K2 Scada 20130117 - Eng PDF

USE AND CONFIGURATION MANUAL FOR THE
K2 CONTROL SYSTEM.
Frumecar S.L.
Tel: 0034 968 89 00 00 frumecar@frumecar.com
Fax: 0034 968 89 07 77 www.frumecar.com
K2 SCADA
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Frumecar S.L Grupo Frumecar. Tel: 0034 968 89 00 00 Fax: 0034 968 89 07 77 frumecar@frumecar.com www.frumecar.com 2
K2 SCADA
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INDEX OF CONTENTS
INDEX OF CONTENTS...................................................................................................................................................... 3
1. INTRODUCTION .......................................................................................................................................................... 4
1.1 SYSTEM AND ELEMENTS COMPRISING A PLANT EQUIPPED WITH K2. ............................................................................................. 5
1.2 CONTROL COMPUTER ........................................................................................................................................................ 6
1.3. ACCESS TO THE PROGRAM .................................................................................................................................................. 7
1.4. MAIN SCREEN ............................................................................................................................................................... 10
2. MANUFACTURE ........................................................................................................................................................ 11
2.1 FAST DOSING. ................................................................................................................................................................ 15

2.2. SCREENS....................................................................................................................................................................... 16
2.3. HELP. .......................................................................................................................................................................... 17
3. CONFIGURATION ..................................................................................................................................................... 18
3.1 SCALE CONFIGURATION .................................................................................................................................................... 19

3.2 LANGUAGE..................................................................................................................................................................... 22
3.3 DATE AND TIME .............................................................................................................................................................. 23
3.4 AGGREGATE DOWNLOAD ORDER. ...................................................................................................................................... 24
3.5 MANUAL DOWNLOAD REGISTER. ....................................................................................................................................... 27
3.6 CONFIGURATION OF THE MOISTURE SENSORS........................................................................................................................ 28
3.7 PLANT PARAMETERS ........................................................................................................................................................ 30
3.8 ASSUMING SILOS. ........................................................................................................................................................... 34
4. WARNINGS AND ERRORS ......................................................................................................................................... 36
4.1 WARNINGS .................................................................................................................................................................... 36

4.2 ERRORS ......................................................................................................................................................................... 37
5. PLANT CONFIGURATION. ......................................................................................................................................... 39
5.1 CONFIGURATION OF THE NUMBER OF ELEMENTS IN THE PLANT.......................................................................................... 39

5.2 PLANT PROGRAMMING IN THE PLC. ............................................................................................................................. 42
HOW TO PERFORM FAST DOSING ................................................................................................................................ 43
FAQ .............................................................................................................................................................................. 45
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1. INTRODUCTION
This system has been designed to perform all of the actions required to control a concrete batching plant
quickly, completely and simply.
This document contains all of the information regarding the use and configuration of this control system in
order to resolve all doubts arising in its handling.
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1.1 SYSTEM AND ELEMENTS COMPRISING A PLANT EQUIPPED WITH K2.
The image below gives a general view of a plant and its principal components.
The control hut is where all of the plant parameters can be monitored and production can be planned.
The whole system is monitored by a robot. This robot monitors both the plant and the feeding system if the
plants have one.
To ensure greater ease in handling and viewing the plant parameters and tasks, the interface monitoring the
plant is a PC.
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1.2 CONTROL COMPUTER
This section explains the general features of the system.
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1.3. ACCESS TO THE PROGRAM
The system automatically shows the following screen when the program is run.
The top bar allows us to browse all program options and also shows the system date and time.
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The top buttons allow working in full screen, window minimisation, restoration of the window to the chosen size
and the program to be closed.
1. Main Screen.
2. Fast dosing. This enables loose elements to be dosed or simple concrete manufacture.
3. Configuration. This gives access to the configuration menu.
4. Information. This gives detailed information of all system processes and allows the element
parameters to be programmed.
5. Help. This shows this manual.
Status bar.
This is located at the bottom of the window. It includes a pause button to inhibit scale download, a panel
showing the plant warnings and an operating mode selection button.
PAUSE / RESTART.
This button can be used to stop the process momentarily without interrupting it and activates a download
inhibition signal on the concrete mixer.
An inhibition signal is one that disables the use of certain elements or part of the plant at a certain time. In this
case, the scale download on the concrete mixer is disabled.
If the button has a “pause” symbol, the process is stopped when it is clicked.
If the button has a “restart” symbol, the process is started when it is clicked, and the cycle is resumed from
where it was stopped.
When the controller is working normally, the button shows this symbol to allow the dosing to be paused and
when it is paused it shows this symbol allowing normal operation to be resumed when it is pressed.
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MODE CONTROL.
Go from automatic dosing with the PC to manual to control the elements directly from the PC with the mouse.
When the plant is loading automatically, this button allows us to cancel the present load
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1.4. MAIN SCREEN
The main screen is divided into 4 sections: aggregates, cements, liquids and concrete mixer, loading mouth
and others.
Each of these sections is described in detail below.
The colours of the scale give a visual indication of its status. If the scale is ready to receive load it is white, if it
is holding more than minimum weight to start the scale's weighing process it turns orange. And when it is
downloading, the scale is green.
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This outline of elements and functions is repeated in the four sections of the main screen.
2. MANUFACTURE
The main screen shows all of the plant information when we are dosing. Below, we will describe each of
the elements that can be viewed on the screen:
The following screen with its options appears next.
Current status of the aggregate scale and information on the quantities yet to be dosed in hoppers 1, 2, 3 and
4.
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View B Current status of the cement scale and information on the quantities yet to be dosed in silos 1 and 2.
View C Current status of the water scale and water and admixture meters.
View D. Number of the cycle being mixed in the concrete mixer and mixing time remaining.
View D. Visual information on the present progress of the load, name of the formula and number of cubic
metres requested.
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View E. Status of the aggregate hoppers (1) and their corresponding vibrators (2), number of the hoppers (5)
and name of the materials (6), information on the scale (3) and aggregate scale download inhibition button (4).
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View F. Status of the cement silos (1) and their corresponding fluidizers (2), identification number of the silos
(5) and name of the materials (6), information on the scale (3) and cement scale download inhibition button
(4).
View G. Water status by meter and status of the two admixtures in the plant.
View H. Status of the concrete mixer [1], information on the status of the concrete mixer and of the gate (open
or closed) [2] and the actions being carried out there (open or close) [3], concrete mixer discharge cone
vibrator [4], Elements downloading in the concrete mixer [5].
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2.1 FAST DOSING.
This screen shows us the latest allocations that have been sent to dosing and allows us to fast dose any
of the elements in the plant and even to send several metres for manufacture.
The data shown and entered will be by the metre.
The delete button allows us to clear all the allocations and sets the volume to 1.
For example, if we want to dose 100 litres of water, we click delete, put 100 in WATER_C, click ENTER to set
the data, make sure the volume is 1 and click the dose button.
If, for instance, we want to dose 8 metres of a known formula, we will click “Delete” to clear the previous
allocations, set the amount of each material per metre by clicking ENTER to set each value, set the mixing
time, put 8 in VOLUME and click ENTER. Having set the data, we click “Dose”.
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2.2. SCREENS
The program shows all of the plant information on the main screen as we have seen, and also allows a view of
each of the plant processes.
The information button shows details of the plant elements and allows us to program the operation
parameters.
Once the information or detail button is clicked a new bar can be seen at the bottom for moving
between the different plant elements. We click the home-shaped button to go back to the main screen
By clicking on the name of the process on the bar, we can access the details of each of the processes.
Hoppers Silos
Liquid Concrete mixer
With the system in manual (see page 14), it is possible to interact with the plant elements using these 4
screens; in other words, they can be handled directly. The buttons to activate in manual mode will also appear
on the screen.
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Inhibitors
These allow the material download to be controlled and are located on the scales and in the concrete
mixer. When they are activated, they prevent undue material downloading.
► This is the only screen that can be controlled with the plant in automatic mode
Vibrators
These are activated by clicking on them and stopped when clicked again. They change colour when they
are working.
Indicators
Their function is to indicate the status of the screen or button next to it. They work as LED indicators.
Siren
This gives the truck an acoustic signal when the complete load has been made.
Generally, when an element is in operation, changes can be seen in its shape and colour.
When the system is in automatic mode (see page 15) it is not possible to interact with the elements
although changes are seen in the shape and colour when they are in operation.
2.3. HELP.
This button shows the electronic version of this manual.
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3. CONFIGURATION
This screen allows the plant control system to be configured, as well as certain parameters that have a
direct influence on the production process.
By clicking on each of the options we are able to access the configuration menus.
Scale configuration (see page 48)
Language (see page 51)
Date and time (see page 53)
Aggregate download order (see page 54)
User control and administration (see page 55)
Manual download control (see page 56)
Configuration of the moisture sensors
By clicking we can return to the MAIN SCREEN.
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3.1 SCALE CONFIGURATION
By clicking on we access the following screen:
From this screen we can calibrate all of the scales in the system.
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CALIBRATION
Before calibrating, it must be ensured that the scale to be calibrated is completely empty. Once this has
been checked, the “CALIBRATE” button on the previous screen can be clicked. This will open the
following screen.
The image shows that there are three distinct blocks, each in a different black rectangle. The following
steps are necessary for correct calibration:
1) With the scale totally empty, click update on the button of the first block, which corresponds
to the reading for 0 Kg. of weight on the scale, as shown in the image.
2) Having performed this step, the scale is loaded with a known weight.
3) Enter the weight manually in the weight 1 field in the image.
To enter the value, click on the field, enter it with the numerical keyboard and click ENTER to confirm.
4) When the value has been changed, click update on the button of the second block, which
corresponds to the reading for the kilograms of the known weight.
5) To complete the calibration process, click on transmit to transmit the data to the system.
The K2 controller requires a variation of at least 5% of the total load of the cells between point 1 and point 2. If
there is not sufficient weight to make this 5% variation, it is theoretically possible to find a point which does
meet this requirement. The “Theoretical calibration” button allows us to find point 3 to perform a calibration
with less weight than the necessary amount.
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Having obtained points 1 and 2 we click theoretical calibration, which allows us to find point 3 theoretically,
which must be as close as possible to the 5% variation.
An example of use.
We have a scale with 4 cells of 3,000 Kg each, so we have a total of 4x3,000 = 12,000 Kg.
A 5% variation would be at least 12,000 x 0.05 = 600 Kg of difference between the 1st and 2nd point.
In other words, we should carry out the calibration with at least 600 Kg in weights.
If we only have 200 Kg, we have to make a theoretical calibration; taking the two points with 0 Kg and 200
Kg and then clicking the theoretical calibration button to obtain point 3. In the Weight 2 box we enter the
minimum weight that we would need to achieve a 5% variation (600 Kg) and click calculate.
The program will theoretically calculate the reading of the scale and we can then click transmit.
A correct calibration requires a variation of at least 5% to guarantee the weighing results.
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3.2 LANGUAGE
This menu allows us to change the system language, therefore changing that of all of its options and
menus.
To select a language, click on the flag of the language required.
For instance, if we want to change to French, we click on the French flag and the language will
automatically change.
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3.3 DATE AND TIME

This menu allows us to change the time and date of the whole system.
In these fields, we can enter the date and time required for the system. The required date is entered and
we can confirm by clicking ENTER.
To change the time, enter the required time and confirm by clicking ENTER
By clicking, the date and time of the system is updated.
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3.4 AGGREGATE DOWNLOAD ORDER.
From this menu we can configure the aggregate download order.
The hopper number is shown at the top of the square and the selected download order is on the side.
In the image, the download order would be configured as follows: the first hopper would be the first to
download; the second hopper would be the second to download; the third hopper would be the third to
download; the fourth hopper would be the fourth to download and finally, the fifth hopper would download
fifth.
To change this order, we click the desired squares and once the order has been decided, click save. If the
combination is correct, it will be saved and the new download order will be established.
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If the selected download order were incorrect, an error message would be shown and the incorrect
configuration would not be saved.
In the example in the image above, the error would lie in trying to configure the second hopper as both
second and third to download, leaving the fifth hopper out of the assigned order.
In the image above, the download order would be configured as follows: the first hopper would be the first
to download; the second hopper would be the third to download; the third hopper would be the fourth to
download; the fourth hopper would be the fifth to download and finally the fifth hopper would download
second.
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3.5 MANUAL DOWNLOAD REGISTER.
This screen is divided into two parts: the first shows the accumulated number of kilos dosed in manual
download. These numbers increase as the manual buttons of the table are pressed and may be reset to 0 by
clicking “RESET”.
The second section of this screen allows us to configure which inputs correspond to the manual buttons.
In each box we will enter the corresponding input number and press “save” to confirm the configuration.
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3.6 CONFIGURATION OF THE MOISTURE SENSORS.

This screen has the following appearance:
It is divided into two parts: the first shows us a calculator to calculate the moisture of each of the points on the
calibration line. The second allows us to calibrate the moisture sensors.
moisture calculator:
To calculate the sand's moisture, we must follow the procedure shown on the screen. We must pass the sand
through the moisture sensor, take a sample of it, weigh it, heat the sample in a container to eliminate any
water it might contain and then weigh it again.
The program asks for the weight of the empty container that will contain the sample (A), the weight of the initial
sand sample (B) and the weight of the sample after heating it to get rid of the water (C). When we have
entered the 3 weights, we click “Calculate moisture” and are given the water content of the sample (D).
Calibration of the moisture sensors.
We will use the bottom section of the screen to handle the moisture sensor.
We can activate or deactivate the sensor with button A. To make the calibration, the moisture values of two
points B and C must be entered and button D must be pressed for programming.
The “Moisture sensor calibration” manual contains more information on this process.
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Finally, the sensor reset button allows us to restore the moisture sensors' initial configuration.
By clicking this button, we eliminate the calibration made in all the moisture sensors, leaving them with their
default value.
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3.7 PLANT PARAMETERS

Each of the plant elements has a series of parameters to define its behaviour in automatic operation. To
access these, we must enter the detailed view of each process by clicking i
To access the parameters of the cement scale, we will go to the process detail screen and click on the scale.
At the top right of the screen we will find the parameters of the scale. To change their value, we will enter the
new value and confirm by pressing ENTER.
Before allowing access to the parameters, the user will have to be confirmed as the administrator, as any
undue changes in the parameters can cause the plant to malfunction.
The parameters are common to some elements. The plant parameters that can be configured are presented
below, grouped by similarities.
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Parameters of hoppers, silos and liquids.
Description.
Stabilization time: This is the time in seconds between material loads for the weight to stabilize.
Minimum flow: This is the flow value below which the vibrators are turned on.
Vibrator: this gives the number of the vibrator or fluidizer that will work in this hopper or silo
T.OFF. The time in which the vibrator is turned off.
T.ON. The time in which the vibrator is turned on.
Refining: this allows the refining type to be selected. There are three possibilities. Double mouth. Flip-flop.
Four mouth.
% Percentage of allocation above which the refinement is activated.
S. time in seconds for the flip-flop mouth opening and closing cycle.
The refinement parameters only affect the aggregate download hoppers.
Meter parameters
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Download delay time: This is the delay time of the scale download in seconds with respect to the master.
Pulses / litre: This is the sensitivity of the liquid meters (water and/or admixtures).
Correction Factor. The value by which the metering result will be multiplied to adjust possible deviations in the
equipment.
Scale parameters:
Download delay time: This is the delay time in seconds to start scale downloading.
Minimum Flow: This is the flow value below which the vibrators are turned on.
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Start Maximum weight: This is the maximum value the scale can have to start the loading process.
Minimum weight: This is the value below which the scale is understood to be empty and loading is stopped.
Start Maximum weight: This is the maximum value the scale can have to start the loading process.
Vibrator delay: The delay time from the download start-up before the vibrator starts to work.
T.OFF. The time in which the vibrator is turned off.
T.ON. The time in which the vibrator is turned on.
Siren time. The time that the siren will be active when the loading is complete.
Time to reach the half position: The time in seconds required to reach the half download position.
Half position time: The time in seconds for which the gate remains in half position.
Downloading time: The time in seconds for the concrete mixer to download with the gate open.
Inhibition Type: The signal that prevents the concrete mixer from downloading incorrectly, that is without a
loading container underneath. There are 3 types:
Without Inhibition: This deactivates this function.
First cycle inhibition: If the process has several cycles, this function is only activated for the first
cycle.
All cycle inhibition: This activates the function in every cycle of the process.
To select the required type of inhibition, click on . A scroll-down menu opens with the 3 types.
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3.8 ASSUMING SILOS.
When one of the silos in the plant runs out of cement in the middle of the manufacturing process, it is possible
for one of the remaining silos to assume the material left to be dosed in order to avoid order cancellation.
To do this, we must go to the cement process detail screen, select the silo with cement that will replace the
empty silo. At the bottom of the screen there is a scroll-down menu in which we will select which silo is going
to assume the process and then we click on save
From this moment, the detail will be as in the image below.
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The picture shows us that silo 1 will dose its allocations and the allocations of silo 2, whereas silo 2 is
annulled.
Once the silo has cement once more, we click reset to eliminate the programmed replacement configuration
and return everything to its initial status.
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4. WARNINGS AND ERRORS
This section explains the meaning of each warning and/or error.
4.1 WARNINGS
The warning indicator flashes on the main panel.
To check the warnings, we look at the notifications panel.
In this case, there is a warning because when the cement scale has downloaded it has fallen below the
minimum flow set in the configuration parameters and the program activates its vibrator.
The warnings may point to minimum flow:
"WARNING Min. Flow Hopper XX"

"WARNING Min. Flow Silo XX"
"WARNING Min. Flow Water Scale XX"
"WARNING Min. Flow Scale XX"
The following warnings are possible:
"WARNING Emergency input"

"WARNING Concrete Mixer Open"
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4.2 ERRORS
The error indicator flashes on the main panel.
To check the warnings, we look at the notifications panel.
The following is the list of errors:
"ERROR m3 SELECTED <= 0"

"ERROR ALL ALLOCATIONS = 0"
"ERROR ALLOCATION WEIGHT > MAXIMUM WEIGHT"
"ERROR OUTGOING ORDER"
Other possible errors, algorithm errors, will require the work of the Frumecar technical service. If you receive
one of the following errors, please contact Frumecar:
"ERROR Admixture Process"

"ERROR Hopper Process"
"ERROR Silo Process"
"ERROR C Water Process"
"ERROR B Water Process"
"ERROR Cement Scale Process"
"ERROR Cement Scale Maximum Weight"
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MEANING OF ERRORS
The dosing amount entered is 0.0 or under.
There are allocations of 0.0.
There is an allocation of more than the maximum weight.
Algorithm error in hopper1
Algorithm error in silo1
Algorithm error in silo2
Algorithm error in water
Algorithm error in admixture1
Algorithm error in admixture2
Algorithm error in scale1
The weight of scale1 is higher than the permitted initial maximum.
Algorithm error in scale2
The weight of scale2 is higher than the permitted initial maximum.
Algorithm error in concrete mixer
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5. PLANT CONFIGURATION.
The K2 system allows the plant elements and their control outputs to be quickly defined on the following panel,
which can be accessed from the system's main screen by clicking on the 2 of K2 in the upper right corner.
Access to this screen is password protected as the changes made on this screen can unconfigure the plant
and hinder its operation.
5.1 CONFIGURATION OF THE NUMBER OF ELEMENTS IN THE PLANT.
This screen allows the number of elements in the plant to be configured as well as the outputs of each of
these elements.
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In the following details, we can see the configuration options of the program. For example, we can change the
number of hoppers, silos and admixtures the program controls; we can assign two outputs per hopper and one
vibrator; for the silos we can only assign one output and one vibrator in addition to configuring the capacity of
the cement silo.
The admixtures may be selected with or without cup. If they have a cup, the downloading and loading outputs
must be indicated.
Similarly, we can also configure whether the plant is a dry channel or a wet channel. If we select “wet channel”
the concrete mixer configuration options will appear on screen.
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Finally, we will be able to configure siren and plant capacity in the plant scale options.
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5.2 PLANT PROGRAMMING IN THE PLC.

Once the necessary changes have been made, the data must be saved in the PLC by clicking the Program
PLC button.
This screen can also be used to recover all of the plant parameters and configurations.
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HOW TO PERFORM FAST DOSING
A dosing example is explained below:
1) Access the fast dosing screen.
2) With the plant in automatic mode, enter the allocations to be dosed per square metre.
3) Enter the desired number of cubic metres.
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4) Press DOSE. The loading process starts when DOSE is pressed.
5) The process starts with the loading of aggregates, cements, water and admixtures in their respective
scales.
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FAQ
1) If the program fails to start automatically. Make sure the system is in automatic mode. If it is in
automatic mode, make sure there is no weight on the scales. Make sure the concrete mixer gate is
closed
2) What happens if a hopper does not have enough aggregate? In plants without a feeding system,
the production in course stops until there is sufficient material in the hopper for the process to
continue.
If the plant has been purchased with a feeding system, the material may be fed almost automatically
to ensure that the hoppers are not left without aggregate at any time and to make the production more
efficient.
3) What happens if a silo does not have enough cement? If there are two types of cement when a
silo does not have sufficient cement, production stops until there is sufficient material. If there is only
one type of cement but divided between 2 silos, the process will continue as if the cement in one silo
runs out, there is another silo to continue dosing in its place.
4) How can you know if the scale is not properly calibrated? When a known weight is placed on it,
the reading does not give us the right value in kilograms.
5) Why do scales sometimes fail to give the right weight? In time, scales accumulate material and
logically are not so accurate. To solve this, their calibration must be periodically checked to ensure
that the error is as small as possible.
6) What do you do in the event of a “Max. Weight Scale --” error? The first step is to make sure there
is no material on the scale. If there is, all surplus material must be removed from the plant. If there is
no material on the scale, it must be calibrated.
7) How do you remove the surplus material from a plant? To empty the plant of surplus material on a
belt or a scale, put the system in “Manual” mode (see page 15) and use the screens to empty
manually (see page 42).
8) How do you ensure correct concrete downloading in the container or truck? To ensure this, the
plant control system has a signal known as the inhibition signal ensuring that the concrete mixer
scales download when they are empty and the concrete mixer downloads into the container or truck
when it is in the correct position.
9) What do you do if the process stops completely? This situation will only occur when there is a
serious problem in the plant. The technical service must be informed in such an event.

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USE AND CONFIGURATION MANUAL FOR THE

2.1 FAST DOSING. ................................................................................................................................................................ 15

3.1 SCALE CONFIGURATION .................................................................................................................................................... 19

4. WARNINGS AND ERRORS ......................................................................................................................................... 36

4.1 WARNINGS .................................................................................................................................................................... 36

5. PLANT CONFIGURATION. ......................................................................................................................................... 39

5.1 CONFIGURATION OF THE NUMBER OF ELEMENTS IN THE PLANT.......................................................................................... 39

HOW TO PERFORM FAST DOSING ................................................................................................................................ 43

1.1 SYSTEM AND ELEMENTS COMPRISING A PLANT EQUIPPED WITH K2.

1.2 CONTROL COMPUTER

This section explains the general features of the system.

1.3. ACCESS TO THE PROGRAM

1.4. MAIN SCREEN

Each of these sections is described in detail below.

The following screen with its options appears next.

2.1 FAST DOSING.

The data shown and entered will be by the metre.

Liquid Concrete mixer

This button shows the electronic version of this manual.

Language (see page 51)

Date and time (see page 53)

Aggregate download order (see page 54)

User control and administration (see page 55)

Manual download control (see page 56)

Configuration of the moisture sensors

By clicking we can return to the MAIN SCREEN.

3.1 SCALE CONFIGURATION

By clicking on we access the following screen:

3) Enter the weight manually in the weight 1 field in the image.

A correct calibration requires a variation of at least 5% to guarantee the weighing results.

To select a language, click on the flag of the language required.

3.3 DATE AND TIME

By clicking, the date and time of the system is updated.

3.4 AGGREGATE DOWNLOAD ORDER.

From this menu we can configure the aggregate download order.

3.5 MANUAL DOWNLOAD REGISTER.

3.6 CONFIGURATION OF THE MOISTURE SENSORS.

Calibration of the moisture sensors.

3.7 PLANT PARAMETERS

Parameters of hoppers, silos and liquids.

T.OFF. The time in which the vibrator is turned off.

T.ON. The time in which the vibrator is turned on.

% Percentage of allocation above which the refinement is activated.

The refinement parameters only affect the aggregate download hoppers.

T.OFF. The time in which the vibrator is turned off.

T.ON. The time in which the vibrator is turned on.

Without Inhibition: This deactivates this function.

3.8 ASSUMING SILOS.

From this moment, the detail will be as in the image below.

4. WARNINGS AND ERRORS

This section explains the meaning of each warning and/or error.

The warning indicator flashes on the main panel.

To check the warnings, we look at the notifications panel.

The warnings may point to minimum flow:

"WARNING Min. Flow Hopper XX"

The following warnings are possible:

"WARNING Emergency input"