual button, two virtual scale vibrator buttons, two virtual weigh scale gates that
indicate batcher open and close and a horn. All these virtual buttons and icons give you total
control over your plant with quick reference eye appeal.
As you batch certain mix designs, each associated icon or virtual bin will be displayed with a
target volume. As the product is being measured you will see the actual volume accumulate
under the displayed target weight within the same virtual bin or icon.
Under each icon and virtual bin there will always be a “status” message for that
product. When the product is not being used in the particular mix design the message for that
product will be “IDLE.” More explanations of these status messages will be explained later.
On the right hand side of the screen you will see a column of virtual buttons. They are listed
as:
Batch (F7):
Click or hit F7 to begin batching.
27
Demo: Click on this button and you will see the system batch concrete without actually
opening any gates or valves. This is used primarily for training.
NOTE: Inventory and totals are affected when using the demo program.
Abort (ESC): This button is the virtual “panic button.” Use this button to stop all batching
processes and reset the batching program. NOTE: Totals are affected when a batch has
started and then aborted.
OVRD. (F2): This button will allow the system to continue batching even when there is an out
of tolerance situation occurs. This button will override any weighed or metered errors.
LAST DROP (F5): This button is used when systems drop repeat mode is set to 2. This mode
is for continuous batching of the same mix. Usually used in block plant type
application. Pressing this virtual button during batching will cause the program to finish the
current batch and not begin another until made to do so by the operator.
Disch (F10): This button is used to tell the plant to start the material discharge of what has
been weighed or metered into bins, silos, bottles or tanks. If a transfer conveyor is used it
must be on before the discharge cycle will begin.
+ - : These two buttons are used to control the discharge of weighed materials
proportionally. The calculation will be explained later in this manual.
In the lower left hand corner of the screen you will notice the word manual or
automatic. Which ever word is displayed indicates the status of the control system or simply
the position of the security key on the manual panel.
Located at about the same level as the auto/man status is a colored box about one inch by ¼
inch. If the system is functional then this box should appear to be green. Any other color and
the system will not batch. This also will be explained later.
Along with having a full manual back up this system has a virtual control panel. It works
much like your physical manual panel, including interlocks. If you click and hold on the gray
area of the virtual bin, icon or silo, the product will start to accumulate once you release the
button the weighing or metering will cease. To indicate this action the gray area will change
to green.
If you will bear in mind that whatever button is green on the screen is open, including batcher
gates. If the button is gray the gate or valve is de-energized. Green for Go and Gray for Stay.
Once a mix has been set up for batching you will see the more vital information concerning
that mix at the top center to right in a tan colored box. The information given is Job, Cust.,
Truck, Mix, Unit, Size, Drop Size and Drop # of #.
From this screen if you click on the BATCH (F7) button a small menu will appear requesting
the following information:
Qty Sold: Quantity of concrete to be batched in this load.
Mix: A pull-down window is associated with this field. You can only select a mix from the pulldown windows list.
Truck: A pull-down window is associated with this field. You can type in a truck name or
number without being restricted to the available trucks in the pull-down window list. NOTE:
28
By using a truck name or number in this field will cause the discharge sequence to be ignored
and will use the default load rate located in the Utils / Operation Parameters.
Mix Description: This name or description is taken from the mix design menu associated with
the mix entered in the mix field. This field is automatically filled in once a mix has been
selected.
Unit: This field has a pull-down window to allow the selection of YD for yards or M3 for cubic
meters. The default value for this field will be YD.
Project: This field is unique as such will only allow pre-selected mix designs to be batched
with this particular job.
Driver: This field will automatically be filled in if the driver is listed with the truck number or
name inserted above.
Qty In Truck: If the truck being loaded has a quantity of usable concrete in this amount of
concrete will be deducted from the load to be batched and still print the desired yardage on
the delivery ticket. This information can be found in the Report menu. (Quantity sold –
quantity produced).
Note: To use this field you must enter cubic yards or meters, (or decimal fractions thereof).
Job#: Job numbers can be searched in this field by typing the characters of the job or simply
using the pull-down menu. The button to the right of Job# is represented by three dots,
(ETC); once job # has been located the specific details can be recalled, obtained and changed
with this button.
Truck Weight: This feature is used when truck tare weights are needed for calculations. This
feature will be explained later.
2nd Water: When two different waters are used this feature allows you to “blend” both waters
by percentage. For example, by putting a 20 in this field you are telling the program that you
wish to get 20% of the second water and 80% of the primary water. This field is typically
used for hot water.
Water Adjust: By entering standard of measure units of water or decimal thereof you can
add water to the mix about to be batched. By putting a (-) negative symbol in front of the
number entered you can deduct per yard above and beyond any other deductions, i.e.,
moisture probes.
Water Adjust feature is a global field. The value manually entered will remain until the
operator changes the value or until the program has been terminated.
Example: If using yards a standard of measure, you can place a 3 in this field and you will get
an additional 3 gallons per yard. If you place a -2 in this field, despite the moisture
calculations you will take out 2 gallons per yard.
#Of Drops: This is an automatic calculation based on maximum size of load to be batched at
one drop. If the maximum is exceeded then the program will automatically divide the batch
size into two equal drops. If the drop is still too large in may be divided further into 3 equal
drops and so on.
Batch Size: This is the size of the load about to be batched. The calculation is figured as such:
Qty Sold – Qty In Truck = Batch Size.
29
Tolerance Check: This field requires a check mark to be bypassed. There are very few
reasons to bypass the Tolerance Check mode. When checked the program will not wait for
any input from the operator to acknowledge out of tolerances of any materials. The program
will simply continue batching.
Print: Placing a check in this box will cause the program not to print a delivery ticket or
recordation.
Trim:
Check this field if material trims are to be used for this particular load.
Trim: Clicking this button will take you into the Trim menu.
represented as follows:
There are six columns
Material: Each material is listed to be batched this load.
Amount: The volume of each material to be batched per yard or meter.
Trim: The amount of material to be added or deducted per yard of each material. By
placing a positive value in this field the material weight desired will be increased by its
batch unit this amount. By placing a negative symbol in front of this number will have
the opposite effect. The total amount per yard or meter will be deducted.
Net: This is the sum or product of the newly adjusted amount.
Unit: This is not an adjustable field. This is the unit of measure for this material.
By: This is not an adjustable field. This informs you that the material is being altered
either per yard / meter or by 100 weight of cement.
Once all adjustments are made to your satisfaction then select the OK button. If changes are
not as intended then select the Cancel button.
Note: The Trim menu is a global field for the particular job in which is used. If you wish not
to trim for a particular load simply uncheck the Trim box.
AX ByPass: There are four available admixtures by pass fields. Each one have their own pulldown menu. These fields are global. If you do not wish to use an admixture that has been
set up in your mix design you can select it for by pass by entering the admixture into the field.
The six remaining buttons are used to determine how this load will be batched.
Start: Clicking this button will start the batching process without any further input from the
operator.
Verify: Clicking this button will force the program to ask you to verify whether you wish to
start the process or cancel. This feature is used primarily when an operator is getting
acquainted to the batching process.
Demo:
This button is used for demonstration purposes. When all the batch fields
required are filled in then the batch will start without actually affecting the gates or solenoids
on the plant. However, inventory and reports will reflect all demo batches as if they were live
batches.
30
Manual: When setting up an automatic batch you may wish to see all the weight targets
without actually having the computer opening the gates. In which case the program will wait
for you to manually batch all the products on the screen for this load and will give you all the
prompts as though the computer were actually batching. Once you have manually batched all
the products you wish to be in the load you may click on DISCH (F10) to automatically
discharge.
Semi-Auto: This feature is the same as above except the program will automatically batch all
metered materials.
Test: This feature is only used in New York for state testing. Call factory for further details.
You may notice that some labels have an underscore below certain letters of that word. This
meant to be used as a shortcut, (without the mouse). Hold down the ALT key and press the
underscored letter and you will achieve the same results as if you had double clicked the
button with the mouse.
31
Job
Scheduler
There are seven fields on the scheduler and an infinite amount of lines. They are listed as
such:
Ship Date: This is the scheduled ship date.
Ship Time: This is the scheduled ship time.
YDS: This is the quantity ordered
BAL: This is the balance of the order. This is an automatic field. Qty Ordered – Qty delivered
= Balance
Job: This is the assigned job number.
Sold To: This is to whom this job was sold to.
Ship To: This is to where this job has the concrete produced delivered.
NOTE: The scheduler highlights today’s jobs with green color.
Job Maintain
Sort
As mentioned you can accumulate as many jobs as you wish. The header fields have certain
features that my assist you in finding previous jobs. If you know the number or name of the
job then you can alphabetize the Job column by clicking on the gray area around the word
Job.
Query
If you only have a date range you are still able to narrow your search by using the added a
Query, (search) button. If you are seeking a past job you will need to have an idea of the
date in which the concrete was produced. Using the FROM and TO date fields will aid in
finding the job. Simply insert the dates you think apply, if the job has been completed then
check the show finished jobs box and then press the Query button. This will narrow your
search.
Use the Clear button to delete the jobs you don't want any more.
NOTE: The program has no limit of Job data. Use Clear button to delete the
useless job data once a year.
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Job Edit
To add a job click on the Add button and a new window will appear titled Job. The following
fields are listed in the Job menu as follows:
Job ID: This is an abbreviated code to use for quick reference in searching for this job
in the future.
NOTE: You can leave this field blank, the program will assign a job id
automatically. You can set up the initial job id at the TICKET->PRINT
SETTING.
Acct: This is a pull-down window that derives information from the customer data
base to be discussed later.
Acct Type: This field is automatically filled based on information from the customer
data base
Project: Contractors may insist on certain unalterable mixes for their concrete
projects. When a project code is assigned to a mix, then only that mix can be used for
this job. The search field will only display mixes with the corresponding projects.
Project #: This field is used for reference only. This number may be printed on the
delivery ticket.
Ship Date: This field will automatically default to today. If you wish to change the
date then click on the pull-down menu to display a calendar and make the appropriate
changes.
Required Time: Same as above
PO#: Purchase Order number, if used by customer.
Slump: This field is used for printing purposes only. Entering a slump value in this
field has no effect on the actual slump of the concrete associated with this job.
Tol Check: Some jobs may involve less than perfect concrete and tolerance errors
may not be critical. If you are having problems with a gate being inconsistent and are
batching a slurry mix for a filler job you may not wish to be notified for every out of
tolerance. Simply put a check in this box and the program will continue to batch
regardless of out of tolerance errors.
Order Date: Same principle as ship date.
Next Load Time: This is the time the next load is expected at the job site. The
information here determines where on the scheduler this job is placed.
Ordered By: This field may be used to enter the customer or person responsible for
ordering the concrete to be delivered.
Time Apart: This field represents minutes apart for each load to be delivered. This
also represents where and when it will appear on the scheduler.
33
No Tax Of: This is a portion represented by percentage of total per yard cost that is
to be without tax.
Sold To: This field is automatically filled in once the Acct field has been entered. If
the customer is not in the data base then that customer must be added manually.
Ship To: This field represents where the concrete is to be delivered.
NOTE: For the long term job, you can set up the default ship to address
to the customer, so that the ship to information will pop up automatically
when you select the customer.
Product: This first field is reserved for concrete only. This field also has a pull-down
menu. If the product is not in the data base then it must be added here manually.
Description: Once the Product field has been entered this field will automatically be
filled in unless the product does not exist in the data base in which case must be
added manually.
Unit: Once the Product field has been entered this field will automatically be filled in
unless the product does not exist in the data base in which case must be added
manually.
Quantity: This field represents the quantity of product PER LOAD to be shipped.
Price: Once the Product field has been entered this field will automatically be filled in
unless the product does not exist in the data base in which case must be added
manually.
Taxable: Once the Product field has been entered this field will automatically be
filled in unless the product does not exist in the data base in which case must be
added manually.
Amount: Once the Product field has been entered this field will automatically be
filled in unless the product does not exist in the data base in which case must be
added manually.
Comment: This area has been reserved for any comments that you may wish to
convey to the mixer driver, delivery instructions or to the recipient of the concrete. If
this field is set up to print on tickets then this comment field will be printed on all
tickets.
Qty Ordered: Total amount of concrete ordered for this job.
Qty To Date: Total amount of concrete delivered to the job.
Sales: the name of the sales man who gets the order.
Sub total $: This is a total money amount of all products on the ticket less the tax
amount.
Qty Today: This is the total amount of product delivered TODAY.
34
Today Amt$: This is the total money amount of product delivered TODAY.
Pour Time: This is the total amount of time a mixer truck can be on site unloading
before the customer incurs additional charges.
Tax %: This field is automatically filled in by the customer data base. If none exist
then you can manually place a value in this field.
$: This field represents the money value of the tax amount.
Truck#: Enter the truck number of the mixer truck to deliver this load.
Driver: If the mixer profile is set up then the mixer operator name will automatically
appear. If not, then you must manually enter the name of the mixer driver.
Qty In Truck: If a balance of concrete from a previous delivery is in the mixer to be
loaded enter that amount here and it will be compensated from the batching process
however, will give you a delivery ticket showing full amount ordered.
Print: If unchecked the job will not print any delivery or recordation. However, the
data will still be stored and readily available to be viewed or printed at a later time.
Total: This field represents the gross total of this delivery.
Truck Weight: Not in use.
OK: Upon entering correct data in all fields then press the OK key to place this job on
the scheduler.
Cancel: If the information is incorrect and you wish to start again or omit from the
scheduler then press the Cancel button.
One you have clicked on OK for a new job then you can click on the Batch icon and
you will automatically be sent to the Batch screen.
To remove a Job simply select the job to be remove, make sure the entire line is blue in color
then click on the Remove button.
To see the properties of a previously batched job or on going job then click on the job
line and click on the Property button. This will bring up the Job window containing all data
of that particular job.
35
36
Mix
Once selecting this tab you will find three different windows. Mix Design, Parameters and
Material windows. They will be explained as follows:
Mix Design
There are three fields in this menu:
Code: This is an abbreviated name for the mix design or product for quick reference.
Project: Contractors may insist on certain unalterable mixes for their concrete
projects. When a project code is assigned to a mix, then only that mix can be used for
this job. The search field will only display mixes with the corresponding projects.
Description: Use this field to describe to your customer what exactly it is being
delivered. Whatever is put in the description field will be printed on the delivery ticket.
There are two buttons at the bottom of this menu. The Remove button will remove
the highlighted mix design. The Save button will save a recently entered mix design.
Note: There is virtually unlimited space for mix designs.
Parameters
In this menu there are two columns: Parameter and Value.
They will be explained as follows:
Unit: Your choice of YDS or M3.
Note: If you want to make a metric mix design, you must put M3 as the
unit.
Price 1: General price per yard or meter of concrete.
Price 2: Special price per yard or meter of concrete.
Price 3: And yet a really special price for a yard or meter of concrete.
Note: Customer price code decides which price is selected for a order.
Not Tax Of: This is the amount of a yard or meter of concrete delivered that is not
taxable.
Tax: Select either Y for yes if this product is taxable or N for no if it is not.
Max Drop Size: This is the maximum yardage or meter of this mix design that either
weigh batcher can manage.
37
Mixing Time: This is the maximum amount of mixing time for this mix.
Accounting Code: This is used for accounting interface.
Materials
This menu has four columns labeled as follows:
Material: There is a pull-down menu from the data base in the Material tab that you
can select materials to be batched. Remember the first material of that is weighed in
a particular scale the first material weighed.
Amount: This is the amount of this particular material per yard or meter to be
weighed.
By %: This field is typically used by admixture. Placing a Y in the field will cause the
admixture to be metered by cement weight otherwise ounces, gallons per yard.
Unit: This is unit of measure, i.e., gallons, oz, lbs.
Change Material Name: You would use this if you wanted to change any particular
material name from one name to another name. Executing this feature will change all
the mix designs to reflect the new name.
38
Material
This tab contains two windows. The Material Type and Material windows are explained as
follows:
Material Type
This is a pull down window with two options, Weighed or Metered.
Weight material
This menu has ten columns of information. Weighed material is as listed:
Name: Enter the name of the material, usually in bin number one.
MST: In this column you can manually enter a fixed moisture value for this
material. This value will remain until changed by the operator.
BIN: This is the overhead bin or storage silo number, as wired by the technician. It is
possible for your plant to only have three aggregate bins but have up to 16 aggregates
listed in this menu. Simply give the bin number to the specialty aggregate. When
the mix design “sees” that material the program then looks for the bin number
assigned to determine which bin to open for weighing.
Begin Date: Once a balance is put in this field a date will be stamped
automatically. This date will be used to establish a history of reports. This will be
explained in more detail later in this manual.
Beginning Balance: This represents the inventory at the time of the installation of
the batching system to start tracking materials. Point and click on the Set Beginning
button. A small window will appear.
Enter New Beginning Balance: Enter your current inventory in this field.
Shipped In: Once the Beginning Balance has been set there is no need to update that
field when new material arrives. Point and click on the material that requires
inventory update. Now point and click on Ship In. A small menu will appear titled
Ship In.
Material: This field displays the material that is to be updated. If the incorrect
material appears then click cancel and point and click on the appropriate name.
Quantity: Enter the quantity of material delivered. Enter the inventory weight as
established in the Detail menu of that product.
Supplier: Enter the name of the supplier of the material being delivered. This is for
reference only.
Truck: In this field you can enter the truck number of the hauler. This is for reference
only.
Hauler: Enter the name of the company hauling the material to your site or the name
of the company supplying the material. This is for reference only.
39
Ticket: Enter the ticket or bill of laden.
Delivery: This field defaults to current date and time of material being entered. If
you are entering a list of tickets at the end of the day then you can change this field to
reflect the correct date and time of delivery.
When all data has been recorded then point and click on the OK button.
Total Usage: This field reflects the total usage of this material since the Begin
Date. If you wish to have this field reset then reenter the Begin Balance. Today’s
date will appear in this field and the usage will be set to zero.
Usage Today: This reflects usage of this material since midnight this morning. This
field will reset every night at midnight.
Current Balance: This field reflects the current balance of this material.
Supplier: This field is updated by the Ship In information.
Set Begin: Click here to enter your beginning balance.
Ship In: As described above
Add: Click here to enter a new material to be monitored by the batching computer. A
window will Detail window will appear. Enter the following details to assure proper
batching of this material.
Name: Enter the name of the unique name of this material. This name will be used
by other parts of the program such as Mix designs, bin assignments, Reports, etc.
Bin ID: Enter the storage bin or silo number assigned to this material during the
installation of the system.
Auto Cut Off: This feature is more of an “auto pilot” control. You must first manually
adjust the cut off numbers get the system batching, (weighing up the material), as
desired. Then the switch this feature on and the program will continue to maintain an
efficient weighing process.
Type: Select from the pull-down menu the type of material you are setting up. This
information will be used to determine metering and discharging of liquid products.
Fast Cut Off: This feature is used when two or more bins or silos of the same product
are weighed simultaneously. The number put in this field is in weighing units, (lbs or
meters) and will be the weight point that all gates opened will be shut and only the
primary gate will reopen to finish the weighing process.
Tolerance: This value represents the % of allowable overage or under batch the
program will allow without the need for an OVRD prompt.
Slow Cut off: This is the free fall compensation value. This number represents the
weight in weighing units the gate will shut prior to the target. The program will check
to see if reopening or jogging is required. If not, the program continues to the next
material.
40
Scale Settling Time: This is the time in seconds the weigh scale will allow the scale
to settle from initial weight shock of the material falling into the scale.
Small Cut Off: This is the free fall compensation value for small loads. Go to Utils /
Operation Parameters, Small Load Size. This number represents the weight in
weighing units the gate will shut prior to the target. The program will check to see if
reopening or jogging is required. If not, the program continues to the next material.
Auto Jog: If this feature is selected the program will learn to jog appropriately.
Specific Gravity: Not currently available.
Jog Open Time: This is the amount of time in seconds; an electrical pulse of
approximately 115VAC is applied to the solenoid attached to the cylinder associated
with the bin or silo of this material. The following is explained in such detail so you
will not be confused by this feature and “gate open time.” To say this feature keeps
the gate open this many seconds is to say a golfer should hit a hole-in-one every time
after his first hole-in-one.
Inventory Unit: This is the unit of measure for tracking inventory. This number does
not have to be the same as the weighing unit. Example: inventory in tons and batch
in pounds.
Jog Close Time: This is a little confusing. This in not the amount of time in seconds
the system shuts the bin or silo gate. The system can only open the bin or silo gate.
The system does not shut and cannot shut the bin or silo gate. This field represents in
seconds how much time there should be between the jog open signals.
Alarm Level: This is the weight in Inventory Units a low inventory message appears
on the screen.
Min. Flow Rate: This feature is currently not in use.
Alarm On: This feature works with the Alarm Level. Check this feature and enter a
low level amount in the Alarm Level to be warned of low levels of this material.
Small Jog Open: This represents time in seconds how long a small jog is to be, if
needed. The small jog is determined by the settings of the Small Load Size in the
Utils / Operations Parameters.
Aeration Cut Off: This is the point at which the cement aeration, in pounds or
kilograms short of the target the aeration will cut off.
Max. Amount In Mix Design: This field is just for protection only. This is the
greatest value in weighing units that can be batched in one drop from the bins or silos.
Manual Batch: This is a unique feature that you can use to inventory and monitor
products that are not electrically connected to the batching system. Example: You
may have a material bin of special aggregate that is not hooked up to the plant. You
can enter this material in mix designs and when you batch the mix the program will
show you the exact amount of this material to be used based on batch size. Also, this
amount will be deducted from the inventory of this material.
Show Balance: Check here if you want your material balance to be displayed for this
material on the batch screen while batching in automatic.
41
Moisture Amount: This is a fixed value, in percentage that the program will
compensate for moisture. This is a global field so this value will not change until you
change it.
Auto Moisture: Point and click on this button if you are using a moisture probe with a
0-10VDC output and wish the computer to compensate automatically.
Auto Moisture Setting:
Auto: Place a check in this box to indicate to the computer that there is an
auto moisture gauge present.
Auto Moisture: This value is the moisture percentage last compensated for
automatically.
Delay Seconds: Some moisture probes mount under the bin gate and in the
weigh batcher. If yours is installed this way then you will need to allow
enough time for the bin to open and the first few pounds of material to wipe
off the face of the probe. Usually a half to whole second is used. If an in the
bin probe is used then leave this value at zero.
Min. Weight: Some moisture probes mount under the bin gate and in the
weigh batcher. If yours is installed this way then you will need to allow
enough time for the bin to open and enough volume of material to flow across
probe to allow the probe to take several samples. Usually a ton is adequate
for this procedure. If an in the bin probe is used then leave this value at zero.
Min Moisture: Some moisture probes mount under the bin gate and in the
weigh batcher. If yours is installed this way then you will need to allow
enough time for the bin to open and the first few pounds of material to wipe
off the face of the probe. Usually a half to whole second is used. If the
moisture value measured is not at the minimum level then the program will
use the last good reading above minimum level and below maximum moisture
level was obtained. A typical setting is around 2.00%
Max Moisture: Some moisture probes mount under the bin gate and in the
weigh batcher. If yours is installed this way then you will need to allow
enough time for the bin to open and the first few pounds of material to wipe
off the face of the probe. Usually a half to whole second is used. If the
moisture value measured is not at the minimum level then the program will
use the last good reading above minimum level and below maximum moisture
level was obtained. A typical setting is about one percent higher than the
maximum you would batch this material at.
Note: If no auto moisture probe is used it is important that the Max Moisture
value is set to zero.
Absorption: If the moisture probe is currently set up to account for absorption, then
leave this value at zero. Otherwise, enter absorption value.
Detail: See Add above.
Remove: To remove a material point and click on the material you desire to
delete. Point and click on delete button and the entire line will disappear.
42
Ship In History: See Ship In description above.
Metered: The Metered material has eight columns as listed:
Name: As described in the Weighed material screen.
Pump: This is the admixture pump number, as wired by the technician. It is possible
for your plant to only have three admixtures but have up to 16 admixtures listed in
this menu. Simply give the pump number to the specialty admixture. When the mix
design “sees” that material the program then looks for the pump number assigned to
determine which pump to operate to dispense.
Begin Date: As described in the Weighed material screen.
Begin Balance: As described in the Weighed material screen
Shipped In: As described in the Weighed material screen
Total Usage: As described in the Weighed material screen
Usage Today: As described in the Weighed material screen
Current Balance: As described in the Weighed material screen
Set Begin: As described in the Weighed material screen
Ship In: As described in the Weighed material screen
Add: See Detail description below.
Detail: As described in the Add section of the Weighed material screen
Mater Material
This menu has nine columns of information. Metered material is as listed:
Name: As described in the Weighed material screen.
Pump: This is the admixture pump number, as wired by the technician. It is possible
for your plant to only have three admixtures but have up to 16 admixtures listed in
this menu. Simply give the pump number to the specialty admixture. When the mix
design “sees” that material the program then looks for the pump number assigned to
determine which pump to operate to dispense.
Begin Date: As described in the Weighed material screen.
Begin Balance: As described in the Weighed material screen.
Shipped In: As described in the Weighed material screen.
Total Usage: As described in the Weighed material screen.
Usage Today: As described in the Weighed material screen.
43
Current Balance: As described in the Weighed material screen.
Set Begin: As described in the Weighed material screen.
Ship In: As described in the Weighed material screen.
Add: As described in the Weighed material screen.
Detail: As described in the Weighed material screen.
Name: As described in the Weighed material screen.
Pump ID: This field is used to identify which pump this product will be dispensed
from. This information is obtained from the admixture technician.
Auto Cut Off: If the liquid product continuously over batches you may enter the
amount of overage in units of metering to prevent future over batching. Some
Sysdyne units, depending upon software version will automatically fill in this amount.
Material Type: As described in the Weighed material screen.
Tolerance: As described in the Weighed material screen.
Max.AMT.In Mix: As described in the Weighed material screen.
Batch Start: Select the point of the batching process that you wish to start metering
any liquid controlled by the program.
Batch Unit: Select the unit of measure for this product in the batching process.
Batch Delay: With this feature you may delay the start batching of this product in
seconds.
Meter Rate: The meter rate for this admixture will be supplied by the technician. The
meter rate is one pulse equals X ounces, milliliters, liters or gallons.
Discharge Start: Select at which point you desire this product to be discharged from
the bottle or container it has metered into.
Metric Batch Unit: In the event you may wish to change the batching measures to
metric please indicate what the metric batch unit is to be by selecting from the pulldown menu.
Discharge Delay: This feature is only used for “bottled” products. You may wish to
delay this product discharge, in seconds, from the bottle. Note: If this product is an
admixture and you wish to delay the discharge you must put the same delay for
admixtures 1, 2 and 3, (group a). You must also do the same for 4, 5 and 6, (group
b).
Spec. Gravity: As described in the Weighed material screen.
Min. Flow Rate: As described in the Weighed material screen.
44
Inventory Unit: As described in the Weighed material screen.
Man Batch: As described in the Weighed material screen.
Alarm Level: As described in the Weighed material screen.
Bottle: Check this box only if the admixture is dispensed from a bottle type
container. Leave this box unchecked if the admixture / water are metered directly into
the truck or scale.
Alarm On: As described in the Weighed material screen.
Remove: Use this button to delete a field from the delivery ticket. point and click on
a line to be edited. The line will change to a blue color. Click on Remove.
45
Utilities
This is the area in which scale parameters are set.
Scale List
Scale 1
Aggregate scale parameters.
Scale 2
Cement scale parameters.
Scale Setting
Name: Enter the name of the scale, agg or cem.
Unit: Enter the weighing units from the pull-down menu.
Capacity: Enter the gross capacity of the scale.
Max. Load: Enter the maximum working load of this scale.
Graduation: Enter the scale increments or graduations for this scale.
Motion Width: Not used
Start Tare: This is the amount of product or material in weigh units that can remain
on the scale and still allow you to start a new load or batch without a tare error.
Disc. Tare: This is the amount of product or material allowed to remain in the scale
after the computer has attempted and unsuccessfully tried to empty.
Settling Time: This is the amount of time in seconds the scale will be allowed to
settle before moving on to another product to be weighed in the same scale.
Disc. Close Delay: This is the amount of time in seconds the batcher gates will open
as wide as possible after the scales have discharged completely or reached the
discharge tare amount.
Disc. Gate Type: There are two types of discharge gates. One is a single acting
solenoid in which a constant open signal needs to be provided. The other is a double
acting solenoid in which case requires a close signal.
Note: entering a 1 in this field means you are using a single solenoid. This
arrangements offer no control over the discharge of this product. Entering 2 in this
field represents a double acting solenoid.
Adj. Tolerance: This is the amount in percent that the desired flow rate can deviate
from the target flow rate without the program forcing a change in the gate status.
46
Flow Rate Average: The flow rate average is taken every one second. It takes 10
samples every second. Therefore, if you have a 20 in the flow rate average the
program will not update for two seconds, if needed.
Open/Close Duration: This is that amount of time in seconds the batcher gate will
have signal on the solenoid that opens and closes this gate.
Vibration On: Enter the weight in weigh units in which the vibrator is to be energized.
Discharge Open: Enter the time in seconds in which the discharge gate will remain
open after the scale has reached the Discharge Tare weight or zero.
Metric Graduation: This field is for the metric scale graduations.
Metric Unit: This is metric weighing unit value.
Metric Start Tare: This is the amount of product or material in metric weigh units
that can remain on the scale and still allow you to start a new load or batch without a
tare error.
Metric Disc. Tare: This is the metric amount of material allowed to remain in the
scale
Calibration: This field is not a user-editable field. The numbers displayed in the area
are part of an algorithm sequence to determine whether the program is receiving input
from the digital readouts.
Zero Offset: This field is part of the same algorithm mentioned above. This is not a
user-editable field.
Zero: This feature is used to zero the computer together with the digital scale
readouts. Before using this feature insure the scales are sitting on zero.
Span: When using this feature the first small window to appear will ask you to enter
weight on scale.
Enter Weight On Scale: Put approximately ½ of the scale capacity into the
scale. Allow the scale to settle for several seconds. Then enter the exact reading
from the digital scale readout and click on the OK button.
Calibration: This feature is used to do a complete calibration of the computer to the
digital scale readouts. When you click on this button the next window will be:
Enter New Graduation: Enter the graduation or increments desired for scale reading.
Setting Zero, Ready? Check the digital scale indicator for any bounce in the scale. If
a solid zero is read then click on Yes
Enter Weight On Scale: Put approximately ½ of the scale capacity into the
scale. Allow the scale to settle for several seconds. Then enter the exact reading
from the digital scale readout and click on the OK button.
Save: Once all features have been updated then press the Save button to save all
changes.
47
Horn List
Horn Setting:
This menu contains settings for warning horns or alarms.
Delay: This field is for time in seconds to delay at the end of the auto batching cycle
to sound the warning device.
Duration: This is the duration of time in seconds the warning device will be energized.
Save: Once all features have been updated then press the Save button to save all
changes.
Hoist List
Hoist Setting
Top: This is the amount of time in seconds the hoist will remain in the “top” position.
Down: This is the amount of time in seconds the hoist will remain in the “down”
position.
Save: Once all features have been updated then press the Save button to save all
changes
Mixer List
Select which mixer parameters you wish to update by using the pull-down window.
Mixer Setting
PreMix Time: Not used.
First Mixing Time: Not used.
Mixing Time: Enter the time in seconds you wish the mixer to mix the load before
prompting you to discharge.
Final Mixing Time: Not Used.
Top/Open Time: This is the amount of time in seconds the mix door will remain open
or the mixer drum will remain fully tilted to allow the discharge of mixed materials.
Down/Close Delay: This is the amount of time in seconds the mixer will delay the
“home” position signal.
Max. Mixing Time: This is the maximum amount of mixing time for any load.
Charging Rate: This is the rate in weighing units per pound the mixer will be loaded
at.
Discharge Seq.: This is the discharge pattern preset in the Discharge Sequence menu
48
Save: Use this feature to save any changes made in this menu.
Operation Parameters
Max. Drop Size: This is the maximum of yardage or meters any one batch the plant
is able to do.
Jog, If Less Than: This feature is useful for batching small loads that are difficult for
the computer to handle quickly. By putting a yardage or meter amount here, Example:
placing a 1 in this field, every batch 1 yard or meter and less will jog all the weigh to
the target.
Weighed Water: Check this box if you have a weighed water system.
Water Holding Tank: Check this box if your plant has a water holding tank.
Drop Repeat Mode: Repeat mode 1: If the calculated drop size is larger than the
maximum drop size that can be loaded by the plant (found in UTILS in the Operation
Parameters menu), the computer automatically corrects the error condition by
increasing the # of drop until the actual drop size is smaller or equal to the maximum
drop size.
Repeat mode 2: The drop size is set to maximum drop size defined by the plant
UTILS. Neither the #_OF_DROP, nor the QTY_SOLD has any effect. The computer will
batch repeatedly, load after load, of the same mix and of the same drop size until it is
stopped by activating a function key. Repeat mode 2 is designed basically for block
plant, pipe plant or pre-cast plant applications.
Tolerance Mode: This field controls the way the weight tolerance is
calculated. Difference base is used to derive the acceptable variation of target
weight. The low and high limit of tolerance is calculated by multiplying the
base with the percentage of tolerances. See the table below.
Tolerance Mode Selection:
Tolerance is based on the percentage of the accumulated
1.
1.
target weight of the material being batched.
2.
2.
Tolerance is based on the percentage of the individual weight
of each ingredient.
Tolerance is based on the final accumulative target weight of
3.
3.
all ingredients batched into the scale.
Tolerance is based on the final accumulative target weight of
4.
4.
all ingredients batched into the scale for aggregate scale.
Tolerance is based on the individual weight of each ingredient
does not override the looser tolerance for the ingredient
batched prior to it.
NO Tax Amt. In Price: This field is used to exclude taxation of a percentage of the
concrete price that may include delivery cost.
Default Disc. Rate: When no sequence number is used, then this will be the rated at
which the material will attain.
Target On Net Weight:
Water Weight/Volume: The default value is a constant so just leave this field at 8.3,
(8.3 lbs of water per gallon).
49
Number Of Scales: Enter the number of scales the computer is required to monitor.
Number Of Mixers: Enter the number of mixers the computer is required to monitor.
SemiAuto Meter Batch: This field is used to enable or disable the SemiAuto batch
feature.
Run Mode: At this time it is necessary for the Run Mode to be set to Normal.
Plant Name: This field is for the Plant Name that may be used to identify the system
via network or internet.
Plant Code: This is code or plant ID number. This ID number may be printed on the
delivery ticket if your company has more than one plant.
Small Load Size: This value is yards / meters or any part thereof. Put the smallest
size load that the program can quickly and accurately weigh. Any size load this value
or smaller yet larger than the Jog, If Less Than value will use small load parameters.
Save: Use this feature to save any changes made in this menu.
Printer Setup
Name: This is the printer name to be selected from a pull-down window. This setting
will typically be LPT1 for the delivery ticket..
Type: This is the printer type to be selected from a pull-down window.
NOTE: If you use a printer supported by Windows Operation System to
print report, the Type is Windows Graphic Printer.
Parameter: This field is not used when using a parallel printer. If using a serial
printer then enter baud rate.
Form: This is the form length of the delivery ticket or report paper.
Report: Select Y for yes from the pull-down window if this printer is to print reports.
Ticket: Select Y for yes from the pull-down window if this printer is to print delivery
tickets.
Record: Select Y for yes from the pull-down window if this printer is to print
recordation.
Init_String: Not used.
Diagnose
Click the Diagnose button to bring up the board level diagnosis information to help you fix the
problems.
50
Dos Data
Click the Dos Data button to import the dos data from your old dos sysdyne batching system.
51
Charge
Truck Charge: This is the mixer truck charging profile. Each truck will have its
individual charge rate and may be updated after every batch.
Truck: Enter the mixer truck number.
Seq. #: Enter the Scale Discharge Sequence number. (99% of users have only one
sequence number. It is usually 1).
Charge Rate: This field will automatically be updated after every automatic batch
loaded into this mixer truck.
Drum Capacity: Enter the mixer drum capacity. This amount is stated in yardage.
Driver: Enter driver’s name or any identifiable number.
Remove: Use this button to delete a field from the delivery ticket. point and click on
a line to be edited. The line will change to a blue color. Click on Remove.
Save: Once all features have been updated then press the Save button to save all
changes.
Scale Discharge Sequence
Name: Sequence number
Scale: ID number from configuration menu, not available to end user. This field will
be typically set to Scale #1.
Delay: This is the time in seconds the scale 1 discharge will delay in order to get more
head water.
W/Water: Selecting Y for yes to this field will allow water and scale 1 to discharge at
the same time.
Wash Start: Put the percentage amount of scale 1 already discharged before the
wash water may begin. The typical setting here is 99.
Wash Qty. this is the fixed amount in meter units that will be held back for wash
water.
Wash %: This is the fixed percentage of water to be held back for wash water.
This will be scale 2 – 8 settings. All materials discharged are
based on Scale 1 discharge.
Scale Discharge:
Scale: Select the scale from the pull-down window that you wish to set the
parameters for.
Start: This is based on percentage of scale 1 already discharged. Insert at what percent of
scale 1 already discharged do you want this scale to begin discharging. Typical range is 5-20%.
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Finish: Based on scale 1, select the percentage of material left on scale 1 do you want this
scale to be finished loading. Typical range is 5-20%.
W/Water: Select from the pull-down window whether you wish water to begin or remain
loading while this scale is open. Typically on dry batch plants water and cement are not set to
go together.
Remove: Use this button to delete a field from the delivery ticket. Point and click on a line to
be edited. The line will change to a blue color. Click on Remove.
Save: Once all features have been updated then press the Save button to save all changes.
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Customer
Name:This is the customers name as it will be printed on delivery tickets and other reports.
Account: This field is an alpha-numeric. Enter the customer account number you wish to
use. This will be the account number printed on the delivery ticket and other reports.
Telephone: Customers telephone number.
Address: This field is reserved for the customers billing address.
Add: Point and click on this button to add a new customer to your database.
Acct Code: Enter the customers account code
Acct Type: Enter the customers account type, i.e., Open, C.O.D., Cash.
Name: Enter the customer’s name.
Tax Rate: Enter the customer’s sales tax rate percentage.
Credit Limit: This feature is used to remind the batchman that this particular customer has
exceeded a preset credit limit. The program will automatically prompt the batchman when the
open account amount reaches this amount.
Telephone: Enter the customer’s telephone number.
Credit Used: This money amount in this field automatically accumulates unless this customer
is on C.O.D. or cash only account status.
Address: Enter the billing address for the customer here.
Comment: This field is reserved special notes regarding this customer. This information will
not be seen anywhere else in the program.
Ship To: This field is used to automatically fill in the Ship To: field on the delivery ticket. This
is the address of where the concrete is to be delivered.
Remove: Point and click on a customer and then click on this button to delete the customer
from the database.
Property: This button shows the filled in information as the Add button.
Print: Use this feature to print customer list.
Import ASC: When you select this feature a small window appears with the heading
Customer Asc Import. This feature is for importing ASCII from different applications.
Asc Type: You have a pull-down window to select the type of ASCII application.
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Asc File Path: This is the location of the ASCII file to retrieve.
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Ticket
Date: Date of load delivery.
Time: Time of load delivery.
Job#: Job number of load delivery.
Ticket: Ticket number of job delivery.
Truck: Truck number used to deliver load.
Driver: Name of mixer driver whom delivered the load.
Sold To: To whom the load was sold to.
Ship To: To where the load was delivered.
Print: To print a duplicate ticket of a prior delivered load. You must point and click on the line
of the load you wish to print. Once the line has changed to blue in color then you can point
and click on the Print button to begin printing.
View:
Pressing this button will cause a copy of the original ticket to appear.
Remove: If you wish to remove a load record then follow the same procedure used to print
but click on remove instead. Caution, once deleted the record cannot be retrieved.
TO and From Dates: This is a search feature to help narrow search parameters. Enter the
earliest possible date of a load and then on the TO field enter the latest possible date of
delivery and point and click on the Query. This will bring up all the loads between these two
dates. If you are still unable to locate the load then simply broaden your search dates.
Clear: Once you have found what you are looking for you can click on Clear and the Load
Records menu will be wiped clean.
Export ASC: This feature allows you to export an ASCII formatted information. You simply
put in the From date and the To for the information you wish to send and then show the
ASCII File Path.
ASC Format: This function is for batch ticket exporting in an ASCII file. You have a pull-down
window with options for:
ASC Ticket: For export of ticket files
ASC Item: For importing Mix files
ASC Customer: For importing Customer files.
Ticket Format: This menu is used to align data with different style tickets. These fields are
aligned by:
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Line: This is the line number the data will be printed on. Typically, on an 11” page there are
66 lines.
Column: This is the column number the data will start printing in. Typically on an 81/2” wide
paper there are 80 columns.
Field: This is the information that will be printed in the column and on the line stated above.
Type: there are several types of fields all of which have the type pre-selected in the Insert
Variable list.
Length: This is the longest length of the data required for this field. All characters must be
counted. For example, to insert the date, you must count the numbers day, month and year,
then you must count the colons between the day month and year. So your total length for
01:01:1999 will be 10.
Ticket Length: This represents the number of lines the delivery ticket portion of the page will
use. The next line after the Ticket Length stated will be where the recordation starts printing.
Insert Literal: If you wish to print a field that is not listed in the Insert Variable then you can
do so with this feature. The following fields listed in this menu are:
Line: Line number as described above.
Column: Column number as described above.
Field: Type the word or words you wish to appear on your delivery ticket.
Insert Variable: This is a list of pre-selected variables that may be printed on your
delivery ticket. The following fields listed in this menu are:
Line: Line number as described above.
Column: Column number as described above.
Field: (pull-down menu), showing all available pre-selected fields. Scroll through the list of
fields until you find the one that suits your needs then click on that field. The new field will
appear on the line.
Type: left blank
Length: Insert the length of the field as described earlier.
Fraction: If a number is to be used for the field selected then you must indicate how many
decimal places beyond zero you want to print. Example, for dollar amounts you will set the
Fraction to 2 so that the cents will be displayed.
When all is correct then select OK and continue, if the change is no longer desired then click
on Cancel.
Edit: Use this feature to Edit the current ticket shown on the left. Simply point and click on a
line to be edited. The line will change to a blue color. Click on Edit
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Remove: Use this button to delete a field from the delivery ticket. point and click on a line to
be edited. The line will change to a blue color. Click on Remove.
When all changes are made to your satisfaction then click on OK to exit.
Print Setting: Use this menu for the following features:
Delivery Ticket: Check this box if you want to print delivery tickets for every batch.
Ticket Number: Insert the ticket number you wish to start printing on the next delivery ticket.
Job Number: Insert the next Job Number to be printed on the next delivery ticket.
Ticket Message: Insert a message here you wish to be printed on your delivery Ticket. This
field must be set up in the Ticket Format menu.
Recordation: Leave this field at its default value.
Limits: Check here if you wish to print the limits of each materials target tolerance on the
recordation portion of the ticket.
Mix: Check here if you wish to print the mix design weights on the recordation portion of the
ticket.
Start Tares: Check here if you wish to print the weight already on the scale prior to loading
this mix on the recordation portion of the ticket.
Trims: Check here if you wish to print the any trims to the original mix design on the
recordation portion of the ticket.
Discharge Tares: Check here if you wish to print the amount of material left in the scale
after the batch has been loaded in the mixer on the recordation portion of the ticket.
Targets: Check here if you wish to print the mix design target weights on the recordation
portion of the ticket.
Batch Weights: Check here if you wish to print the recordation data on your delivery ticket.
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Report
This menu will give you a history of batched loads in several varieties. You can sort by
the following fields:
Total: This report will relate more to Totals.
Date: Date of load.
Time: Time of load.
BAT#: Batch number.
DROP#: Drop number of a multiple drop load.
M: Manual batch.
TKT#: Ticket number.
Truck: Truck number
Mix: Mix ID or code.
Mixer: Mixer number or code.
DiscTime. Time of batching discharge complete.
Temp: Amount of temper water added to load.
Job: Job number, name or code.
Account: Account number, name or code.
Customer: Customer name, number or code.
Mix: This report will relate more to Mix features.
Date: Date of batch.
Time: Time of batch.
BAT#: Batch number.
DROP#: Drop number of a multiple drop load.
M: Manual or automatic batch.
TKT#: Ticket number.
Truck: Truck number.
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Mix: Mix ID.
Mixer: Mixer number
Disc Time: Time at completion of batch discharge.
Temp: Amount of temper water added to load.
Job: Job number, name or code.
Account: Account number, name or code.
Customer: Customer name, number or code.
Job: This report relates mostly with Jobs.
Date: Date of Job.
Job: Job name, ID or code.
Acct: Account number, name or code.
Customer: Customer name, number or code.
Sold: Yards or meters sold during this period.
Prod: Yards or meters produced during this period.
Open: Value of concrete sold on open accounts during this period.
Cash: Amount of cash taken in during this time period.
Tax: Amount of tax on concrete sold during this period.
Total: Total money amount of concrete sold during this period.
Load: This report relates mostly with Loads.
Date: Date of load.
Time: Time of load.
BAT#: Number of batched loads during this period.
DROP#: Number of drops for this period.
M: Manual and automatic batches during this period.
TKT#: Ticket numbers of batches for this period.
Truck: Loads on this truck during this period.
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Mix: Number of loads of this mix during this period.
Mixer: Mixer number.
Disc Time: Time at the end of discharge for this load.
Temp: Temper water added.
Job: Job number, name or code.
Account: Account number, name or code.
Customer: Customer number, name or code.
Customer: This report relates mostly with Customers.
Date: Date of batch.
Acct Code: Account name, number or code.
Name: Customer name.
Acc Type: Open or C.O.D., Cash sale.
Sold: Amount of concrete sold to this customer.
Prod: Amount of concrete produced for this customer.
Open: Money amount sold to this customer on an open account.
Cash: Cash amount of concrete sold to this customer.
Tax: Tax amount of concrete sold to this customer.
Total: Total amount of concrete sold to this customer.
Truck: This report mostly relates to Truck profiles.
Date: Date truck carried concrete.
Truck: Truck number, name or code.
Driver: Drivers name.
Sold: Amount of concrete sold and delivered by this truck.
Prod: Amount of concrete produced and delivered by this truck.
Open: Money amount of concrete delivered by this truck.
Cash: Cash amount of concrete delivered by this truck.
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Tax: Tax amount on concrete delivered by this truck.
Total: Total amount of money earned by this truck.
Material Req.: This report relates to materials required for a given period of production.
Material: Material needed for this given period.
Unit: Unit of measure for this material.
Required: Amount of this material needed for this given period.
On-hand: Amount of this material on-hand.
Balance: Balance of this material needed for this period.
Plant Analyze: This report relates mostly to plant performance.
Material: Material being analyzed.
Since: Since the Beginning Balance date.
Target: Total of all this material batched during this period.
Actual: Actual amount of this material batched during this period.
% Variance: Percent of variance from the target for this material during this period of time.
Loads: Number of loads batched of this material for this period of time.
Under: Number of loads under batched during this period of time.
Over: Number of loads over batched during this period of time.
%OV: Percent of overage during this period of time.
Query: Use this feature to look up data during a given period of time based on the FROM date
and TO date. Putting the desired dates in these fields and clicking on the Query button will
give you the information you are looking for.
Print: Use this feature to print the displayed data.
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TOTAL REPORT
63
CUSTOMER REPORT
64
DRIVER REPORT
65
JOB REPORT
66
67
LOAD REPORT
68
MIX REPORT
69
TRUCK REPORT
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Quote
Calculator
Type: Select from a pull-down window for what it is you want to figure.
SLAB
BLOCK
PRISM
COLUMN
CYLIN.
Measurement: Select either yards or meters.
Dimensions: Put in the dimensions of the area of concrete you are measuring.
Factor: This field contains the factor for figuring meters or yards.
Once the dimensions have been entered, go to the Price/UN field and enter the price per yard
or meter for this mix. If price is not known then skip this field. Enter Quantity of slabs,
prisms, etc… volume will be needed.
Now point and click on the Calculate button. This should give you the volume in meters and
yardage. You will also, if used, be given price for quantity of concrete.
It may be necessary to use this calculator for several different calculations for the same
job. In this case after each calculation you can Add To List and begin tallying a total for
several different items and sizes. If one or two of the calculations are no longer needed or
have been updated you can delete one calculation at a time by pointing and clicking on that
line and press the Delete Item button. Once you are finished with the calculator you press
the Clear button to delete the entire page.
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Dispatch Interface
The interface supports UNIVERSAL BATCH-DISPATCH COMMUNICATION LINK.
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Accounting Interface
Sysdyne accounting interface supports QuickBooks. Also, we provide customized service
to your specific accounting system.
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Auto Seek’N Feed
Auto Seek’n Feed is sysdyne material handling system. The batching program can
integrated the control interface.
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