Scale-Tron, automation, sensors and weighing systems

BATCHTRON OPTIONS - explains the standard options and add-ons

This guide gives a short description of the options available for the BatchTron system.  Not all are available on BatchTron I.  If you need more details, call us;  we are always glad to help.

-M, MIXER OPTION

Extra outputs and software control all mixer functions: warning horn output with delayed start, separate start and run outputs for reduced voltage (Wye/Delta) starters, automatic sequencing of all ingredients into the mixer (special block and paver cycles are available), programmable mix timer and choice of auto or manual discharge, door being held open for a programmable time. Full interlocking prevents "double batching" into mixer.

-S. SKIP HOIST OPTION

Raising and lowering of aggregate or concrete skip is controlled automatically, with a holding position prior to the tipping station. Skip raises to holding position; when mixer is ready for a new load, skip continues to tipping station, tips for a preset time and then lowers to the bottom position for a new batch.

-ML, MIXER & LESUEUR MOISTURE METER

Mixer option as above with the addition of software and hardware interface for a Lesueur meter to control the addition of water (note that our MicroMix supersedes the Lesueur). The Lesueur is suitable only for dry cast concrete. Lesueur meter not included in this price.

-LE, MIXTRON/HYDRONIX INTERFACE

Software/hardware kit for connection to MixTron or Hydronix water dosing system. Automatically compensates for different formulas and batch sizes, as well as errors in batched weights. Alarms created by dosing system during water cycle are displayed on BatchTron screen, plus audible alarm. MixTron is the fastest and most accurate separate water dosing system available for precast, block and paver applications.  MasterMix (below) is a better choice for use with BatchTron, however, since the overall cost is lower. 

-STI, SERVICE AND TRAINING BY INTERNET

The BatchTron PLC is usually connected to a local PC computer for reporting and inventory control (BatchLink).  This connection can be used with an Internet connection to the computer to allow Scale-Tron engineers to remotely control this computer and diagnose faults, add software updates and train operators.  We recommend STI on all new installations.

-MDM, MODEM OPTION

For fault diagnosis, program updates and addition of new features, a modem can be used when Internet is not available. Kit includes cables, connectors, adaptor unit and software, plus an on-line session to train your operator in its use.

-RP, REPORT PRINTER

Not required when BatchLink is installed.  Where batch reports are necessary and no local computer is available, this option includes printer, cables, adaptor unit and software to give simple but complete reports on all batches (see sample printout). Meets all NRMCA / NPCA requirements. Requires real time clock in PLC to print date and time.

-TP, RUN TOTAL REPORTING

Not required when BatchLink is installed (requires -RP). Special software for use with printer accumulates totals during a run of batches. The run can be any length from a few batches to a daily or weekly total. A special form of the run total, the "truck filler" accumulates a fixed number of batches discharged into a single container or truck, correcting the accumulated errors on the last batch. The report includes more advanced statistics for quality control and ISO-9000 documentation (see sample printout).

BATCHLINK - THE LINK BETWEEN BATCHTRON AND DATA BASE

BatchLink connects BatchTron to a PC computer running Microsoft Access database; part of the Microsoft Office suite.  This allows order entry and production reporting to be customized to your business.  No longer do you need to buy expensive software and have costly customization done to suit your needs.  Do it yourself with BatchLink. For more information - BatchLink

REMOTE CONTROL - FOR BATCHLINK

Allows BatchLink Oreder Entry or Reporting software to control the batching process.  A series of buttons on a screen that mimics BatchTron`s touch screen allow all the normal control functions to be used on the PC computer, wherever it is located:  Start and halt batches, correct tolerance errors, deal with alarms, discharge mixer, correct water amount or moisture values, etc.

-ES, -WS, EXTRA SCALE OR WATER SCALE

Water scale replaces volumetric meter. Although a water scale is bulky and expensive, it gives better speed and accuracy than a volumetric meter.  Extra scales are often necessary for cement and aggregates in BatchTron-III's 2 and 3 mixer systems.  Filling during the aggregate and cement charging period, it discharges into the mixer (or directly to the truck in "dry mix" ready-mix plants). Includes load cell input interface and software.

-SL, SLUMP METER

Wet cast mixes can be poured with well controlled slump by monitoring the power required to turn the mixer. As water is added, the motor power climbs until the mix attains a "doughy" consistency. Further addition of water starts to liquify the mix, causing the power to drop rapidly. The water is shut off when it drops below a preset setting. Actual and set values are displayed on bar graphs on the touch screen. Note that measurement is of actual Watts; not Amps, which vary with the power voltage, causing errors.

ME04K, MEMORY CASSETTE FOR BASIC BATCHTRON

 This option stores all data created during the batch process, allowing it to be transferred to a PC computer for permanent storage and printing.

-MT, PLANT MAINTENANCE TIMER

This specialized software option allows routine maintenance to be scheduled according to preset time periods. Two lists are available. RUNNING TIME is for items which require checking after a number of running hours (mixer gearbox etc.). FIXED INTERVAL is for items which require service after a fixed number of days or weeks. Items due for maintenance appear as alarms during morning startup and will reappear each morning until cancelled, when they will again wait until the time period has elapsed.

MICROMIX WATER ADDITION SYSTEM

MicroMix uses Scale-Tron's microwave sensor technology to measure moisture in the mixer.  The BatchTron computer displays the moisture value and controls the addition of water by fast and slow water valves as measurement continues.  This method is not as fast as MixTron but is adequate for many lower production plants.  Its economical price makes it a winner. For more information - MicroMix

MASTERMIX WATER ADDITION SYSTEM

MasterMix also uses Scale-Tron's microwave sensor technology but is much faster, equalling MixTron's speed and accuracy.  Intended for high production plants where the shortest mixing cycle time is important, MasterMix is lower in cost than MixTron because it does not require a separate controller.  For more information - MasterMix

FAST MICROMIX

Combining the speed of masterMix with the ease of use of MicroMix, Fast MicroMix does not require accurate sensor calibration but does need a water meter.  It pre-measures most of the water at a fast rate and uses the mosture sensor for the final adjustment only.  Feedback of the results optimizes the speed and accuracy on a batch to batch basis.

EXTRA FUNCTIONS

In order to standardize the pricing of custom features, BatchTron uses the concept of FUNCTION, which is an input, output or both, plus associated programming. Thus, a travelling hopper with 4 stopping positions would require 4 functions (4 input switches and 2 outputs for motor direction). Any non-standard features can be priced in this way.

POWER SUPPLY, 24V 10A

The internal power supply is adequate for load cell excitation and a few relays but will not power a 24 volt I/O system with motor starters and solenoid valves. This unregulated power supply has enough capacity for most 24 volt-powered systems, including hydraulic solenoid valves.

MOBILE CONTROL

Requires BatchLink Reporting or Order Entry software running on local PC computer, plus Remote Control option.  Tablet computer can connect by WiFi and display the same screen as the BatchLink Remote Control screen.  This allows an operator anywhere within WiFi range of the local network to carry out all batching functions:  Start and halt batches, correct tolerance errors, deal with alarms, discharge mixer, correct water amount or moisture values, etc.  For more information - Mobile Control

PRECAST DEMAND STATION

To reduce the need for operators to call for batches from the touch screen, a demand station can be mounted at the casting location or near the bucket filling station. It controls the ordering of concrete. Price includes the station plus I/Os and software.  For additional information - Demand Stations

MIXER CLEANOUT STATION

When the control panel is not located close to the mixer, a means is needed to start/stop the mixer, open the doors etc. This station is located near the mixer to provide the necessary control. It is normally locked out by the BatchTron controller and is activated after production has ceased.

BIN LEVEL PROBE, EXTENSION, RELAY

For use on dry casting machines, this probe monitors the bin level and calls for more mix when the level is low. Its adjustable extension allows variation of the sensing level and the special relay is calibrated to react to mixed concrete in the bin.

RADIO CALL

In precast plants, often the plant foreman, fork lift or crane operator needs to order concrete while mobile. Radio Call is the ultimate in convenience, saving precious production time. A holster radio can request up to 8 different formulas and batch sizes or 7 different formulas and batch sizes plus initiate discharge of the mixer when the bucket is placed in position. Consult the RADIO CALL brochure for more details. For additional information - Radio call

CONSTANT FEED

For block and paver plants, constant feed controls the level in the machine hopper by modulating the speed of the hopper feed belt.  It improves product quality and reduces the need for frequent adjustments.  For additional information - Constant feed

RADARTRON

Microwave based moisture sensor for aggregates, the RadarTron mounts in the aggregate bin and passes the moisture reading to the BatchTron controller, allowing automatic compensation of the aggregate and water amounts. See RadarTron brochure for full details. For additional information - Radartron

LOAD CELL

If connecting the BatchTron to an existing batch plant with mechanical lever scales (dial or beam type), a load cell is required on each scale for transmission of the weight value to the BatchTron controller. The "S" type load cell can be inserted in the steelyard rod of any lever-type scale.  We can also supply kits of load cells to replace the complete mechanical lever system.