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The Data`s indicated in this Operating Instruction may diIIer Irom plant to plant in accordance with constant
improvement, and we reserve all right to change or modiIy any parts at any time without any prior
notiIication.




PLANT - M1.COMPARTMENT BATCHER
CONTROL SYSTEM - MCI 360


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M1 MCI 360





Total Pages

01. SaIety Instruction 02

02. Technical Data 03

03. MCI-360 Generic InterIace SoItware User Guide 96

04. Cable List 06

05. Spare Parts List 08

06. Recommended Spare Parts List 01

07. PLC Input / Output List 05

08. Control Panel General Arrangement 01

09. Control Panel Circuit Diagram 25

10. Junction Box & Terminal Detail 05

11.3 Phase Induction Motor Fault Finding Procedure 03

12. Silo Level Meter 22

13. Moisture Meter 37

14. Phase Failure Relay 03






M1-MCI 360

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All Electrical works and connections to be done by an Electrical Expert. Any work on the plant
may be perIormed only when the plant is switched oII.

In case oI the Plant is completely switched oII during Maintenance and repair works, it must be
SaIeguarded against unexpected Switching On.
- Lock up Main Switching Equipment, Press Emergency Stop and Draw oII the key.

In case oI Disorder in Electric Supply (ie) Unbalanced Voltage, Single Phasing and
Over/Under Voltage, Please switch oII the Plant immediately. And do not try to start. Ensure
that the problem is sorted out and then start the plant.

Use Voltage Insulated tools only, when working in electrical areas.


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The cross section oI the Incomer conducting cable Ior the power is on "#$%&'() $"&*( and
should be oI +,-. /0 '' 1# or +,2- /0 '' 34.
Since earth plays very important role Ior accuracy oI the plant, we request the customer to
provide proper earth to the structure and control panel oI the plant.


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The minimum capacity oI the D.G provided by the customer should be 56- 783 and should
have 5-.9 overload capacity.


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In the event oI power Iailure, during the mixing cycle, the Pan Mixer can be started in Direct
on Line mode and that is why direct starting oI mixer is provided and not Ior Irequent
operation. Schwing Stetter does not take any responsibility at any circumstances iI the above
Iacility is misused.


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II it is necessary to do Welding in the batching plant, kindly /:;%"< =>> the Control Panel
Power and ?$&4@%( the load cell Irom the weigher by tightening the transportation lock.


M1-MCI 360

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All Protective and saIety devices are to be kept operative and must be repaired / replaced
immediately, in the event oI Iailure. Bypassing the saIety devices may result in heavy injuries
or even loss oI lives.

No claim can be made in the event oI Bypassing oI any Protective / SaIety Devices in the
control system. Schwing Stetter does not take any responsibility to such kind oI activities
made.

We recommend to keep minimum spare parts available with you all times. ReIer the
Recommended Spare Part List available in the manual.


+$3)"*$2$%# '5 $)*#+&*") &#$2,

The electrical liIe time oI the Power and Control Contactors are 0.5 million operations at a
Constant Ambient temperature oI 45

degree

C. De-ration is applicable when operating at
higher temperature.
Any how considering the dusty atmosphere and to get best result we recommend to replace the
Contactors every 1, 20,000M
3
or 5000 Working Hours whichever is earlier and do not
replace the Contacts.


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Schwing Stetter does not take any responsibility in the event oI misuse oI materials (i.e.) taking
Cement instead oI Fly ash / additional consumption oI materials iI batching done in manual
mode and no claim can be made. Material consumption in manual mode to be recorded by the
customer only.


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M1 MCI 360



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Supply Voltage:.................. 415 Volts
Permissible voltage Iluctuation:............ / - 10
Frequency:..................... 50 Hz
Connected Load:.................... 83 kVA
Operating Temperature:............... 5 40 deg C
Incomer cable requirement:.............. 4*50 Sq mm Cu
D.G.Requirement:................. 125kVA



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Aggregate..................... 2500 Kg
Cement...................... 500 Kg
Water...................... 250 Kg
Admixture..................... 10 Kg
Aggregates .................... 4 Components
Cement....................... 2 1 Max
Water....................... 1
Admixture..................... 1 Component















M1 MCI360



Technical Data




Motor Details


Compressor Motor:.................. 2.2 kW / 3 HP
Sand Vibrator Motor..:....................0.18kW /0.24 HP
Screw Conveyor Motor-1:.................11 kW /15HP
Screw Conveyor Motor-2 :(Optional)...........11 kW / 15HP
Fly Ash Screw Conveyor: (Optional)...........11 kW / 15HP
Cement Vibrator Motor..: ..................0.18kW /0.24 HP
Mixer Motor:......................37 kW / 50 HP
Skip Motor:........................15 kW / 20 HP
Admixture Dosing Motor:..................0.75 kW / 1 HP
Admixture Discharge Motor : (Optional )..........0.75 kW / 1HP
Water Pump Discharge Motor:................7.5 kW / 10 HP








Note:

All the above Motors are 3 Phase 415 V AC + 10 , 50Hz, Otherwise SpeciIied in the Drawing
All Contactor Coil Voltage - 220V AC 50Hz
All Relay Coil Voltage - 24V DC
All Solenoid Coil Voltage - 24V DC
All Indication Lamp Voltage - 24V DC
Skip Motor Brake RectiIier Input Voltage 415V AC

All the Motor Protection Breakers and the Multi core Cables Provided by us are designed Ior
Constant Ambient temperature oI 45

C. De-rating is applicable when operating at higher
temperature.


M1 MCI360



Technical Data


Panel Wiring Cable Color Code Details:

Red : 230 V AC
Black : Neutral
Blue : PLC Input side
Grey : PLC Output side
Orange : 24 V DC
Violet : 0 V DC
White : Thermister Connecting cable
Brown : BeIore Incomer ie Power will be available even iI incomer is in OFF

Load Cell Details:

Input Resistance : 350 Ohms + 2
Output Resistance : 350 Ohms + 2
Excitation Voltage : 10 V DC
Non-Linearity : + 0.025
Full Scale Output : 2 mV /V

Load Cell Wiring Details:

Red : Excitation ( 10VDC)
Black : Excitation (0 V DC)
White : - Signal
Green : Signal



MCI360 Control System
1




















MCI-360 and MCI-360 Generic Interface Software
User Guide
























MCI360 Control System
2
Contents


MCI360 SoItware

Sno. Description Page

1. Introduction on MCI 360 3
2. System Requirement 4
3. Getting Started, Login and Main Screen Details 5
4. Master Details. 12
5. Start Schedule. 28
6. Mimic Text View 30
7. Plant Setup 32
8. Manual Operation 54
9. Report 55
10. Alarm Accept 91
11. Help Option 91
12. Divert Concrete 92
13. Exit 93
14. Mimic Screen 93
15. Mixer Gate Locked / Unlocked 94
16. Alarm View 94
17. Water Direct 95
18. View Maintenance message 95
19. Tips and Troubleshoot 95




















MCI360 Control System
3





1. Introduction on MCI 360


Micro Controller India -360 which is shortly called as MCI 360 is a complete automated
solution Ior the concrete production industries. In the past concrete production the
machinery was just used as a device which mixes Iew constituents and drops them out as
a concrete but now in the new era it is not the way it happens.

M/s Schwing Stetter has changed the deIinition oI this. In the early days Schwing Stetter
introduced the MCI 300 control system which is user Iriendly system to control and
monitor the productivity and perIormance oI the machine, where as now it has come up
with the new solution in to the concrete business which is MCI 360.

Main Ieatures oI MCI 360 are as Iollows.

1. Schedule based batching Not usable in case oI generic interIace enabling
2. Maintenance schedule
3. Cement batching silo can be changed in between in case oI silo empty- Not usable in
case oI generic interIace enabling
4. Automatic calibration and manual calibration available.
5. All kinds oI statistical reports are available.
6. Slump measurement (optional)
7. PID control based batching (addition to the material in air control)
8. Automatic batching aIter power recovery
9. Centralized connection oI load cell with plc
10. Common soItware Ior all Stetter plants ranging Irom M1 to H6
11. Introduction oI touch panel
12. Introduction oI membrane keypad instead oI control desk
13. Connectivity to USB camera (optional)
14. Customer credit locking system (optional)- Not usable in case oI generic interIace
enabling
16. Provision Ior slurry water batching
17. Introduction oI authority based password control
18. Facility to divert the concrete Irom one customer to another (delivery docket) - Not
usable in case oI generic interIace enabling
19. Possibility Ior networking the plants (optional)
In the below chapters we will have a brieI look on all the Ieatures and advantages oI the
MCI 360 control system.



MCI360 Control System
4






2. System Requirements.


The control system is inclusive oI computer this is just Ior inIormation
1. P-IV processor 2.6 G Hz speed or above.
2. 1 GB Ram or above
3. Loaded with win 2000 proIessional OS / win XP ProIessional
4. Built in internal modem
5. WINCC Version 6.2
6. Crystal tools and ms-tool with other components.
7. IE 6
8. Batching soItware
9. Communication Processor (5611) / TS Adaptor
10. WIN 2k SP4 / WIN XP SP3


























MCI360 Control System
5




3. Getting Started, Login and Main Screen Details


To get started with the loading oI soItware we need to Iollow the bellow mentioned
procedure but this is a one time process


Fig 3.1
First we need to go to start menu select simatic menu iI it is win XP classical view
or else select programs and simatic menu
Select the submenu called winCC
Select another submenu called Autostart
A window appears as shown in Iig 3.1.
Select the project Irom the browse button given, most oI the case
'C:\ConvertedSap\Converted\SSIMCI300N\SSIMCI300N or 'C:\Grasim
Mci360\ConvertedSap\Converted\SSIMCI300N\SSIMCI300N
Mark check to both 'Activate project at startup and 'Allow cancel during
activation
Click 'Add to Autostart button to get registered.

AIter perIorming the above steps kindly restart the computer. Once the computer reboots
the system will automatically run MCI 360 soItware Irom the startup, please note that the
MCI360 Control System
6
above procedure is to be done only Ior one time and that too during Iirst time when we
run the MCI 360 soItware.

The login screen will appear as shown in Fig 3.2 .Enter the user name and password
provided by the commissioning engineer and click on the login button this will allow us
to enter into the MCI360 SCADA SoItware main screen as shown in Iig 3.4. Incase iI we
provide wrong user name or password

Fig 3.2

The system will automatically generates a warning dialogue box with a message
unauthorized user as shown in Iig 3.3

Fig 3.3

In case iI it is required to exit Irom the soItware then we can click on exit to quit the
application.


MCI360 Control System
7





Fig3.4

The above screen is the main MIMIC screen which appears once we login to the MCI
360 control system soItware at the top we can see the Iollowing screen navigation
buttons.

a. Master
b. Schedule start
c. Mimic text view
d. Plant setup
e. Manual operation
I. Report
g. Alarm accept
h. Help option
i. Divert concrete
j. Exit
k. Mimic Screen
MCI360 Control System
8
l. Mixer Gate Locked / Unlocked
m. Alarm View
n. Wtr Direct
o. Maintenance View Disable / Enable

About which we will be seeing in the Iollowing chapters.
Apart Irom the above the below inIormation are also available in the main screen, more
over the screen has been designed in such a way that it opens its entire supplementary
screen with in the main screen.

Alarm Reference
A separate display box has been provided to view the online event occurrence in the
alarm reIerence box by which we can come to know what has happened during the
process and the entire details will be recorded. How to acknowledge to the occurred
alarms will be listed bellow in the Iollowing chapters.

Moisture / Correction
Separate buttons have been provided to set the moisture and perIorm the material
corrections in each component.
The bellow screen (Fig 3.5) will give you a clear picture on how to set the moisture.

Fig 3.5

MCI360 Control System
9
Basically the moisture parameter is set to correct the total moisture value identiIied in the
material through sampling.
There are two diIIerent options available to set the moisture, First option is iI we had
availed Ior moisture automatic correction during ordering the plant then the moisture can
be set or identiIied automatically and correct the corresponding materials automatically
with the help oI moisture meter and probe, to the maximum oI two bins can be
conIigured Ior automatic moisture correction and the selection oI bin is independent
which we will be seeing in the Iollowing chapters.
The second option is to enter the moisture percentage manually in the given Iields as
speciIied in Fig 3.5. Here the system will not identiIy the moisture where as the human
being which is our civil technical expert need to identiIy the moisture percentage
available in material and provide the same to batcher then aIter knowing the exact
moisture percentage Irom the quality department the batcher can enter the provided
percentage value in the given Iield as shown in Fig 3.5 to consider the corrections in the
system.
Please note that iI the batching plant is opted with automatic moisture correction then we
need to enable automatic moisture corrections by clicking the available 'Automatic
Moisture Disabled button when this button is clicked the caption oI the button will
automatically turns to 'Automatic Moisture Enabled and the corrections will be done on
per batch basis based on the percentage value Ieed by the calibrated moisture probe
automatically, we can also do manual entry Ior other non probe connected bin while the
moisture automatic mode is enabled. It is not mandatory to always run the moisture in
auto mode iI it is available we can also choose to run in manual mode by disabling it
based on the requirement.

Moisture Absorption: There is an option to adjust the moisture absorption the limit
value speciIied here is 0 to 3.9 and this is a manual entry Iields which is available Ior
all the 6 bins to correct the absorption Iactor.

Silo Section: The silo selection is provided to switch Irom one silo to the other during
auto mode batching, procedure is as Iollows, all we need to do is to click the silo
selection button Irom the moisture screen which will prompt you to enter 'Irom silo
number and 'to silo number respectively aIter entering the same click the activate silo
change over button which will automatically switch silo number 'Irom value to silo
number 'to value. Please note that we can change or select silo in any order, ascending
or descending based on the availability oI cement stock.
Please note that silo selection option will not be eIIective in case oI generic interIace
option is active.

Slump Trend View: The slump meter is an optional Iacility available with MCI360
control system where it measures the approximate slump through measuring the power
consumed by the mixer motor and the power drawn is converted to 0 10 V output
through a transducer. The approximate slump derived is displayed in a Iorm oI trend as
shown in Iig 3.5.
Please note that this is an optional item as similar to that oI moisture kit to avail this we
need to place order Ior this separately.
MCI360 Control System
10

Corrections: Other correction can also be perIormed in MCI360 Irom cement1 to
admixture all the materials can be corrected but there are some limits deIined Ior these
correction basically Ior cement the limit value starts Irom -40 kg to 40 kg and the same
is applicable Ior water too where as Ior admixture the correction value can go Irom -500
grms to 500 grms .The correction screen can be enabled by licking on the correction
button Irom main screen as shown in Iig 3.6.





Fig 3.6

Scan Time: The plc scan time is displayed in the main screen always to monitor the plc
response and scan time by which we can clearly get to know about the load on plc
memory.

Moisture1 and Moisture2: When we had opted Ior the moisture optional kit along with
the plant the moisture reading Irom the probe is always displayed in these 2 Iields.

Silo Level: There is a way to integrate the cement silo level display with the MCI360
control system this is also an optional Iacility available iI it was ordered separately with
MCI360 Control System
11
the plant. Here it works on capacitance basis and when the signal is transIerred Irom the
silo measurement wire rope sensor the MCI360 control system will display the
approximate value the error on measurement Ialls some where around 3 to 5 .

Tolerance: The tolerance indication is also available in the main screen the occurrence
tolerance is intimated to the operator in 2 diIIerent.
1. Through alarm reIerence
2. Through a red blinking bulb available in main screen.
By the above available indications we can analyze and acknowledge the occurred
tolerance by pressing the alarm accept button Irom main screen or Flt Tol button Irom
the membrane keypad.
Pause and Terminate Schedule: These both buttons Iunctionality is as equal to that oI
auto pausing and terminating the batch Irom the membrane keypad.

Swap Order: The orders which were been executed through schedule can be swapped
among themselves by using this swap button Ior example iI we need to swap order1 and
order2 respectively based on the priority then keep in order1 and press button then it
will move order 1 to order2 place and order 2 to order1 place same way the button work
in the reverse condition.
Please note that we should not swap a currently batching order.

Other details display: The other details like aggregate, cement, water, water2, silica and
admixture weigher values are also displayed in main screen along with that while auto
batch the details about currently batching materials its target and actual values are also
displayed with the customer it belongs to recipe that batched with and the location its
about to deliver were also displayed.
For our inIormation the batch size, total batch, elapsed batch, with this load, total with
this load, truck no, driver and batch number were also displayed as shown in Iig3.6.

Diverting on going batch: In MCI360 control system there is a provision to divert an on
going batch to any other customer or site based on the requirement and situation. A Iactor
that we need to consider is that it is possible only iI both the customer opted Ior same
recipe.
To change a customer Iirst we need to click in Get Customer button then the system will
get all the available customer details Irom the database and display it in the available
Iield then we need to double click on the selected customer which will prompt us with the
available sites now we can select what ever site is required Ior the diversion.
Please note that this has to be done beIore the last batch is batched. Same way it is
applicable Ior truck also.







MCI360 Control System
12




4. Master Details

All the available master details are provided Ior addition, modiIication and deletion
purpose, to access the master details all we need to do is click on the master button Irom
main screen which will load a screen as shown in Iig 4.1


Fig 4.1

In which we can add, modiIy and delete the Iollowing masters.
1. Customer Master
2. Site Master
3. Truck Master
4. Recipe Master
5. Order Master
6. Schedule Master
7. User Master
8. Inward
9. Maintenance Master
MCI360 Control System
13


Customer Master: AIter entering in to the master details screen to access the customer
master we need to click in the customer master button which will open the customer
related details as shown in Iig4.1.

Adding New Customer: Press Add new button to start with adding a new customer then
start entering the values in the Iollowing Iields
*Customer code - Iield size (75)
*Customer Name - Iield size (100)
Contact Person Iield size (100)
*Customer Address Iield size (80)
City Iield size (100)
Pin code Iield size (50)
Phone Iield size (10).
Please note that in the above Iields what ever is marked with '* symbol is to be
considered as mandatory Iields and it should not be leIt blank while going Ior a save
event. Once it is made sure that all the required Iields are Iilled then we need to press
save button to store the data into the database

Modifying Existing Customer: To modiIy an existing customer press customer code
load button, this will load all the available customer code Irom database into the customer
code Iield.
Select the customer code oI which we need to modiIy the data. When we select the
required customer Ior modiIication the system will automatically display all the relevant
data in the corresponding Iields, later which ever Iield need to be modiIied can be
modiIied and saved back in to database by pressing the save button. Please note that
except customer code we can modiIy all the Iields


Deleting Existing Customer: To delete an existing customer press customer code load
button, this will load all the available customer code Irom database into the customer
code Iield
Select the customer code oI which we need to delete. When we select the required
customer Ior deletion the system will automatically display all the relevant data in the
corresponding Iields now we need to press the delete button to erase that particular
selected customer completely Iorm the database
Please note what ever records we are deleting will be separately stored in a temp table Ior
our reIerence and Iault analysis.




Site Master: To access the site master we need to click in the site master button which
will open the site related details as shown in Iig4.2.

MCI360 Control System
14

Fig 4.2

Adding New Site: Press Add new button to start with adding a new site then press
customer code load button which will load all the available customer code Irom customer
master table to the customer code Iield, the major reason to load the customer code is to
segregate the site based on the customers. AIter selecting customer code start entering the
values in the Iollowing Iields
*Site - Iield size (50)
Contact Person Iield size (100)
*Site Address Iield size (100)
City Iield size (50)
Pin code Iield size (50)
Phone Iield size (10).
Please note that in the above Iields what ever is marked with '* symbol is to be
considered as mandatory Iields and it should not be leIt blank while going Ior a save
event. Once it is made sure that all the required Iields are Iilled then we need to press
save button to store the data into the database and also we need to remember one thing
that we should not enter any Iields and go Ior save event with out selecting a proper
customer code

Modifying Existing Site: To modiIy an existing Site press customer code load button,
this will load all the available customer code Irom database into the customer code Iield.
Select the customer code oI which we need to modiIy the data. When we select the
MCI360 Control System
15
required customer Ior modiIication the system will automatically load all the sites which
belongs to that particular customer in the site Iield aIter that we need to select the site
Irom the listed Iield then it will display all the relevant data in the corresponding Iields,
later which ever Iield need to be modiIied can be modiIied and saved back in to database
by pressing the save button. Please note that except customer code and site we can
modiIy all the Iields

Deleting Existing Site: To delete an existing site press customer code load button, this
will load all the available customer code Irom database into the customer code Iield
Select the customer code oI which we need to delete the data and this selection will load
all the available site oI that particular customer in site Iield then we need to select the site
which is to be deleted. When we select the required site Ior deletion the system will
automatically display all the relevant data in the corresponding Iields now we need to
press the delete button to erase that particular selected customer`s site completely Iorm
the database
Please note what ever records we are deleting will be separately stored in a temp table Ior
our reIerence and Iault analysis.


Fig 4.3




MCI360 Control System
16

Truck Master: To access the truck master we need to click in the truck master button
which will open the truck related details as shown in Iig4.3.

Adding New Truck: Press Add new button to start with adding a new truck then start
entering the values in the Iollowing Iields
*Truck type Iield type number deIault 1 options (1/2) select whether transit mixer or
tipper
*Truck Capacity Iield type number deIault value 6
*Truck Driver Iield size (100)
*Mixer Mid Position Iield type integer deIault value 0 this Iield helps us to deIine
the halI open position oI the mixer gate based on the truck chute opening condition.
Please note that in the above Iields what ever is marked with '* symbol is to be
considered as mandatory Iields and it should not be leIt blank while going Ior a save
event. Once it is made sure that all the required Iields are Iilled then we need to press
save button to store the data into the database

Modifying Existing Truck: To modiIy an existing truck, press truck no load button, this
will load all the available truck no Irom database into the truck no Iield.
Select the truck no oI which we need to modiIy the data. When we select the required
truck Ior modiIication the system will automatically display all the relevant data in the
corresponding Iields, later which ever Iield need to be modiIied can be modiIied and
saved back in to database by pressing the save button. Please note that except truck no we
can modiIy all the Iields


Deleting Existing Truck: To delete an existing truck press truck no load button, this will
load all the available truck no Irom database into the truck no Iield
Select the truck no oI which we need to delete. When we select the required truck Ior
deletion the system will automatically display all the relevant data in the corresponding
Iields now we need to press the delete button to erase that particular selected truck
completely Iorm the database
Please note what ever records we are deleting will be separately stored in a temp table Ior
our reIerence and Iault analysis.


Recipe Master: To access the customer master we need to click in the recipe master
button which will open the recipe related details as shown in Iig4.4.








MCI360 Control System
17

Fig 4.4



Adding New Recipe: Press Add new button to start with adding a new recipe then start
entering the values in the Iollowing Iields
*Recipe code - Iield size (15)
*Recipe Name - Iield size (150)
Slump Iield type number and deIault value is 0
Aggregate bin 1 target Iield type number and deIault value is 0
Aggregate bin 2 target Iield type number and deIault value is 0
Aggregate bin 3 target Iield type number and deIault value is 0
Aggregate bin 4 target Iield type number and deIault value is 0
Aggregate bin 5 target Iield type number and deIault value is 0
Aggregate bin 6 target Iield type number and deIault value is 0
Cement Silo 1 target Iield type number and deIault value is 0
Cement Silo 2 target Iield type number and deIault value is 0
Cement Silo 3 target Iield type number and deIault value is 0
Cement Silo 4 target Iield type number and deIault value is 0
Filler Silo 1 or Cement silo 5 targets Iield type number and deIault value is 0
Water1 target Iield type number and deIault value is 0
Slurry target Iield type number and deIault value is 0
MCI360 Control System
18

Water2 or Ice target Iield type number and deIault value is 0
Admixture1 sort1 target Iield type number and deIault value is 0, 2 decimal place
Admixture1 sort2 target Iield type number and deIault value is 0, 2 decimal place
Admixture2 sort1 target Iield type number and deIault value is 0, 2 decimal place
Admixture2 sort2 target Iield type number and deIault value is 0, 2 decimal place
Silica target Iield type number and deIault value is 0
*Mixing time Iield type number and deIault value is 0, while entering should not be leIt
0 because based on this value the mixing process happens in the batching plant.
*Mixer Capacity - Iield type number and deIault value is 0, while entering should not be
leIt 0 because based on this value the mixing process happens in the batching plant.
Cement Water Percentage - Iield type number and deIault value is 0, basically this Iield is
given to alert the operator while batching to give intimation whether the cement water
percentage ratio exceeds. In this Iield the operator need to enter the desired cement water
percentage and based on the calculation iI the ratio is maintained in recipe then no
problem or else a warning message will be popped up every time the particular recipe is
batched
Cement Filler Percentage - Iield type number and deIault value is 0, basically this Iield is
given to alert the operator while batching to give intimation whether the cement Iiller
percentage ratio exceeds. In this Iield the operator need to enter the desired cement Iiller
percentage and based on the calculation iI the ratio is maintained in recipe then no
problem or else a warning message will be popped up every time the particular recipe is
batched
Water Ice Percentage - Iield type number and deIault value is 0, basically this Iield is
given to alert the operator while batching to give intimation whether the water ice
percentage ratio exceeds. In this Iield the operator need to enter the desired water ice
percentage and based on the calculation iI the ratio is maintained in recipe then no
problem or else a warning message will be popped up every time the particular recipe is
batched
Water Slurry Percentage - Iield type number and deIault value is 0, basically this Iield is
given to alert the operator while batching to give intimation whether the water slurry
percentage ratio exceeds. In this Iield the operator need to enter the desired water slurry
percentage and based on the calculation iI the ratio is maintained in recipe then no
problem or else a warning message will be popped up every time the particular recipe is
batched
Premixing time - Iield type number and deIault value is 0, this Iield can be used when we
are about to batch silica. The silica mix will be consistent iI it is premixed one and more
over there is an interlock available to make sure that silica target value is available.
Please note that the entire component which is entered in recipe has an interlock to make
sure that operator does not enter more then the prescribed weigher value.
Please note that in the above Iields what ever is marked with '* symbol is to be
considered as mandatory Iields and it should not be leIt blank or zero while going Ior a
save event. Once it is made sure that all the required Iields are Iilled then we need to
press save button to store the data into the database

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19
Modifying Existing Recipe: To modiIy an existing recipe press recipe code load button,
this will load all the available recipe code Irom database into the recipe code Iield.
Select the recipe code oI which we need to modiIy the data. When we select the required
recipe Ior modiIication the system will automatically display all the relevant data in the
corresponding Iields, later which ever Iield need to be modiIied can be modiIied and
saved back in to database by pressing the save button. Please note that except recipe code
we can modiIy all the Iields


Deleting Existing Recipe: To delete an existing recipe press recipe code load button, this
will load all the available recipe code Irom database into the recipe code Iield
Select the recipe code oI which we need to delete. When we select the required recipe Ior
deletion the system will automatically display all the relevant data in the corresponding
Iields now we need to press the delete button to erase that particular selected recipe
completely Iorm the database
Please note what ever records we are deleting will be separately stored in a temp table Ior
our reIerence and Iault analysis.

There is important inIormation to add up with is that when we go Ior an optional package
oI generic interIace soItware the entire master will be disabled except truck, user and
maintenance master as shown in Fig 4.5

Fig 4.5
MCI360 Control System
20

Fig 4.6

Order Master: To access the order master we need to click in the order master button
which will open the order related details as shown in Iig4.6.

Adding New Order: Press Add new button to start with adding a new order then start
entering the values in the Iollowing Iields
*Order No Iield size (50)
*Order Name Iield size (100)
*Customer Code Iield size (100).this is a non entry Iield we need to press the button
next to this Iield then all the data will be listed in the Iield through which we need to
select one.
*Truck Registration No Iield size (100).this is a non entry Iield we need to press the
button next to this Iield then all the data will be listed in the Iield through which we need
to select one.
Total Ordered Qty Iield type number and deIault value is 0, this Iield is given to
deIine the total quantity ordered by the customer.
Total with this load Iield type number and deIault value is 0, this Iield is given to
deIine the total load so Ior sent against the order.
Scheduled Order Qty Iield type number and deIault value is 0, this Iield is given to
deIine the scheduled order qty Ior the order iI we are about to execute the order in a
schedule. II the order is not executed in schedule then it need to be kept as 0.
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21
*Production Qty Iield type number and deIault value is 0, this Iield is given to deIine
the production qty. II the production qty was not deIined here then we can enter the
production qty while we start the production but it is better iI it is pre-deIined here.
Returned Qty Iield type number and deIault value is 0, this Iield is given to deIine
the production qty. II the production qty was not deIined here then we can enter the
production qty while we start the production but it is better iI it is pre-deIined here.
*Job No dummy Iield to enter a value which reIlects in docket printing. II not used
it has to be Iilled with 0 values.
*Aggregate Used - dummy Iield to enter a value which reIlects in docket printing. II
not used it has to be Iilled with 0 values. II need to be used then we need to Iill in
maximum size oI aggregate used Ior this order.
*Cement Used - dummy Iield to enter a value which reIlects in docket printing. II
not used it has to be Iilled with 0 values. II need to be used then we need to Iill in type oI
cement used Ior this order.
*Slump - dummy Iield to enter a value which reIlects in docket printing. II not used
it has to be Iilled with 0 values. II need to be used then we need to Iill in slump target
used Ior this order.
*Admixture Used - dummy Iield to enter a value which reIlects in docket printing.
II not used it has to be Iilled with 0 values. II need to be used then we need to Iill in type
oI admixture used Ior this order.
*Remarks - dummy Iield to enter a value which reIlects in docket printing. II not
used it has to be Iilled with '-'or '0 values. II need to be used then we need to Iill in any
special instruction required Ior this order.
*Account No - dummy Iield to enter a value which reIlects in docket printing. II
not used it has to be Iilled with 0 values.
*Type - dummy Iield to enter a value which reIlects in docket printing. II not used
it has to be Iilled with 0 values. II need to be used then we need to Iill in whether pump
is used or manual concreting is on in site Ior this order.
No oI trucks DeIault value 0 and it got no implication in order.
Please note that what ever Iield used in docket printing are oI Iield size (50).
Please note that in the above Iields what ever is marked with '* symbol is to be
considered as mandatory Iields and it should not be leIt blank or zero while going Ior a
save event. Once it is made sure that all the required Iields are Iilled then we need to
press save button to store the data into the database

Modifying Existing Order: To modiIy an existing order. Press order number load
button, this will load all the available order number Irom database into the order no Iield.
Select the order no oI which we need to modiIy the data. When we select the required
order Ior modiIication the system will automatically display all the relevant data in the
corresponding Iields, later which ever Iield need to be modiIied can be modiIied and
saved back in to database by pressing the save button. Please note that except order no we
can modiIy all the Iields


Deleting Existing Order: To delete an existing order press order number load button,
this will load all the available order no Irom database into the order no Iield
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22
Select the order no oI which we need to delete. When we select the required order Ior
deletion the system will automatically display all the relevant data in the corresponding
Iields now we need to press the delete button to erase that particular selected order
completely Iorm the database
Please note what ever records we are deleting will be separately stored in a temp table Ior
our reIerence and Iault analysis.


Fig 4.7

Schedule Master: To access the schedule master we need to click in the schedule master
button which will open the schedule related details as shown in Iig4.7.

Adding New Schedule: Press Add new button to start with adding a new schedule then
start entering the values in the Iollowing Iields
*Schedule ID Iield size (25)
*Schedule Type need to select any one among 2 available options alternative or
normal. The basic diIIerence between these 2 options is iI we choose alternative the order
is batched based on production qty and aIter completing the batch the scheduler will
automatically execute next order where as in normal mode it completes all qty speciIied
in schedule order qty oI order master then it starts executing the next order Irom the
scheduler.
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23
*Order list Ior schedule the available order need to selected Ior scheduling Irom the
order list use '~~ button to select and ' button to unselect to list the available order
click on list order button and select Irom the available list.
Please note that in the above Iields what ever is marked with '* symbol is to be
considered as mandatory Iields and it should not be leIt blank or zero while going Ior a
save event. Once it is made sure that all the required Iields are Iilled then we need to
press save button to store the data into the database

Modifying Existing Schedule: To modiIy an existing schedule. Press schedule ID load
button, this will load the entire available schedule id Irom database into the schedule id
Iield. Select the schedule id oI which we need to modiIy the data. When we select the
required schedule Ior modiIication the system will automatically display all the relevant
data in the corresponding Iields, later which ever Iield need to be modiIied can be
modiIied and saved back in to database by pressing the save button. Please note that
except order no we can modiIy all the Iields.


Deleting Existing Schedule: To delete an existing schedule press schedule ID load
button, this will load the entire available schedule id Irom database into the schedule id
Iield. Select the schedule id oI which we need to delete. When we select the required
schedule Ior deletion the system will automatically display all the relevant data in the
corresponding Iields now we need to press the delete button to erase that particular
selected schedule completely Iorm the database
Please note what ever records we are deleting will be separately stored in a temp table Ior
our reIerence and Iault analysis.

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24

Fig 4.8


User Master: To access the user master we need to click in the user master button
which will open the user related details as shown in Iig4.7.

Adding New User: Press Add new button to start with adding a new schedule then start
entering the values in the Iollowing Iields
*User Name Iield size (20)
*Password Iield size (14), please note that this Iield is a password Iield and it will be
displayed in '* symbol.
We have a provision to select the user rites Ior each and every event in the system as
shown in Iig 4.8.
Please note that in the above Iields what ever is marked with '* symbol is to be
considered as mandatory Iields and it should not be leIt blank or zero while going Ior a
save event. Once it is made sure that all the required Iields are Iilled then we need to
press save button to store the data into the database

Modifying Existing User: To modiIy an existing user. Press load user name button, this
will load the entire available user name Irom database into the user name Iield. Select the
user name oI which we need to modiIy the data. When we select the required user Ior
modiIication the system will automatically display all the relevant data in the
corresponding Iields, later which ever Iield need to be modiIied can be modiIied and
MCI360 Control System
25
saved back in to database by pressing the save button. Please note that except order no we
can modiIy all the Iields.


Fig 4.9

Inward Master: To access the inward master we need to click in the inward master
button which will open the inward related details as shown in Iig4.9.
The material inward master can be utilized in entering daily materials which are stocked
in the production area to save in database based on date wise click save to database
button then it will get stored Ior recording stock details which we will be seeing in below
chapters and iI we insist to change the inward item to some other values then we need to
use reset in database button to get the things done.











MCI360 Control System
26


Fig 4.10

Maintenance Master: To access the maintenance master we need to click in the
maintenance master button which will open the maintenance related details as shown in
Iig4.10.

Adding New Maintenance Instruction: Press Add new button to start with adding a
new maintenance instruction then start entering the values in the Iollowing Iields
*Maintenance Code Iield size (50)
*Maintenance Description Iield size (100) ,this is the maintenance instruction details
Duration in days Iield type number, deIault value 0
Duration in mixer running hours Iield type number, deIault value 0
Duration in production quantity Iield type number, deIault value 0
Among the above duration any one oI the duration should be speciIied to activate or
trigger the maintenance instructions.
Please note that in the above Iields what ever is marked with '* symbol is to be
considered as mandatory Iields and it should not be leIt blank or zero while going Ior a
save event. Once it is made sure that all the required Iields are Iilled then we need to
press save button to store the data into the database

Modifying Existing Maintenance Instruction: To modiIy an existing maintenance data.
Press load code button, this will load the entire available maintenance code Irom database
MCI360 Control System
27
into the maintenance code Iield. Select the maintenance oI which we need to modiIy the
data. When we select the required maintenance Ior modiIication the system will
automatically display all the relevant data in the corresponding Iields, later which ever
Iield need to be modiIied can be modiIied and saved back in to database by pressing the
save button. Please note that except order no we can modiIy all the Iields.


Deleting Existing Maintenance Instruction: To delete an existing maintenance press
load code button, this will load the entire available maintenance code Irom database into
the maintenance code Iield. Select the maintenance code oI which we need to delete.
When we select the required maintenance instruction Ior deletion the system will
automatically display all the relevant data in the corresponding Iields now we need to
press the delete button to erase that particular selected maintenance schedule completely
Iorm the database
Please note what ever records we are deleting will be separately stored in a temp table Ior
our reIerence and Iault analysis.






























MCI360 Control System
28
5. Schedule Start


Fig 5.1


The start schedule screen is where we need to select the schedule Ior execution. To get
into this screen we need to click on start schedule screen Irom the main screen which
opens a screen as shown in Iig 5.1 with already created schedule listed in the list box
Irom the schedule master database to start production we need to select one oI the
schedule Irom list box by double clicking on the schedule id which we need to batch by
doing this it will list all the details related to that schedule in its corresponding Iields in
case iI we need to change production quantity or production adjustment we can edit those
Iields in this screen apart Irom that all the other Iields are just a read only Iields Iinally
aIter doing all the required changes we need to press start schedule to start with the
production.
In case iI the control system is opted with generic interIace soItware then the screen will
be like as shown in Iig 5.2 and more over there wont be any schedule id available Ior
selection instead we will have ticket no which will be listed in it and we need to select
that to start the production, one thing we should note here is that in this screen there wont
be any Iacility to change production quantity or production adjustment quantity instead
we have a provision to change the mixer capacity and this is given because all the master
details are generated Irom the dispatch system the editing oI mixer capacity in recipe
master becomes impossible and to override this we have given an option to change the
MCI360 Control System
29
mixer capacity and moreover we can decide mixer capacity based on the mix design and
type oI plant which we are using since editing oI mixer capacity is very essential in the
plant end.



Fig 5.2
















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30
6. Mimic Text View


Fig 6.1

The Mimic text view screen which is shown in Iig 6.1 can be used in case iI we are not
preIerred to have our monitoring screen as graphics mimic screen as shown in Iig 6.2.
The only diIIerence in both the view is the graphical representation oI the batching plant
and there will be an approximate accuracy in the any input and graphical movement
events.
All the displays given in the screens like mixer running hours, mixing time, mixer mid
position, mixer discharge time and input Iield mixer mid position are common in both the
screen view.
MCI360 Control System
31

Fig 6.2





















MCI360 Control System
32
7. Plant Setup

The plant setup menu is the key menu to make any settings related to operation oI any
batching plant. The Iollowing are the key parameter settings which help an operator to
operate the plant in an eIIective way both operation and maintenance wise and certain
parameters in this menu help us to get material accuracy in batching process. To modiIy
any plant setup we need to press the plant setup button which is available in the top oI the
screen as shown in Iig 7.1.




Fig 7.1

a) Material in air
b) Coarse to Iin
c) Tolerance
d) Empty value
e) Discharge delay
I) Step time
g) Gate sequence
h) Jo on time
i) Other settings
MCI360 Control System
33
j) Calibration I
k) Calibration II
l) Calibration III
m) Calibration IV
n) Name setup
o) Other settings
p) Mixer / Moi calibration
q) Weigher Max Value

This chapter will brieI us all about all the above plant setup parameters in detail.

a) Material in air: To perIorm any setup activity Ior this parameter we need to
select Material in air option as shown in Iig 7.2


Fig 7.2

The terminology material in air or in Ilight weight is nothing but the assumed weight oI
material which remain in air Ior Iew milliseconds aIter closing oI gate / withdrawing any
(dosing / batching) output and beIore Ialling in to the weigher, this parameter value varies
based on plant to plant, material to material, material density, material size and distance
between the gate and weigher and this is applicable Ior all Iorm oI material like cement,
water etc
MCI360 Control System
34
b) Coarse to fine: To PerIorm any setup activity Ior this parameter we need to click
on the coarse to Iine button as shown in Iig 7.3



Fig 7.3

This parameter is basically used to control the Ilow and batching speed oI the material
and this parameter can not be used Ior all the dosing / batching process, it is only used Ior
aggregates and water1 component. The system actually structured in such a way that 2
gates and valves provided Ior both the aggregates and water component mechanically
these gates and valves are controlled based on the weight given in the corresponding
coarse to Iine Iields and the plc by reIerring the load dosed in the weigher controls the
aggregate coarse / Iine gate outputs and water coarse / Iine valve outputs.



c) Tolerance: To PerIorm any setup activity Ior this parameter we need to click on
the tolerance button as shown in Iig 7.4

MCI360 Control System
35

Fig 7.4


The tolerance option is used to Iix the below and above range oI weight which is
allowable Ior batching a material, apart Irom aggregates all the other materials have
individual tolerance. When we Iix certain value in tolerance Iields it acts as an input
value to veriIy the actual batched weights and popup alarms during auto batching, in case
iI the batched weight exceeds targeted weight tolerance then an alarm will popup
saying tolerance value exceeded and waits Ior acknowledgement beIore starting the next
material Ior batching iI it comes in the same series oI weighing and once the alarm is
acknowledged then it proceed Iurther by batching the next material oI the same weighing
series. In case iI the batched weight is below speciIied tolerance range then the system
will try to dose material by jogging and bring the weight with in the tolerance range.
DeIault value 15 Ior aggregate, 4 6 kg Ior cement, 3 kg Ior water / ice / silica and 10
(1*10) Ior admixture


d) Empty Value: To perIorm any setup activity Ior this parameter we need to
click on the empty value button as shown in Iig 7.5

MCI360 Control System
36


Fig 7.5

The empty value is nothing but the tare value oI all the weighers. To start the batch in
auto we need to ensure that there is no materials available in weigher so to identiIy that
we need to give some approximate weights in Kgs in empty value setting Iields which
will be considered as a 0 value oI weighers and while batching oI the materials the
system will alarm the operator in case the weigher has some material more to that oI
speciIied empty value and while discharging the system will try to discharge material
incase it doesn`t come below speciIied empty value range. The empty value should not
have huge values. Empty value should be set Ior all the weighers and should not be kept 0
in case the empty value is set to 0 then the system will always popup alarm weigher not
empty and may the discharge oI the material will be kept on hold. DeIault value 15 Ior
aggregate, 4 6 kg Ior cement, 3 kg Ior water / ice / silica and 10 (1*10) Ior admixture

e) Discharge Delay: To perIorm any setup activity Ior this parameter we need to
click on the discharge delay button as shown in Iig 7.6

MCI360 Control System
37


Fig 7.6

This parameter is set to sequence or line up the material discharge Irom the weigher to
the mixer. We all know that Iirst aggregates will be discharged in to the mixer and next to
aggregate all the other items this discharge event can be made as a sequence by
speciIying delay in milliseconds in the available Iields based on that the discharge event
will be made as a sequence. The higher limit Ior this is 15000.DeIault value 1000 Msec
Ior all the components.

f) Step Time: To perIorm any setup activity Ior this parameter we need to click on
the step time button as shown in Iig 7.7.
The step time is other wise known as weigher stability time or step up time Irom one
batching material to the other material. When target value is attained Ior a material then
system will wait until the step time (time delay given in milliseconds) is complete then it
stores the value with in plc memory then starts next material batch. DeIault setting 1600
Msec Ior all the components.


MCI360 Control System
38

Fig 7.7

g) Gate sequence: To perIorm any setup activity Ior this parameter we need to click
on the gate sequence button as shown in Iig 7.8.
In MCI 360 control system we can change the batching sequence oI the aggregate
gates as per our choice, iI we speciIy the batching order in the gate sequence Iields
the batching sequence will change based on the numbering that was speciIied in the
gate sequence Iields. DeIault sequence 1, 2,3,4,5 and 6.


MCI360 Control System
39

Fig 7.8

h) 1og on time: To perIorm any setup activity Ior this parameter we need to click on
the jog on time button as shown in Iig 7.9.
To control the gate / screw / valve operation during batching this parameter can be
used. When we batch it is not certain that always the weight batched in a batch will
continue in all batches some time it can go more or some time it can go less but the
system should make sure when it goes less it should always bring it to a tolerance
range, Ior example while targeting Ior 300 kg`s oI sand, while batching the system
batched till 285 Kg`s considering material in air, stock and Ilow oI the material and
the tolerance range is oI 10 kg`s in such case the system should not open the gate
Iully because the Ilow may be more and this could batch more quantity oI material
but the case here is it has to batch the 15 kg`s oI material to achieve the target or at
least 6 kg`s to make it Iall with in tolerance so in such cases the jog on time come in
to play based on the milliseconds time entered in the Iields the plc will give pulse to
respective solenoid coil or motors and the operation oI these gate / screw / valve is
controlled by this. DeIault value 400 Msec Ior all components except aggregate and
Ior aggregate 1000 Msec.

MCI360 Control System
40

Fig 7.9

i) Other settings: To perIorm any setup activity Ior this parameter we need to click
on the other settings button which is next to jog on time button as shown in Iig
7.10.
The other settings will have various other important parameters / settings oI the
batching plant as shown in Iig 7.10 the usage and inIormation about these parameters
are as Iollows.
Mix.Dis.Time (sec): This Iield is nothing but the mixer discharge time and we need
to give time delay in seconds Ior this Iield as input and based on the entered time
delay the mixer discharge gate is kept Iully open during auto operation while
discharging concrete in to the transit mixer. This parameter need to be site based on
the plant capacity and the deIined time cycle.
Mixer Open (sec): This Iield is nothing but the mixer halI discharge time and we
need to give time delay in seconds Ior this Iield as input and based on the entered
time delay the mixer discharge gate is kept partially open during auto operation while
discharging concrete in to the transit mixer. This parameter helps to avoid spillage
during discharge oI the concrete. This parameter need to be set based on the plant
capacity and the deIined time cycle.

MCI360 Control System
41


Fig 7.10
Pre.Mix.Time (sec): This parameter will be useIul only when we go Ior a silica
batching. This is an integer type Iield and we need to speciIy the pre-mixing time in
seconds, which in turn while discharging the materials in to the mixer the system will
Iirst discharge aggregate and silica together and enables this pre-mixing time delay
and aIter that delay is completed the system will start to discharge other materials
based on the speciIied discharge delay.
Wait.Hopp.Max (M"): This parameter is set to monitor the level oI the waiting
hopper during auto batch and based on this the level is calibrated and alarm is also
popped up. This is applicable only Ior plants which come with inclined conveyor Ior
aggregate discharge. !
Skip Up Delay (Msec): This parameter is set to avoid the skip waiting in the waiting
position Ior long time, in auto batch every time when the aggregate batch is complete
the system will move the skip up only considering the value given in this parameter.
Here the time delay has to be mentioned in milliseconds. This is applicable only Ior
plants which come with skip Ior aggregate discharge.
Moisture 1 Bin in No: This parameter is set to speciIy the system that moisture 1
sensing probe is Iitted in the corresponding bin number and auto moisture calculation
to be done by getting the signal Irom the probe.
MCI360 Control System
42
Moisture 2 Bin in No: This parameter is set to speciIy the system that moisture 2
sensing probe is Iitted in the corresponding bin number and auto moisture calculation
to be done by getting the signal Irom the probe.
Conveyor Run While Batch (sec): This parameter is set to make the conveyor run
while batching the aggregates to avoid heap Iormation and to make sand bed layer
over the belt. This is an integer value and the deIault value is 0.
Batching bin for conveyor run (Sec): This parameter has a relation with the
previous parameter because we need to deIine while batching which bin the conveyor
needs to be moved. DeIault value is 0.
Skip.Dis.Time (Sec): This parameter is used to deIine Ior how long the skip should
be place in the discharge position (top position).This is an integer type Iield and it
varies based on plant type need to be set based on time cycle, This is used only Ior
skip type plant.
Mixer.Off.Delay (Sec): Since heavy duty motors are used Ior mixers it is
recommended that the on and oII operations are not done at a Irequent intervals, to
avoid Irequent on / oII occurrence we have to speciIy the mixer oII delay. Normally
the mixer switches oII immediately aIter completion oI the auto batch and switches
on again when we start an auto batch, iI there is continuous concreting then switching
oII the mixer is not advisable to avoid these kind oI switch on/oII activity we have
provided this parameter. The mixer remains in on condition until the given time delay
in seconds is completed.
Discharge Pump Cut Off in Kg: This parameter is used Ior the plants which are
provided with both pressurized water discharge and gravity water discharge in the
water weigher and the weight or value that we give in this Iield will be taken as a
reIerence weight while discharging the water through pump (pressurized water
discharge) once the water weigher value reaches the speciIied cut oII value while
discharging immediately the water pump will switch oII and gravity discharge will
switch on. II the plant does not have pressurized discharge option then Iull weigher
capacity to be speciIied in the cut oII value.
Vibrator 1 connection for bin no: In this Iield / parameter we need to provide the
bin no which is installed with the vibrator 1 and based on this the vibrator operation
while batching made dynamic and in depended
Vibrator 2 connection for bin no: In this Iield / parameter we need to provide the
bin no which is installed with the vibrator 2 and based on this the vibrator operation
while batching made dynamic and in depended
Weight for conveyor run while batching: Along with bin no and conveyor running
time while batching we should also provide this weight Ior conveyor run while
batching taking this parameter / Iield as a reIerence, while batching the particular bin
no and aIter reaching the mentioned weight as per this parameter the conveyor will
run Ior the speciIied time during batching.
Start value for moisture in Kg: This parameter is set to deIine the start or initial
value to take moisture samples while auto moisture is enabled in auto batching, Ior
example iI we speciIy 50 kg as start value then the system will start considering the
samples Ior moisture correction once the batching weight crosses 50 kg only.
MCI360 Control System
43
Stop value for moisture in Kg: This parameter is vise versa to that oI start here we
need to speciIy when the system should stop taking the moisture samples while
batching.
Docket Type: MCI360 has an optional Iacility oI printing delivery docket apart Irom
printing batch report and to get this option you are requested to place an order
commercially and provide Iormat in which you require the DC to be printed and
based on your request the printing option will be made ready and a separate docket
type will be assigned. Right now the docket type available is 1 IJM, 2-RMC and 3
RDC.
Conveyor Runtime (Sec): This parameter deIines the runtime check Ior the
conveyor while discharge. Normally in all inline silo plants the material is weighed in
the conveyor and once the weighing is complete the material is discharged into skip
or in an inclined conveyor Irom the weighing conveyor. Incase the weighing
conveyor remains running continuously because oI not reaching empty value then the
system will take the conveyor runtime parameter as reIerence and stop the conveyor
aIter crossing the deIined time delay in seconds to stop material wastage.
Mixing Time in Sec: This parameter is also available Ior conIiguration in recipe
master in case iI it is required to change while batching then we can do that Irom
here.
Printer 1 on / off: This parameter is used to enable and disable printer. II we enter 1
in this Iield then it means enabled and 0 means disabled and this is Ior printer 1
connected to computers motherboard.
Printer 2 on / off: This parameter is used to enable and disable printer. II we enter 1
in this Iield then it means enabled and 0 means disabled and this is Ior printer 2
connected to computers motherboards add on card.
Cement Screw 1 flap disabled / enabled: In most oI the higher capacity plants a
butterIly valve will be provided in the dosing mouth end oI cement screw conveyor
which is near to that oI cement weigher, iI this Ilap is available then the cement 1 Ilap
should be enabled iI it is not available then it must be disabled. II this parameter is not
set correctly the cement batching both in auto and manual will not happen it is
because iI we had enabled this parameter with out connecting Ilap then the system
will look Ior Ilap Ieed back and stop batching and vice versa to the other way oI
selection.
II the Ilap is available then iI it is enabled the system will look Ior Ilap Ieedback then
switches on Ilap output Iirst then cement screw on Ior dosing.
Cement Screw 2 flap disabled / enabled: similar to that oI previous cement screw 1
Ilap disabled / enabled option
Cement Screw 3 flap disabled / enabled: similar to that oI previous cement screw 1
Ilap disabled / enabled option
Cement Screw 4 flap disabled / enabled: similar to that oI previous cement screw 1
Ilap disabled / enabled option
Cement Screw 5 flap disabled / enabled: similar to that oI previous cement screw 1
Ilap disabled / enabled option
Teach Mode On / Off: Teach mode on / oII option can be used to set material in air
automatically Ior one batch to get an idea oI approximate material in air but beIore
switching this on we need make sure that all the values in material in air is kept 0
MCI360 Control System
44
Continues / Discrete mode: Two modes oI batching available in MCI360 control
system continues and discrete. When we select continuous mode iI we batch a truck iI
a particular material in a particular batch exceeds the tolerance limit then the system
will automatically start to correct the exceeded weight in all the other subsequent
batches. When we select discrete mode what ever the excess weight batched the
system will target only as per the recipe value Ior all the batches which means there
won`t be any revision in target in between the batch.
Inline silo batcher / compartment batcher: This parameter is provided to select the
plant type whether the plant type is oI inline silo with weighing conveyor or
compartment type with skip weighing. II this is selected wrongly then the system will
malIunction while skip movement.
Skip Version / Inclined Conveyor Version: This is also one oI the parameter to
deIine whether the plant is with skip or inclined / ascending conveyor. II this is
selected wrongly then the system will malIunction.
j) Calibration I, II, III, IV: To perIorm any setup activity Ior this parameter we
need to click on the Calibration I, II, III, IV button as shown in Iig 7.11, 7.12,
7.13, 7.14 respectively.



Fig 7.11

The calibration in MCI360 can be carried out in 2 diIIerent modes one is auto and the
other is manual about which we will be brieIing in this topic. Calibration I screen is
MCI360 Control System
45
designed to calibrate 2 weighers per screen now we will see the available parameters
and it Iunctionalities.
Characteristic value: The characteristic value is one the essential parameter required
Ior calibration. The characteristic value is nothing but the mV /V categorizing value.
Normally all stetter plant comes with 2.
Filter Settings: This parameter is useIul in Iiltering the samples which means the
speed in which samples are required to be extracted Ior process, we recommend 2 hZ.
Weight: This is where we need to speciIy the total weight Ior calibration in case oI
manual and total load cell capacity Ior calibration in case oI auto.
Gross Weight: This is where the current weigher value is displayed.
Weigher off set mV: This parameter is used to speciIy the oIIset value oI the
weigher which is 0 mV.
Weigher full scale mV: This parameter is used to speciIy the Iull scale mV value oI
the weigher which 20 mV should be entered as 2.00 mV
Module Address: The module address is used to deIine the address in which the
weigher load cell is connected to. The Iollowing are the deIault module address
assigned to each weigher
Aggregate Module address 384
Cement Module address 384
Water Module address 400
Admixture 1 Module address 400
Ice Module address 416
Admixture 2 Module address 416
Silica Module address - 432
Weigher Channel Assignment: The parameter is used to deIine the channel to which
each and every individual weigher is connected. The Iollowing are the channel no
assigned to each weigher
Aggregate channel no 1
Cement channel no 2
Water channel no -1
Admixture 1 channel no -2
Ice channel no -1
Admixture 2 channel no 2
Silica channel no 1

Please note that parameters other then 'Module address and 'Weigher channel
assignment every thing remains same Ior all weighers.

One major diIIerence that occurs during admixture is that the decimal place we need
to speciIy the decimal place -2 in the Iield decimal place which converts the units oI
measurement Irom grams to kg.

MCI360 Control System
46

Fig 7.12


Calibration procedure for Auto Mode:
1. Click on the 'Manual / Automatic button to change the calibration mode.
The button must indicate 'Automatic.
2. Enter characteristic value as '2
3. Enter Filter Setting as '2 (iI we want to increase the sampling we can go
up to '5)
4. Decimal place 2 (only Ior admixture)
5. Enter the total capacity oI the load cell in the weight Iield
6. Weigher oIIset mV 0.00
7. Weigher Iull scale value 2.00
8. Module address depending the weigher as given above
9. Weigher channel assignment depending the weigher as given above
10. Click on Send and aIter 10 seconds
11. Click on Theoretical adjust button until it displays the weigher / tare
weight in the gross weight Iield and aIter 2 seconds
12. Click on Move Zero button until it displays zero value in the gross weight
Iield.
With the above 12 steps the weigher is ready to use Ior weighing purpose, now keep
some test weights in the weigher and cross check Ior accuracy
MCI360 Control System
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Fig 7.13

Fig 7.14

MCI360 Control System
48

Calibration procedure for Manual Mode:
This is a little time taking process. We need to Iollow the bellow steps to the
manual calibration.
1. Click on the 'Manual / Automatic button to change the calibration mode. The
button must indicate 'Manual.
2. Enter characteristic value as '2
3. Enter Filter Setting as '2 (iI we want to increase the sampling we can go up to
'5)
4. Decimal place 2 (only Ior admixture)
5. Enter the total weight that you are planning to calibrate Ior in the weight Iield. It
should not be more than the weigher capacity oI the plant
6. Weigher oIIset mV 0.00
7. Weigher Iull scale value 2.00
8. Module address depending the weigher as given above
9. Weigher channel assignment depending the weigher as given above
10. Click on Send and aIter 10 seconds
11. Click on Set Zero button until it displays zero in the gross weight Iield and aIter 5
seconds
12. Start loading the weights stones into the weigher, wait until all the weight stone
which was speciIied by you in the weight Iield is completely loaded.
13. Click on the Adjust button until it shows what ever weight loaded and what ever
weight entered in weight Iield in the gross weight Iield.
With the above 12 steps the weigher is ready to use Ior weighing purpose, now remove
loaded weight one by one and cross check Ior accuracy.

k) Name setup: To perIorm any setup activity Ior this parameter we need to click on
the name setup button as shown in Iig 7.15.
This is where we need to assign bins Ior all the materials Ior example iI we have Iilled
bin no 1 with 20 mm then physically we know that it is 20 mm but how do the system
know that`s why we need to teach the system, we need to Iill in the bin no in the
corresponding Iields oI this screen. Please note that iI a bin is not used then we should
enter as nil or N/A. The Iield length should not exceed 6 characters so we need to enter
the short Iorm oI the material names
Apart Irom entering the above we need to speciIy the current batch or docket no in
the batch number Iield. Please note that we can change the batch number by
adding few numbers ahead of current batch number in the batch number field
but to inform you that we cannot reduce the batch number from current batch
number by doing this it can result in data overwrite of adding up with the
existing batch data , Plant type need to be speciIied in the plant type Iield and the
reIerence is given in the right top corner oI the screen, always speciIy the correct
plant type choosing wrong plant type will result in malIunction oI the system.
We also have provision to enter the plant serial no and company name as a parameter
and to inIorm that these Iields are used in printout oI the delivery note and batch
report so please enter the correct inIormation and Iinally aIter Iilling all the
inIormation we need to click save button to get stored Ior usage.
MCI360 Control System
49

Fig 7.15

l) Other Settings: To perIorm any setup activity Ior this parameter we need to
click on the other settings button which is next to name setup button as shown in
Iig 7.16.
The other settings will have various other important parameters / settings oI the
batching plant as shown in Iig 7.16 the usage and inIormation about these parameters
are as Iollows.
Aggregate Fault Weight: Mainly Iault weight is reIerred while considering material
in air Ior batching. When we go Ior auto material in air or Ilow based the system will
be monitoring the Ilow Ior ever pulse during such process iI the bin is empty or there
is some Ioreign material stuck this could give a huge impact in subsequent batches on
such cases the Iault weight would be much useIul. DeIault value is 40
Cement Fault Weight: Similar to that oI the above. DeIault value is 20
Water Fault Weight: Similar to that oI the above. DeIault value is 20
Ice Fault Weight: Similar to that oI the above. DeIault value is 20
Admixture 1 Fault Weight: Similar to that oI the above. DeIault value is 5
Admixture 2 Fault Weight: Similar to that oI the above. DeIault value is 5


MCI360 Control System
50

Fig 7.16

Set Batching time aggregate in Sec: Here in this parameter we need to enter the
batching time oI the aggregate based on the time cycle recorded and thus this will
popup alarm aggregate batching time exceeded in case oI any deviation or time
consumption in aggregate batching. This is validated Ior time in seconds so please
enter an integer value which could be calculated as seconds
Set Batching time cement in Sec: Here in this parameter we need to enter the
batching time oI the cement based on the time cycle recorded and thus this will popup
alarm cement batching time exceeded in case oI any deviation or time consumption
in cement batching. This is validated Ior time in seconds so please enter an integer
value which could be calculated as seconds
Set Batching time water in Sec: Here in this parameter we need to enter the
batching time oI the water based on the time cycle recorded and thus this will popup
alarm water batching time exceeded in case oI any deviation or time consumption in
water batching. This is validated Ior time in seconds so please enter an integer value
which could be calculated as seconds
Set Batching time ice in Sec: Here in this parameter we need to enter the batching
time oI the ice based on the time cycle recorded and thus this will popup alarm ice /
water 2 batching time exceeded in case oI any deviation or time consumption in ice
batching. This is validated Ior time in seconds so please enter an integer value which
could be calculated as seconds.
MCI360 Control System
51
Set Batching time admixture 1 in Sec: Here in this parameter we need to enter the
batching time oI the admixture 1 based on the time cycle recorded and thus this will
popup alarm admixture 1 batching time exceeded in case oI any deviation or time
consumption in admixture 1 batching. This is validated Ior time in seconds so please
enter an integer value which could be calculated as seconds.
Set Batching time admixture 2 in Sec: Here in this parameter we need to enter the
batching time oI the admixture 2 based on the time cycle recorded and thus this will
popup alarm admixture 2 batching time exceeded in case oI any deviation or time
consumption in admixture 2 batching. This is validated Ior time in seconds so please
enter an integer value which could be calculated as seconds.
Set Batching time silica in Sec: Here in this parameter we need to enter the batching
time oI the silica based on the time cycle recorded and thus this will popup alarm silica
batching time exceeded in case oI any deviation or time consumption in silica batching.
This is validated Ior time in seconds so please enter an integer value which could be
calculated as seconds.
Set Discharge time water in sec: Here in this parameter we need to enter the
discharging time oI the water based on the time cycle recorded and thus this will popup
alarm water discharge time exceeded in case oI any deviation or time consumption in
water discharge. This is validated Ior time in milliseconds so please enter an integer value
which could be calculated as seconds. For example Ior 1 sec we need to enter as 1000 and
this Iield has a limit oI 30000.
Alarm Choice: In MCI360 audible alarm Iacility is provided we can select the language
choice oI our own on which while any important alarm occurrence the system will play
the recoded voice as an alarm.

Apart Irom setting all the above parameters we have a provision to set material in air
mode or material in Ilow mode Ior all the weigher modules.


m) Mixer / Moi Calibration: To perIorm any setup activity Ior this parameter we
need to click on the Mixer / Moi Calibration button as shown in Iig 7.17.
The mixer / moi calibration is nothing but the screen where we can perIorm the
calibration oI the mixer and moisture Iollowing are the procedures to perIorm the
mixer and moisture calibration.
Mixer calibration: To perIorm mixer calibration, when skip moves up Ior Iirst time
with material it waits at the waiting position to declare the mixer empty value during
such time click on mixer empty button this will automatically enable the skip
movement and once the skip reaches top position click on set maximum button and
this will determine the load actual to the system and with this reIerence the system
will check Ior material remains inside the mixer beIore discharging material in to
mixer Ior every batch.
The mixer calibration also becomes handy in measuring approximate slump value in
every batch, with the calibrated actual value we can reIer the trend in the moisture
slump screen as shown earlier Ior our Iurther reIerences.


MCI360 Control System
52

Fig 7.17



Moisture calibration: To perIorm the moisture calibrations Iirst reIer the moisture 1 & 2
raw value.
Then measure the out put voltage oI the sensor and check the raw value prepare a zero
moisture sample and keep on the surIace oI the probe once we are convinced that the
moisture sample kept on the probe is oI zero value then put the output voltage as oIIset
value in the oIIset Iield. For example iI we get 2 volt Ior zero sample then we need to put
oIIset value as 20 and this will make the raw value to zero.
Prepare a sample Ior 15 or 20 then keep it on the probe now measure the voltage
and reIer to the moisture raw iI the raw value shows 150 Ior 15 and 200 Ior 20 then
no need to change any thing iI it does not show that value based on the measured voltage
please change the moisture span.
This calibration procedure is applicable Ior both the moistures, only additional thing need
to be changed while moisture 2 calibrations is the moisture 2 address we need to keep
that Iield value as 368.




MCI360 Control System
53

n) Weigher Max Value: To perIorm any setup activity Ior this parameter we need
to click on the weigher max value button as shown in Iig 7.18.

Fig 7.18

In this setup we need to speciIy the maximum capacity oI all the weigher based on the
plant capacity taking this as a reIerence the system will automatically validate Ior the
wrong entry in the recipe master.














MCI360 Control System
54
8. Manual Operation


Fig 8.1


This provision is given to support the manual operation in case oI any Iailure in the
membrane keyboard which was provided Ior manual operation. Please to be
inIormed that this option need to be used only when there is a Iailure in membrane
keyboard and all the options are momentary event in this screen except Iew keys like
mixer on, conveyor on and skip up down etc.













MCI360 Control System
55
9. Report


To view statistical report we need to go to the report option as shown in Iig 9.1



Fig 9.1

The statistical reports were segregated into 2 parts, one part is production wise and
the other part is oI consumption wise, Iirst we will look on production wise reports
Total Production Report: Total production report gives us a statistical data on the
total production made Ior a particular period. To deIine the period we need to enter
Irom and to date and Iinally aIter selecting the date we need to click on print
preview button to enable the report view as shown in Iig 9.2 with this we can
identiIy the total production report Ior the particular period.

MCI360 Control System
56
Fig 9.2

Customer wise Production Report: There is a provision to view the statistical
report based on customer wise as shown in Iig 9.3.
This report can be viewed on selection basis which means we can view the report as
a total grouped by customer or only Ior individual customer.
This selection can be made Irom the given optional button as shown in Iig 9.3 to
view Ior all customer we need to select the Irom date, to date and click on the option
button all customers and then click on print preview and the statistical report will get
generated as shown in Iig 9.4, similarly to view the statistical data Ior a particular
customer we need to select Irom date, to date and click on code wise as shown in Iig
9.3 and select the desired code Irom the list then click on print preview this will
generate report Ior particular code wise as shown in Iig 9.4.
MCI360 Control System
57

Fig 9.3


Fig 9.4
MCI360 Control System
58


Recipe wise Production Report: There is a provision to view the statistical report
based on recipe wise as shown in Iig 9.5.
This report can be viewed on selection basis which means we can view the report as
a total grouped by recipe or only Ior individual recipe.
This selection can be made Irom the given optional button as shown in Iig 9.5 to
view Ior all recipe we need to select the Irom date, to date and click on the option
button all recipe and then click on print preview and the statistical report will get
generated as shown in Iig 9.6, similarly to view the statistical data Ior a particular
recipe we need to select Irom date, to date and click on code wise as shown in Iig
9.5 and select the desired code Irom the list then click on print preview this will
generate report Ior particular code wise as shown in Iig 9.6.


Fig 9.5




MCI360 Control System
59

Fig 9.6


Site wise Production Report: There is a provision to view the statistical report
based on site wise as shown in Iig 9.7.
This report can be viewed on selection basis which means we can view the report as
a total grouped by site or only Ior individual site.
This selection can be made Irom the given optional button as shown in Iig 9.7 to
view Ior all site wise data we need to select the Irom date, to date and click on the
option button all site and then click on print preview and the statistical report will
get generated as shown in Iig 9.8, similarly to view the statistical data Ior a
particular site we need to select Irom date, to date and click on code wise as shown
in Iig 9.7 select the desired code Irom the list then by selecting one oI the customer
code Irom the list it will list some sites which belongs to that customer in the site
list box then select the desired site and then click on print preview this will generate
report Ior particular code wise as shown in Iig 9.8.

MCI360 Control System
60

Fig 9.7


Fig 9.8
MCI360 Control System
61
Truck wise Production Report: There is a provision to view the statistical report
based on truck wise as shown in Iig 9.9.
This report can be viewed on selection basis which means we can view the report as
a total grouped by trucks or only Ior individual truck.
This selection can be made Irom the given optional button as shown in Iig 9.9 to
view Ior all truck wise data we need to select the Irom date, to date and click on the
option button all trucks and then click on print preview and the statistical report will
get generated as shown in Iig 9.10, similarly to view the statistical data Ior a
particular truck we need to select Irom date, to date and click on code wise as shown
in Iig 9.9 and select the desired code Irom the list then click on print preview this
will generate report Ior particular code wise as shown in Iig 9.10.This statistical
report will also give us a detail oI number oI trips carried out by each and every
trucks.


Fig 9.9


MCI360 Control System
62

Fig 9.10



Total Consumption Report: Total consumption report gives us a statistical data on
the total consumption happened material wise Ior a particular period. To deIine the
period we need to enter Irom and to date and Iinally aIter selecting the date we need
to click on print preview button to enable the report view as shown in Iig 9.11 with
this we can identiIy the total consumption details oI each and every individual
material Ior the particular period. The result oI the same will resemble as shown in
Iig 9.13 with the complete details oI all materials targeted and actual achieved.


MCI360 Control System
63

Fig 9.12


Fig 9.13
MCI360 Control System
64
Customer wise Consumption Report: There is a provision to view the statistical
report based on customer wise as shown in Iig 9.14.
This report can be viewed on selection basis which means we can view the report as
a total grouped by customer or only Ior individual customer.
This selection can be made Irom the given optional button as shown in Iig 9.14 to
view Ior all customer wise consumption report we need to select the Irom date, to
date and click on the option button all customers and then click on print preview and
the statistical report will get generated as shown in Iig 9.15, similarly to view the
statistical data Ior a particular customer we need to select Irom date, to date and
click on code wise as shown in Iig 9.14 and select the desired code Irom the list then
click on print preview this will generate report Ior customer wise consumption
details particular code wise as shown in Iig 9.15.


Fig 9.14


MCI360 Control System
65

Fig 9.15


Recipe wise Consumption Report: There is a provision to view the statistical
report based on recipe wise as shown in Iig 9.16.
This report can be viewed on selection basis which means we can view the report as
a total grouped by recipe or only Ior individual recipe.
This selection can be made Irom the given optional button as shown in Iig 9.16 to
view Ior all recipe consumption details we need to select the Irom date, to date and
click on the option button all recipe and then click on print preview and the
statistical report will get generated as shown in Iig 9.17, similarly to view the
statistical data Ior a particular recipe we need to select Irom date, to date and click
on code wise as shown in Iig 9.16 and select the desired code Irom the list then click
on print preview this will generate report Ior recipe wise consumption details oI
particular code wise as shown in Iig 9.17.


MCI360 Control System
66

Fig 9.16


Fig 9.17
MCI360 Control System
67
Site wise Consumption Report: There is a provision to view the statistical report
based on site wise as shown in Iig 9.18.
This report can be viewed on selection basis which means we can view the report as
a total grouped by site or only Ior individual site.
This selection can be made Irom the given optional button as shown in Iig 9.18 to view
Ior all site wise consumption details data, we need to select the Irom date, to date and
click on the option button all site and then click on print preview and the statistical report
will get generated as shown in Iig 9.19, similarly to view the statistical data Ior a
particular site we need to select Irom date, to date and click on code wise as shown in Iig
9.18 and select the desired code Irom the list then by selecting one oI the customer code
Irom the list it will list some sites which belongs to that customer in the site list box then
select the desired site and click on print preview this will generate report Ior site wise
consumption oI particular code wise as shown in Iig 9.19.


Fig 9.18

MCI360 Control System
68

Fig 9.19

Truck wise Consumption Report: There is a provision to view the statistical report
based on truck wise as shown in Iig 9.20.
This report can be viewed on selection basis which means we can view the report as
a total grouped by trucks or only Ior individual truck.
This selection can be made Irom the given optional button as shown in Iig 9.20 to
view Ior all truck wise consumption details data we need to select the Irom date, to
date and click on the option button all trucks and then click on print preview and the
statistical report will get generated as shown in Iig 9.21, similarly to view the
statistical data Ior a particular truck we need to select Irom date, to date and click on
code wise as shown in Iig 9.20 and select the desired code Irom the list then click on
print preview this will generate report Ior truck wise consumption details oI
particular code wise as shown in Iig 9.21.

MCI360 Control System
69

Fig 9.20


Fig 9.21
MCI360 Control System
70
Daily Consumption Report:


Fig 9.22

The day wise consumption or daily consumption details will provide us a statistical data
report oI each and every material consumed in a A3 Iormat by which we can come to
know the total material consumed bin wise Ior a particular period oI time which we need
to speciIy in Irom and to date.

Batch No Wise Production Report: The Production statistical data can also be viewed
batch no wise as shown in Iig 9.23.
Enter the Irom batch no and to batch no and then click print preview when we do this the
system will automatically Ietch records Irom database oI those batch numbers which Iall
in the range oI the speciIied Irom and to batch no .
The result oI the same will be like as shown in Iig 9.24


MCI360 Control System
71

Fig 9.23


Fig 9.24
MCI360 Control System
72
Raw Material Inward Report: We all know that there is a provision Ior registering the
material inward into the database through our master entry, this report Iacilitate us to
view the records oI the inward activity on a periodic basis.
To do so we need to speciIy the Irom date and to date then click on print preview as
shown in Iig 9.25 then the system will automatically starts to Ietch records which Iall in
such condition Irom the database, so what ever inward activity carried out during the
speciIied period will be listed in reports.

Fig 9.25

Maintenance Detailed Report: The maintenance detailed report will give us complete
details on the maintenance schedule which has been created and among them which has
been triggered Ior attention in the system over all we can say that this report gives us the
complete history oI the maintenance schedule like when occurred who responded to it
when was the action taken etc. please reIer Iig 9.26 and 9.27 Ior viewing maintenance
report. To view a selective maintenance history we need to select the maintenance code
and click print preview by this the system will show all the maintenance history carried
out Ior this particular code.

MCI360 Control System
73

Fig 9.26


Fig 9.27
MCI360 Control System
74
Delivery Note Duplicate Copy: The delivery note or the autographic record which is
generated online aIter completion oI the batch can be reprinted Ior a duplicate copy by
speciIying the batch no and batched year as shown in Iig 9.28 once the we click on the
print button aIter speciIying the batch no and batched year the system will automatically
print autographic record as shown in Iig 9.29.Please make sure that printer is connected
and in good condition during print action.


Fig 9.28

MCI360 Control System
75

Fig 9.29

Customer Master: This will give us all the available data related to the customer Irom
the customer master database. We can view customer details code wise as well as all
customers as shown in Iig 9.30.
To view all customers we need to select the all customer option and then we need click
on print preview option.
To view a particular customer we need to click on code wise option then click on get
customer button to get the customer code in the list box then select the desired customer
code Irom the list box and then click on print preview as shown in Iig 9.30 and this will
give us report as shown in Iig 9.31.

MCI360 Control System
76

Fig 9.30

Fig 9.31

Site Master: This will give us all the available data related to the site Irom the site
master database. We can view site details code wise as well as all sites as shown in Iig
9.32.
To view all sites we need to select the all sites option and then we need click on print
preview option.
To view a particular site we need to click on code wise option then click on get customer
button to get the customer code in the list box then select the desired customer code and
by selecting desired customer it will list available site Ior that particular customer in the
site list box then select the site Irom that list box and then click on print preview as
shown in Iig 9.32 and this will give us report as shown in Iig 9.33.
MCI360 Control System
77


Fig 9.32


Fig 9.33
Recipe Master: This will give us all the available data related to the recipe Irom the
recipe master database. We can view recipe details code wise as well as all recipes as
shown in Iig 9.34.
To view all recipes we need to select the all recipe option and then we need click on print
preview option.
To view a particular recipe we need to click on code wise option then click on get recipe
button to get the recipe code in the list box then select the desired recipe code Irom the
list box and then click on print preview as shown in Iig 9.34 and this will give us report
as shown in Iig 9.35.
MCI360 Control System
78

Fig 9.34



Fig 9.35


Truck Master: This will give us all the available data related to the truck Irom the truck
master database. We can view truck details code wise as well as all truck as shown in Iig
9.36.
To view all trucks we need to select the all trucks option and then we need click on print
preview option.
MCI360 Control System
79
To view a particular truck we need to click on code wise option then click on get truck
button to get the truck code in the list box then select the desired truck code Irom the list
box and then click on print preview as shown in Iig 9.36 and this will give us report as
shown in Iig 9.37.


Fig 9.36


Fig 9.37

Order Master: This will give us all the available data related to the order Irom the order
master database. We can view order details code wise as well as all order as shown in Iig
9.38.
To view all order we need to select the all orders option and then we need click on print
preview option.
MCI360 Control System
80
To view a particular order we need to click on code wise option then click on get order
button to get the order code in the list box then select the desired order code Irom the list
box and then click on print preview as shown in Iig 9.38 and this will give us report as
shown in Iig 9.39.


Fig 9.38


Fig 9.39

Schedule Master: This will give us all the available data related to the schedule Irom the
schedule master database. We can view schedule details code wise as well as all
schedules as shown in Iig 9.40.
To view all schedules we need to select the all schedules option and then we need click
on print preview option.
MCI360 Control System
81
To view a particular schedule we need to click on code wise option then click on get
schedule button to get the schedule code in the list box then select the desired schedule
code Irom the list box and then click on print preview as shown in Iig 9.40 and this will
give us report as shown in Iig 9.41.


Fig 9.40


Fig 9.41

Batch Report: The batch report gives the statistical data oI batched details grouped by
batch no to view this report we need to speciIy the Irom and to date and click on print
preview as shown in Iig 9.42 this will generate the report Ior that particular time period as
shown in Iig 9.43.This will give us a clear report on batch so Iar completed.

MCI360 Control System
82

Fig 9.42


Fig 9.43



MCI360 Control System
83
Docket Reprint: This Iacility will be useIul iI we had opted Ior 2
nd
online printout which
was discussed in our early chapter. Here we have an option oI reprinting the printout
duplicate copy. To reprint the docket enter batch no in the batch no Iield and then batch
year then click on print button as shown in Iig 9.44 and this will print the docket
duplicate copy.


Fig 9.44

Hour wise Consumption Report: The hour wise consumption report gives us a
statistical report on consumption made Ior all materials on hour basis to view this report
We need to select the date Ior which we need to get the data then we need to speciIy Irom
time in HH:MM AM / PM Iormat and To time with the range oI 1 hour in HH:MM
AM/PM Iormat and iI interested to view the midnight report then iI the data covers the
next day then we need to click on next day check box as shown in Iig 9.45 the click on
print preview button to view the consumption details hour wise.
MCI360 Control System
84

Fig 9.45

Manual Consumption: The manual consumption is also recorded in MCI360 control
system, when we batch concrete manually we need to Iollow the below procedure to
make sure that all the data get stored in database.
Step 1 batch all the materials as per the required quantity
Step 2 take the skip bucket up or load the material in to the waiting hopper through
inclined / ascending conveyor incase oI inclined conveyor plant.
Step 3 when skip discharge starts then discharge cement and other relevant materials and
in case oI inclined conveyor plant discharge waiting hopper, cement and water etc all to
gather by this the system will register the manually batched data.
Please note that incase iI aggregate is not batched then also we need to take the skip to
top position beIore discharging cement to store the data into database and same Ior
inclined conveyor too iI the aggregate is not batched then also we need to click on
waiting hopper discharge to store the data into database.
To view the manual consumption report we need to enter Irom and to date in
DD/MMM/YY Iormat then click on print preview button as shown in Iig 9.46. II the
manual batch is done Ior that period it will get displayed otherwise it will not display.
MCI360 Control System
85

Fig 9.46

Mix wise Daily Consumption: Mix wise daily consumption is similar to that oI recipe
wise consumption details the only diIIerence among these two reports is the material is
presented in column wise in mix wise daily consumption and row wise in recipe wise
consumption and we can also say that code wise selection is not possible in mix wise
daily consumption report.
To view this report we need to speciIy Irom date and to date then click print preview to
display the statistical data

MCI360 Control System
86

Fig 9.47

Customer Wise Daily Consumption: Like mix wise daily consumption customer wise
daily consumption report is also similar to that oI customer wise consumption report only
diIIerence is the data is presented in column wise in customer wise daily consumption
compared to customer wise consumption details and apart Irom that here is customer
wise daily consumption code wise selection is not possible.
To view customer wise daily consumption report we need to speciIy Irom and to date
then click on print preview as shown in Iig 9.48. II the auto batch is batched Ior that
period then the system will Ietch the record Irom database and display.

MCI360 Control System
87

Fig 9.48

Stock: II we Iollow the inward entries Irom the initial stage then we can get stock report
with out any deviation because the stock report is completely depended to inwards and
consumptions made Ior the particular period in auto batch. The stock details will give us
material opening stock which is the last month closing stock and material inward Ior the
month and material consumed Ior the month and current closing stock Ior the month as
shown in Iig 9.50.
To view the stock details we need to speciIy Irom date and to date then click on print
preview as shown in Iig 9.49 this will display the stock details as shown in Iig9.50.
MCI360 Control System
88

Fig 9.49


Fig 9.50
MCI360 Control System
89
Slump: As discussed in our earlier chapters approximate slum value will be registered in
to the database Ior each and every batch to view that slump occurrence in a graph Iormat
we can go to slump report and give the batch no Ior which we need the approximate
slump value and batch year should be mentioned as '0 as shown in Iig 9.51 then we will
get the result Ior that particular batch no as shown in Iig 9.52.


Fig 9.51
MCI360 Control System
90

Fig 9.52

Please note that while viewing any periodic report make sure that you always enter to
date grater then that oI Irom iI you select or enter to date less to that oI Irom date then the
system will not give you proper report.
Please note that some oI the reports will not be available or work properly iI you have
opted Ior MCI360 generic interIace as the masters in MCI360 will be masked or not put
in use. The Iollowing are Iew reports which will not be used
Delivery duplicate report, docket reprint , all master reports and some reports which is
depended on master data.







MCI360 Control System
91
10. Alarm Accept

This button is provided in the main screen to acknowledge all the alarms to proceed
Iurther with the process. Please note that you read the alarm Iirst beIore acknowledge
because all the alarms need attention beIore acknowledging.



11. Help Option


Fig 11.1

The help option is provided to get some inIormation about the system like input output
status as shown in Iig 11.2 and some drawing tips as shown in Iig 11.1 (optional).We can
also perIorm reIresh database Irom this screen with out losing any data Irom master
details.
Please not iI you reIresh database it will delete all batch details Irom the existing database
so beIore reIreshing please copy arun Iolder into some other location beIore reIreshing
database.

MCI360 Control System
92

Fig 11.2

12. Diver Concrete

Divert concrete option is provided to divert concrete Irom one site to other site or even
Irom customer to other customer as shown in Iig 12.1.
To divert a concrete we need to Iollow the below procedures.

Step 1: Click on load batch no
Step 2: Select the batch no which needs to be diverted which will list down the current
details oI the batch
Step 3: Select customer code to which the concrete is diverted
Step 4: Select site to which the concrete is diverted
Step 5: Change the ordered qty as per the diverted customers order details
Step 6: Change the with this load qty as per the diverted customer order details
Step 7: Press divert now to update the changes into database
MCI360 Control System
93

Fig 12.1

Please note that since master details are masked in MCI360 generic interIace soItware
divert concrete option will not be possible iI you have opted Ior third party interIace.

13. Exit

To close the soItware we need to press the exit button this will close the entire project
including the MCI360 Generic interIace SoItware.

14. MIMIC Screen

The mimic screen will give you the pictorial representation oI the entire process that is
going on in plant but please not it is just an animation and approximate occurrence oI the
event and please do not ever compare it with real time events. The other display oI details
is just as similar to that oI mimic text view like display mixer running hours, mixer halI
open, mixer Iull open, mixer discharge time and mixing time etc.





MCI360 Control System
94
15. Mixer Gate Locked / Unlocked

The system will automatically lock the mixer gate on every Iirst batch oI production
quantity execution in auto batching and we can unlock once we make sure that truck is
placed in the correct position to perIorm this activity this button is provided in the main
screen.


16. Alarm View

Alarm view screen provides us history oI the entire alarm occurrence, i.e iI we want to
see the last occurrence oI aggregate tolerance alarm then we can browse through this
screen and enable the scroll bar in the alarm view and see the occurrence oI such alarm as
shown in Iig 16.1.
Please note that the alarm history will display the last 1000 occurrence to view beIore
that the stetter representative should be contact as the data need to be brought Irom the
classiIied division oI alarm status.


Fig 16.1




MCI360 Control System
95
17. Wtr Direct

Wtr direct is nothing but the water direct on option which is provided to switch on the
water directly into the mixer through a solenoid valve Irom the water line which comes to
the plant, this Iacility is mechanically available in all higher capacity plants to use this
option the wtr direct on button has been provided.

18. View Maintenance Message

The view maintenance message enabled or disabled button is provided to enable the list
view control oI the maintenance schedule which is triggered as per the triggering duration
conIigured in maintenance schedule master so what ever maintenance triggered on the
process that can be viewed through this provision as shown in Iig 18.1


Fig 18.1

19. Tips and Troubleshoot

The Iollowing are Irequently occurred problems and remedies to that

1. Auto start not possible.
Solution: check whether computer name is given as batchingplant, check whether sql
servers is running and check whether database context does not exist error occurs.
MCI360 Control System
96
2. Communication loss:
Solution: Check Ior cp5611 or tsadaptor is in working condition to check that go to set
pg/pc interIace in control panel and do diagnosing process.






"# $ "%&'()

















"#$%& '()*







CabIe List for M1- MCI 360 EIectronics & Automation Department
CabIe From CabIe To Comments
S.No. Size Of Cable Mtrs Name Ferrule No. Size Of Cable Mtrs Name FerruleNo.
1 4*50 Cu L1
or L2
4*95 Al L3 SuppIy Iine to
N controI paneI
PE by customer
2 4*2.5 15 X2M 11U 1M1 U
11V V Compressor
11W W
PE PE
X2M
3 4*1.5 18 1 21U 2M1 U Sand Vibrator 1
2 21V V
3 21W W
4 PE PE
X2M
4 4*1.5 18 5 22U 2M2 U Sand Vibrator 2 OPTONAL
6 22V V
7 22W W
8 PE PE
5 4*1.5 16 X2M 23U 2M3 U Cement Vibrator
23V V
23W W
PE
6 4*2.5 30 X2M 31U 3M1 U
31V V Cement screw conveyor 1
31W W
PE PE
7 4*2.5 30 X2M 32U 3M2 U
32V V Cement screw conveyor 2
32W W
PE PE
8 4*2.5 30 X2M 33U 3M3 U
33V V Screw filler
33W W OPTON
PE PE
9 4*4 15 X2M 41U 4M1 U
41V V Skip motor
41W W
PE PE
10 4*2.5 14 X2M 51U 5M1 U Water Pump
51V V
51W W
PE PE
19.06.2006- Page 1 of 6
CabIe List for M1-MCI 360 EIectronics & Automation Department
CabIe From CabIe To Comments
S.No. Size Of Cable Mtrs Name Ferrule No. Size Of Cable Mtrs Name FerruleNo.
11 7*6 10 X2M Brown 6M1 U1 Mixer Motor
Red V1
Grey W1
Blue W2
Black U2
White V2
PE PE
12 4*1.5 15 X2M 71U 7M1 U
71V V Admixture 1 dosing pump
71W W
PE PE
13 4*1.5 15 X2M 72U 7M2 U Admixture 2 dosing pump
72V V
72W W
PE PE
14 4*1.5 15 X2M 711U 7M11 U
711V V Admixture 1 Discharge pump
711W W
PE PE
15 4*1.5 15 X2M 712U 7M12 U Admixture 2 Discharge pump
712V V
712W W
PE PE
19.09.2006 - Page 2 of 6
CabIe List for M1 - MCI 300 EIectronics & Automation Department
CabIe From CabIe To Comments
S.No. Size Of Cable Mtrs Name Ferrule No. Size Of Cable Mtrs Name FerruleNo.
17 7 * 0.34 25 MX1 X19.1
Blue 1 1&2 Loop Black Aggregate loadcell
Green 2 terminal box X19.1
Brown 3 3&4 Loop Red
Grey 4
White 6 Green
Pink 5 White
Shield 15
X19.1 1 Load Red Load cell aggregate
2 Cell Black
3 Green
4 White
5 Shield
18 7 * 0.34 25 MX2 X19.2
Blue 1 1&2 Loop Black Cement loadcell
Green 2 terminal box X19.2
Brown 3 3&4 Loop Red
Grey 4
White 6 Green
Pink 5 White
Shield 15
X19.2 1 Load Red Load cell Cement
2 Cell Black
3 Green
4 White
5 Shield
19 7 * 0.34 25 MX3 1 1&2 Loop X19.3
Blue 1 Black Water loadcell
Green 2 3&4 Loop terminal box X19.3
Brown 3 Red
Grey 4
White 6 Green
Pink 5 White
Shield 15
X19.3 1 Load Red Load cell Water
2 Cell Black
3 Green
4 White
5 Shield
19.06.2006 - Page 3 of 6
CabIe List for M1 - MCI 300 EIectronics & Automation Department
CabIe From CabIe To Comments
S.No. Size Of Cable Mtrs Name Ferrule No. Size Of Cable Mtrs Name FerruleNo.
20 7 * 0.34 25 MX4 X19.4
Blue 1 1&2 Loop Black Admixture-1 loadcell
Green 2 terminal box X19.4
Brown 3 3&4 Loop Red
Grey 4
White 6 Green
Pink 5 White
Shield 15
X19.4 1 Load Red Load cell Admixturte-1
2 Cell Black
3 Green
4 White
5 Shield
21 7 * 0.34 25 MX5 X19.4
Blue 1 1&2 Loop Black Admixture-2 loadcell
Green 2 terminal box X19.4
Brown 3 3&4 Loop Red
Grey 4
White 6 Green
Pink 5 White
Shield 15
X19.4 1 Load Red Load cell Admixture-2
2 Cell Black
3 Green
4 White
5 Shield
19.06.2006 - Page 4 of 6
CabIe List for M1 - MCI 300 EIectronics & Automation Depatment
CabIe From CabIe To Comments
S.No. Size Of Cable Mtrs Name Ferrule No. Size Of Cable Mtrs Name FerruleNo.
22 2*1 10 G1-F 2 2*1 X6:17 Gate1 Fine Open sensor
X2:5
23 2*1 10 G2-C 3 2*1 X6:18 Gate2 Corase Open sensor
X2:5
24 2*1 10 G2-F 4 2*1 X6:19 Gate2 Fine Open sensor
X2:5
25 2*1 12 G3-F 6 2*1 X6:21 Gate3 Fine Open sensor
X2:5
26 2*1 10 G4-F 8 2*1 X6:23 Gate4 Fine Open sensor
X2:5
27 18 * 1 5 X6
1 1 2Y1.1 X6:61 Gate1 Fine
2 2 2Y2 X6:62 Gate2 Coarse
3 3 2Y2.1 X6:63 Gate2 Fine
4 4 2Y3.1 X6:65 Gate3 Fine
5 5 2Y4.1 X6:67 Gate4 Fine
6 6 3Y31 X6:87 Cement Discharge
7 7 5Y4 X6:92 Water Pump Discharge
8 8 5Y3 X6:91 Water Gravity Discharge
9 9 7Y1 X6:81 Admixture 1 Sort-1
10 10 7Y11 X6:85 Admixture 1 Discharge
11 11 5Y1 X6:88 Water Dosing Coarse
12 12 5Y2 X6:90 Water Dosing Fine
13 13 3Y1 X6:93 Cement Blowoff-1
14 14 3Y2 X6:94 Cement Blowoff-1
15 15 3Y31 X6:95 Cement Blowoff-1
16 16 X2:5 24V +ve
17 17 X2:6 Second wires of all solinoid
18 18 Spare to be connected with 24V -ve
19.06.2006 - Page 5 of 6
CabIe List for M1 - MCI 300 EIectronics & Automation Department
CabIe From CabIe To Comments
S.No. Size Of Cable Mtrs Name Ferrule No. Size Of Cable Mtrs Name FerruleNo.
28 9 6S33 1 2*1 X6:30 Mixer gate mid-position sensor
X2:5
29 9 S5 2 2*1 X6:33 Skip bottom sensor
X2:5
30 14 S2 3 2*1 X6:34 Slacksteel Sensor
X2:5
31 11 S4 4 2*1 X6:35 Skip Waiting position Sensor
X2:5
32 10 S3 5 2*1 X6:36 Skip Top Sensor
X2:5
33 9 6S31 6 2*1 X6:31 Mixer Gate open senor
X2:5
34 9 6S32 7 2*1 X6:32 Mixer Gate close sensor
X2:5
35 13 5S36 8 2*1 X6:29 Water scale gate open
X2:5
36 14 3S36 9 2*1 X6:28 Cement scale gate open
X2:5
37 15 4R1 12 2*1 X3:1 Skip Motor protection
4R1 13 X3:2 Skip Motor protection
38 10 6R2 12 2*1 X3:3 Mixer Motor protection
6R2 13 X3:4 Mixer Motor protection
39 15 6Y1 1 2*1 X6:75 Mixer Gate Open Solinoid
X2:6
40 15 6Y2 2 2*1 X6:76 Mixer Gate Close Solinoid
X2:6
41 15 3 2*1 10 Brake coil
4 11 Brake coil
42 10 Z1 7 2*1 X3:5 Hooter
Z1 8 X3:6 Hooter 230V Neutral
43 5 S6 9 2*1 X3:11 Skip bottom limit switch
12 S8 X3:10 Mixer cover limit switch
13 S7 10 2*1 X3:11 Skip Top limit switch
19.06.2006 - Page 6 of 6


"# $ "%&'()

















"#$%& '$%() *+)(







M1 MCI-360 (COMPARTMENT BATCH) - SPARE PARTS LIST
SL.NO REF.NO DESCRIPTION PART. NO REMARKS
1 0Q1 MCCB 160 AMPS WTH UV COL 80400437
2 UNDER VOLTAGE COL 230V 3VL9400-1UH00 80400381
3 0Q1 FRONT DRVE FOR MCCB 3VT9100-3MG12 80400382
4 0F1 MNATURE CRCUT BREAKER 1P/1A 60574460
5 1F2,1F3 MN CRCUT BREAKER - 1P 2A 230VAC 60574461
6 1F4,1F5 MNATURE CRCUT BREAKER 1P 6A 24V DC 60574464
7 1F1 MNATURE CRCUT BREAKER 2P 6A 80000075
8 TERMNAL FOR MPCB 3 PHASE 3VU9135 -1BB01 80400378
9 BUS BAR 4 POLE 63A 3VU 9135 - 1AB04 80400377
10 3Q27 MPCB 0.4 - 0.6 - 3VU1340 80400368
11 1Q1 MPCB 4-6A 3VU1340 1MK00 80400336
12 5Q36 MPCB 14 - 20 - 3VU1340 - MN00 80400375
13 4Q1 MPCB - 28 - 40A/3VU16401MQ00 60573858
14 3K27,2K26,2K27,7K1,7K2. CONTACTOR 9A - 3TF3010 0AM0 60574493
7K11,7K12,4K3
15 3K1,3K2,3K5,5K11 CONTACTOR 32 A 3TF3400 0AM0 60574497
16 Z1 BUZZER 2 TONES 230V 50HZ 80000076
17 6T TMER FOR STAR DELTA 80400343
18 4U1 3PH. UNBALANCED RELAY 80000060
19 Z2 FAN & FLTER UNT SK3323.100 82500065
20 OUTLET FLTER SK3323.200 82500066
21 DOOR STAY - PS4583 82500071
22 CROSS RAL TS 35/7.5(2M)-SZ2313.750 80000081
23 TERMNAL BOX 200X150X80 -KL1528.210 60572780
24 CABLE RETANER (NCLNED)-SZ2366.000 80000082
25 DOUBLE CHANGE OVR RELAY MODULE-24VDC 5A 80000078
26 MX1,MX2,MX3,MX4,MX5 LOAD CELL NTERFACE MODULE 80000383
27 1T3 POWER SUPPLY 230AC/24VDC/5A/F 80000064
28 EARTH TERMNAL USLKG 5-1 60571207
29 EARTH TERMNAL 16SQ.MM USLKG 16 60571208
30 DOUBLE TERMNAL BLOCK 4SQ.MM UDK4 60571190
31 END COVER FOR UDK4 60571192
32 SNGLE TERMNAL 5SQ.MM UK5N 60571177
33 DOUBLE DECKER TERMNAL BLOCK 5SQMM UKK5 60573389
34 END COVER FOR UKK5 D-UKK3/5 60573390
35 END BRACKET E/UK 80000065
36 ZACK STRP UNPRNTED TERMNAL STRP 6.2M 80000066
37 FXED BRDGE BAR FB 10-6 80000068
38 SNGLE TERMNAL 16 SQMM 82500079
39 CABLE GLAND PG9 60574266
40 CABLE GLAND PG 11 60574267
41 CABLE GLAND PG13.5 60574268
42 CABLE GLAND - PG21 60571277
43 COUNTER NUT - PG9 60574276
44 COUNTER NUT - PG11 60574277
45 COUNTER NUT - PG13.5 60574278
46 COUNTER NUT - PG21 60573200
47 PVC CHANNEL SLTTED -60X60 80000120
48 PVC CHANNEL SLTTED -1000*45*60 80000121
49 PVC CHANNEL SLTTED 60x25 80000122
50 1T1 TRANSFORMER 80000123
51 NDUCT. PROX. SWTCH B5124/BE2020-FRKG 60573994
52 15 PN D SUB CONNECTOR 80000384
53 HOOD FOR 9 PN D SUB CONNECTOR 80000377
54 HOOD FOR 15 PN D SUB CONNECTOR 80000385
55 ELECTRO VALVE ADAPATER 80000505
56 LMT SWTCH 10A 500V 1NC 80000058
57 7Q1,7Q11,7Q12 MPCB 1.6 - 2.4A - 3VU1340 MH00 80400372
58 3Q1 MPCB 18 - 25A - 3VU1340 - MP00 80400376
59 EARTHNG BAND L=575 MM 80000239
60 9 PN D-SUB CONNECTOR - MALE 80000373
61 UPS 600VA(NUMERC) 80400256
1
M1 MCI-360 (COMPARTMENT BATCH) - SPARE PARTS LIST
62 BOX TERMNAL FOR 80/50A 80400344
63 AUX. BLOCK-1NC 3TX40012A FOR 32A CONTAC 80400341
64 AUX. BLOCK-1NO 3TX40102A FOR 32A CONTACT 80400342
65 AUXLARY BLOCK FOR MPCB 82500103
66 PRNTER EPSON LQ1150 80400019
67 METRC GLAND M32*1.5 80400431
68 METRC GLAND M40*1.5 80400432
69 METRC GLAND REDUCER M50*1.5 80400433
70 PROTECTON HOSE SLVYN 61746940 PG9 GREY 80400487
71 GLAND FOR HOSE SLVYN KLCK PG9 GREY 80400488
72 2Q1 MPCB 1 - 1.6 - 3VU1340 MG00 80400371
73 CPU 314 82500037
74 KEY PAD 80400316
75 CONTROLLER KEYPAD 80400317
76 KEYPAD ENCLOSURE MODEL T 895P 80400333
77 CP340- 6ES7340 - 1CH02-0AE0 80400421
78 MUSHROOM ACTUATOR 82500005
79 MOUNTNG RAL - 6ES73901AF300AA0 82500039
80 CABNET FOR TP170 80400532
81 TOUCH PANEL - TP177 A 80400362
82 WinCC 1024 RUN TME 80400363
83 NTERFACE MODULE M365 80400360
84 8 CH ANALOG /P MODULE 82500042
85 32 CHANNEL D DGTAL NPUT 24 VDC 82500040
86 FRONT CONNECTOR 40PN 82500043
87 SWAREX DOUBLE CHANNEL 80400359
88 32 CHANNEL DO DGTAL OUTPUT 24 DC 82500041
89 FRONT CONNECTOR 20PN 82500104
90 CONTACT BLOCK 1NO 1C 3SB14000A 80400096
91 HA4 CONNECTOR 4 PN ASSLY 80400113
92 SM323 MODULE 16D/DO 80400364
93 CONNECTOR (PROFBUS) 80000145
94 3Q21,3Q22,3Q23 MPCB 0.4 - 0.6 - 3VU1340 80400368
95 3K21,3K22,3K23 CONTACTOR 9A - 3TF3010 0AM0 60574493
96 Micro Memory Card 128KB 80400529
97 Sticker for panel Traceability 80400614
98 TS ADAPTOR For Production 80400683
99 USB drive - 8GB or above (Trancend make) 80400736
100 Floppy Disk - DS, HD - 3.5" (90mm) 80400737
101 COMPUTER FOR MC300 with 1 GB RAM 80400236
102 CPU, Key Board, Mouse with Adaptors 80400566
103 17 inch color monitor (CRT) For MC360 80400568
104 3F5 3RB20 OVERLOAD RELAY 6 - 25A 80400594
105 6K1,6K2 Contactor, 85A (3TF49) 80400090
106 4K1,4K2,6K3 Contactor, 38A (3TF35) 80400064
107 6Q1 MPCB-57-75A/3RV10414KA10 82500017
108 4F2 THERMSTER PROTECTON UNT - 230VAC 50HZ 80000059
109 CABLE GLAND - PG16 60571279
110 3Q5 MPCB, 25A (MAG only) 80400629
111 FXNG PLATE FOR LMT SWTCH 80204280
112 NPUT / OUTPUT TAGS FOR MC360 80400712
113 6F2 Relay, 230V AC, 4NO+4NC, 5A 80400663
114 RELAY SOCKET 14 POLE 10119593
115 CLP FOR RELAY 10119594
116 M20x1.5 cable gland 80400693
117 15 PN D SUB CONNECTOR-Female type 80400747
118 FXNG PLATE FOR SENSOR-63 X 60 X 6MM 60061978
119 FXNG PL FOR SENSSORCASTNG GK-AL S 12 60029695
120 EMERGENCY STOP LEGEND PLATE 80000368
121 OS2 EMERGENCY SWTCH - 1NC 240 VAC 5A 22.5 80000055
2


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COMPRESSOR MOTOR HEALTHY 4.0
SAND VBRATOR 1 HEALTHY 4.1
SAND VBRATOR 2 HEALTHY 4.2
CEMENT SCREW 1 HEALTHY 4.3
WEGH BELT - PULL CHORD 4.4
WEGH BELT - '0' SPEED SENSOR 4.5
ASC CONVEYOR - PULL CHORD 4.6
CEMENT SCREW 5 HEALTHY 4.7
CEMENT VBRATOR HEALTHY 5.0
SKP HEALTHY 5.1
SKP UP FEEDBACK 5.2
SKP DOWN FEEDBACK 5.3
WATER DSCHARGE PUMP HEALTHY 5.4
CE SCREW HEALTHY 5.5
CE VBRATOR HEALTHY 5.6
MXER MOTOR HEALTHY 5.7
MXER MOTOR RUNNNG FEEDBACK 6.0
MXER GREASE PUMP HEALTHY 6.1
ADM-1 SORT1/2 DOSNG HEALTHY 6.2
ADM-2 SORT 1/2 DOSNG HEALTHY 6.3
ADM -1 SORT 1 DSCHARGE HEALTHY 6.4
ADM -1 SORT 2 DSCHARGE HEALTHY 6.5
ADM -2 SORT 1 DSCHARGE HEALTHY 6.6
ADM -2 SORT 2 DSCHARGE HEALTHY 6.7
WEGHER BELT CONVEYOR HEALTHY 7.0
SPARE 7.1
SPARE 7.2
SPARE 7.3
SPARE 7.4
PHASE FALURE ERROR 7.5
SKP THERMAL OVERLOAD 7.6
MXER THERMAL OVERLOAD 7.7
PLC INPUT DETAILS - MCI-360 - M1
PLC INPUTS ADDRESS REFERENCE
SPARE 8.0
GATE 1 FNE CLOSED SENSOR 8.1
GATE 2 COARSE CLOSED SENSOR 8.2
GATE 2 FNE CLOSED SENSOR 8.3
SPARE 8.4
GATE 3 FNE CLOSED SENSOR 8.5
SPARE 8.6
GATE 4 FNE CLOSED SENSOR 8.7
SPARE 9.0
SPARE 9.1
SPARE 9.2
SPARE 9.3
CEMENT DSCHARGE FLAP SENSOR 9.4
WATER DSCHARGE FLAP SENSOR 9.5
MXER GATE 1/2 OPENED SENSOR 9.6
MXER GATE FULL OPENED SENSOR 9.7
MXER GATE CLOSED SENSOR 10.0
SKP BOTTOM SENSOR 10.1
SLACK STEEL SENSOR 10.2
SKP WATNG SENSOR 10.3
SKP TOP SENSOR 10.4
SPARE 10.5
SPARE 10.6
SPARE 10.7
SPARE 11.0
SPARE 11.1
SPARE 11.2
SPARE 11.3
SPARE 11.4
SPARE 11.5
SPARE 11.6
SPARE 11.7
PLC INPUT DETAILS - MCI-360 - M1
PLC INPUTS ADDRESS REFERENCE
SPARE Q12.0
GATE 1 FNE OPEN Q12.1
GATE 2 COARSE OPEN Q12.2
GATE 2 FNE OPEN Q12.3
SPARE Q12.4
GATE 3 FNE OPEN Q12.5
SPARE Q12.6
GATE 4 FNE OPEN Q12.7
SPARE Q13.0
SPARE Q13.1
SPARE Q13.2
SPARE Q13.3
SAND VBRATOR 1 ON Q13.4
SAND VBRATOR 2 ON Q13.5
SPARE Q13.6
SPARE Q13.7
SPARE Q14.0
SPARE Q14.1
SPARE Q14.2
CEMENT SCREW 1 ON Q14.3
CEMENT SCREW 2 ON Q14.4
CEMENT SCREW 3 ON Q14.5
SPARE Q14.6
CEMENT SCREW 5 ON Q14.7
CEMENT 1 BLOW OFF Q15.0
CEMENT 2 BLOW OFF Q15.1
CEMENT 3 BLOW OFF Q15.2
SPARE Q15.3
CEMENT 5 BLOW OFF Q15.4
CEMENT VBRATOR Q15.5
CEMENT DSCHARGE Q15.6
SPARE Q15.7
PLC OUTPUT DETAILS - MCI-360 - M1
PLC OUTPUTS ADDRESS REFERENCE
SKP UP Q16.0
SKP DOWN Q16.1
WATER DOSNG COARSE Q16.2
WATER DOSNG FNE Q16.3
WATER GRAVTY DSCHARGE Q16.4
WATER PUMP DSCHARGE Q16.5
CE SCREW ON Q16.6
CE VBRATOR ON Q16.7
SPARE Q17.0
SPARE Q17.1
MXER ON Q17.2
MXER GATE OPEN Q17.3
MXER GATE CLOSE Q17.4
ADM1 SORT 1 DOSNG Q17.5
ADM1 SORT 2 DOSNG Q17.6
SPARE Q17.7
SPARE Q18.0
ADM1 SORT 1DSCHARGE Q18.1
ADM1 SORT 2 DSCHARGE Q18.2
SPARE Q18.3
SPARE Q18.4
WEGH BELT CONVEYOR ON Q18.5
SPARE Q18.6
SPARE Q18.7
SPARE Q19.0
SPARE Q19.1
SPARE Q19.2
SPARE Q19.3
SPARE Q19.4
AUTO BATCH HOOTER Q19.5
SPARE Q19.6
SPARE Q19.7
PLC OUTPUT DETAILS - MCI-360 - M1
PLC OUTPUTS ADDRESS REFERENCE
CEMENT SLO-1 LEVEL PW 336
CEMENT SLO-2 LEVEL PW 338
CEMENT SLO-3 LEVEL PW 340
SPARE PW 342
CEMENT SLO-5 LEVEL PW 344
MOSTURE-1 PW 346
MOSTURE-2 PW 348
MXER CURRENT PW 350
AGGREGATE PW 384
CEMENT PW 384
WATER PW 400
CE PW 400
ADMXTURE-1 PW 416
SPARE PW 416
SPARE PW 432
SPARE PW 432
PLC ANALOG DETAILS - MCI-360 - M1
PLC ANALOG INPUTS ADDRESS REFERENCE


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