BATCHTRON batch controllers

WHY BATCHTRON?

BatchTron is RELIABLE more reliable than anything else on the market Maintenance costs are to 1/10th of other, PC-based batch control systems. A proven fact with references! Every system is tailored to the production needs of the plant and crew because we learn how the crew works Highly customizable at modest cost to suit complex arrangements of conveyors, hoppers etc. Engineering and support are first-class Scale-Trons engineering team can handle the most difficult applications, and difficult applications are possible when using PLCs Scale-Trons policy is PQRS Performance, Quality, Reliability and Service

WHY WE DESIGNED BATCHTRON

BatchTrons predecessor, Genie-II, was a PC computer based system with PLC and weight indicators. Although excellent in its day, it was complex, with many interconnections. Problems took a long time to find and fix. PC computer technology changes constantly, making the hardware obsolete quickly. Microsoft Windows is difficult to set up and maintain in plants. It crashes and suffers from numerous bugs. We realized that newer technology could simplify the system while retaining all the power and features we liked. We like this and you will too

PC based system
Weight indicator

PC computer

Weight indicator

Weight indicator

PLC (programmable logic controller)

THE SIMPLICITY OF BATCHTRON

The PLC / touch screen combination is as powerful as a computer. It is much simpler, very few interconnections, fewer things to connect to, so more reliable and far easier to fix when things go wrong. PLC hardware is designed for industrial use hardened against heat, cold, vibration, dirt, dust, electrical interference, and uses long-life components. Parts are guaranteed to be available in up to 15 years time, from local suppliers everywhere. Software is totally crash proof and can be monitored or modified while it is running. A major improvement over PC computer based systems.

PLC / touch screen system

PLC (programmable logic controller)

Load cell transmitters Touch screen

THE DIFFERENCE BETWEEN PLC AND COMPUTER SOFTWARE

Programs that run in your PC computer are sequential; they complete tasks in a set order, branching along the way when they make decisions. There are thousands of branches in a typical program and if only one of these branches is a dead end, the program stops or "freezes". In comparison, PLC programs run in an endless loop like a wheel turning, repeating hundreds of times every second. Every time around, they check all the inputs, make decisions based on the program in the loop and set all the outputs. It is possible for a programmer to make a mistake in the program, but no mistake can halt the operation of the PLC; it keeps on running. Because it cannot freeze, it performs reliably throughout its long life, requiring little if any maintenance. The average PC computer is built with components that last only a few years; it needs a controlled, cool, dry, clean environment and has little tolerance for the electrical noise found in industrial plants. The PLC based batch controllers data collecting and management tasks, however, can be done on a PC computer in an office environment; if the computer breaks down, the PLC based batching system can continue unaided for as long as necessary.

MAIN FEATURES AND BENEFITS

Not PC and Windows based cannot crash No external ventilation to admit dust and make connections unreliable Minimal electronic hardware, maximizing reliability PLC/touch screen is very reliable 15 years with little to no maintenance All controls on screen no switches or lamps to fail No separate weight indicators, saves cost, increases reliability Weight indicators do not have to be purchased separately no hidden costs

MORE FEATURES & BENEFITS

Software developed over more than 15 years many features, mature and bug free Service, training and upgrades via Internet Integrated BatchLink ReadyMix management complete solution from one source Best value for money in the industry Expert engineering and industry knowledge

MAINTENANCE AND SUPPORT AGREEMENTS

24 hour, 7 day a week support direct to your assigned engineer, always on call Competitors take message and page duty technician of the day while we usually solve problems in the very first call First year of support is free Three grades of support agreement includes unlimited service, training and parts for equipment supplied Competitors do not include parts, or charge extortionate rates if they do. They have to, because frequent replacements are a fact of life for them Support includes unlimited training Competitors exclude this feature

PRECAST

READY-MIX

For precast, we have ability to customize software and screens Dirtier environment, not usually run by operator. Wall mount cabinet is best Most installations run unattended. Batches called from demand station Automates delivery of mix to different locations Integrated microwave mixer moisture system BatchLink Reporting software Designed around the way the plant operates, making it more efficient others make the plant operation fit the batch plant

For ready-mix, we have standard program with multichoice buttons for setup in plant Office environment, operator sits at console Little extra automation but emphasis on orderentry/dispatching software BatchLink Order Entry software is for smaller operations with 1 to 5 plants To meet larger operations, Redilink is available by special order

BATCHTRON II - LATEST SPECS

6 aggregates, 3 cements, 2 waters, 6 admixes NEW any number of scales NEW mix of English and metric formulas Self-tuning and tolerance check on admixes 800 formula storage standard, up to 1000 available NY State approval Versions for precast/block/ pavers and ready-mix NEW 8 screen, shaded graphics, animated symbols

BATCHTRON II NEW FEATURES

5 digit weight display for aggregate scale Selectable graduation size, all scales Automatic water/cement ratio calculation Scale Inspect screen for NY State Aggregate moisture sensor calibration screen Adjustment of moisture targets from demand station Cumulative weighing for NY State Recording of all manual feeds or batches, even when reporting computer disconnected True single button access to all menus makes operation simple, requires little or no training Mixer automatic washout sequence initiated from screen, with choice of washout time etc.

MORE NEW FEATURES

Many choices previously customized in software now part of menu screens Example is sequencing admix discharges. Another is choice of full open or ribbon discharge Built-in slump meter for wet cast water dispensing Bin mapping different ingredients in same bin Bilingual operation selectable on screen Many more alarm messages to quickly diagnose faults New manuals are available on dealer web pages

All inputs and outputs are now selectable from screen to aid in setup and service, allowing a burned output to be bypassed

BATCHTRON III SPECS

Up to 32 ingredients Flexible database, up to 12 ingredients per scale Any number of scales Up to 4 mixers 3 waters, 12 admixes per mixer Mix of English/Metric formulas NY State approval

OLD

NEW

BATCHTRON III NEW FEATURES

New screen has same features as BatchTron II but is larger with 12 diagonal Compensation for water in admixes Selectable Metric/English operation Programmable ingredient names Bilingual operation selectable on screen Up to 4 different mixing cycles set as part of formula (different time sequences) Inventory amounts in bins and silos shown on screen Remote touch screens for complete plant operation & data entry as well as entry of formulas/batch sizes/moisture values for each delivery station

LATEST MEMBER OF FAMILY, BATCHTRON I

Most of the features of BatchTron II Standard program, not customized for each user Intended for simple dry or premix plants for ready-mix or products Plant differences (e.g. aggregate by gravity/conveyor/holding hopper) selectable on setup screen Fixed I/Os to suit standard applications

BATCHTRON I FEATURES

Two versions Dry without mixer and Premix with mixer Standard pricing with add-on modules to increase number of ingredients Up to 6 aggregates, 3 cements, 6 admixes, 2 waters, 3 scales and 1 mixer Up to 1000 formulas, password protected Connection to BatchLink reporting and order entry Very aggressive pricing Best value for money no other system offers same features for equal price Can be installed by local electricians without our supervision Can connect to our offices through internet to solve any startup issues and provide training

BATCHTRON ADVANTAGES

Both BatchTron I, II & III have major advantages compared with similar systems from competitors: PLC/touch screen is reliable - customer may never need to call for service once installed and running PC based competitive systems look sharp but suffer from all the PC and Windows quirks that you already know about Separate AUTO/MAN controls for each function others with only one auto/man switch give major operating difficulties when small breakdowns occur With BatchLink, all manual material feeds are recorded unauthorized additions and batches eliminated Able to customize PLC software and touch screens in ways that others cannot examples are weighed mixer, weighed admixes, multiple screens, remote and wireless I/O, radio batch call, tunnel production line controls

Unattended operation Demand Stations

Order batches remotely at loading station Each crew can have their own demand formula plus batch size Select Low or High Priority Low priority makes next batch only when mixer has discharged High priority makes next batch immediately scales have discharged, allowing mixer to be filled immediately it is empty Call button starts batch Bucket In Place button arms mixer discharge function Many additional features available

Radio Call

Order several formulas and batch sizes, anywhere in the plant or yard Control other operations, such as mixer discharge Eliminates the need for a dedicated batch operator Increases production, saves time, reduces cost Finish the shift faster

HOW A BATCH IS SELECTED

Enter formula number and batch size by clicking on the boxes Keyboard appears. Enter new data see next slide

Now select REMOTE and run system from remote demand station (no local operator necessary) or select LOCAL and press CALL Once demands have been set up, no further attention is necessary

When CALL is pressed, batch is started from operator screen Up to 16 remote demand stations or radio calls can be located anywhere in the plant to suit delivery positions Unattended operation saves your most experienced operators for more important tasks

Batch screen shows status is RUNNING Target and actual weight of each ingredient shown on hoppers Scale hoppers show gross weight in scales Mixers show progress of mixing cycles

Indicators show if bucket is in place, conveyor running etc. Traveling hoppers have full display of their status and position Batch screen shows overview. Detail screens allow individual control or monitoring when necessary

MICROMIX OPTION

Simplest built-in mixer moisture control option saves $10K cost of extra hardware, easier to install Can select Micromix water or weighed/metered from formula, eliminating setup errors Direct link with internal actual ingredient weights etc. is simpler and more accurate than external Adjustable operating parameters give flexibility for all mixers Requires MixTron sensor and valve tree Larger mixers require larger valve and meter, correctly sized see our sizing table Low in cost, does not require water meter

MASTERMIX OPTION

Same advantages as MicroMix plus: Faster, for high production plants Can use metered water without moisture measurement for extra speed when extra accuracy not required More critical calibration and more complex setup Requires MixTron sensor, valves and water meter/scale. Cost is higher as a result

FAST MICROMIX

Developed to take advantage of easier setup and calibration of MicroMix but has almost same speed as MasterMix Does not need sensor to be calibrated in % moisture a major advantage for the user Relies on fast feed of metered water, then switches to feedback from sensor for final-wet Final-wet valve can be pulsed to give very slow feed close to final cutoff, for very accurate moisture at high speed Final-wet time period is used to increase or decrease metered water amount on next batch, optimizing all round performance Requires water meter, same total cost as MasterMix For dry-cast only. Will not work with slump concrete, but SCC is possible because of low water content Simplicity and accuracy better than anything else period.

THE MIXTRON SENSOR

Microwave sensing eliminates errors of older technologies Good in spiral blade, pan and twin shaft mixers. NEW installation kit for rotating pan mixers NEW digital version with PC Graphic User Interface, much easier to calibrate and set up NEW silicon nitride faceplate outlasts life of sensor, 5 times life of Sialon, 20 x life of white alumina faceplates. Expect 10 to 20 years life

SLUMP METER

Low cost method for ensuring slump of wet cast is correct before discharge Uses Watt transducer to eliminate error in ammeter systems caused by variation in line voltage Mixer power climbs as water is added until zeroslump consistency is attained. Then as mix becomes fluid, power decreases rapidly This enables the water to be linked to slump in a very accurate manner Graphic screen like Micromix or Mastermix controls water. Cutoff point stored in formula Dependence on power means that different formulas or batch sizes need different cut-off values best for many identical batches Can also be used as slump check for metered water systems

BATCHLINK REPORTING SOFTWARE

Runs on PC computer Save all batch reports Print when needed Enter deliveries Full inventory control Store all formulas, upload or download Custom reports available

APPLICATIONS

Precast excellent reputation and experience, known throughout industry Block, brick, pavers many systems in use Ready mix together with BatchLink Order Entry software BatchTron I is lower in price than comparable systems It is a drop-in fit for small ready-mix plants BatchTron I can be customized to needs of plant builder OEMs and other OEM applications Asphalt and dry bagged products Animal feed, foods, chemical systems, fertilizer Chemicals, dry granulated products, plastics

FOR MORE INFORMATION:

Scale-Tron Inc., Montreal Canada www.scaletron.com scaletron@scaletron.com
1 800 632 7083 +1 514 940 0337 Thank you for participating