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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 K2 SCADA

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 AGGREGATEDOWNLOAD ORDER. .......................................................... .............................................................. .............. 24
3.5 MANUAL DOWNLOADREGISTER. ..................................................................... ............................................................... ... 27
3.6 CONFIGURATION OF THE MOISTURE SENSORS
. .................................................................................................................... ... 28
3.7 PLANT PARAMETERS................................................................................................. ....................................................... 30
3.8 ASSUMINGSILOS. ........................................................................................................................................................... 34

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

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

4.2 ERRORS ............................................................ ................................................................. ............................................ 37

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

5.1 CONFIGURATION OF THENUMBER OFELEMENTS IN THEPLANT................................................................. ......................... 39

5.2 PLANT PROGRAMMING IN THEPLC. ...................................................................... ....................................................... 42

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

FAQ .............................................................................................................................................................................. 45

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 K2 SCADA

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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 K2 SCADA

1.1 SYSTEM K2.

AND ELEMENTS COMPRISING A PLANT EQUIPPED WITH

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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 K2 SCADA

1.2 CONTROLCOMPUTER

This section explains the general features of the system.

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 K2 SCADA

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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 K2 SCADA

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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 K2 SCADA

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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 K2 SCADA

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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 K2 SCADA

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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 K2 SCADA

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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 K2 SCADA

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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 K2 SCADA

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 THENUMBER OFELEMENTS IN THEPLANT.

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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 K2 SCADA

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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 K2 SCADA

Finally, we will be able to configure siren and plant capacity in the plant scale options.

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 K2 SCADA

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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 K2 SCADA

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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 K2 SCADA

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 pa ge 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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