Apex Loadout Manual

10000 W. 75th St., Suite 103

Shawnee Mission, KS. 66204

913-384-0880

913-432-5242 (fax)

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Introduction
Apex Loadout provides control of overhead bins and silos from the Apex Scale Tickets screen. The weighmaster can
enter Loadout parameters and monitor the loading process from the Scale Tickets screen during load time.

Requirements
1. A Loadout controller (PLC) programmed to work with the Apex software
2. A scale indicator compatible with the Apex software
3. A computer meeting the requirements of the Apex software version to be utilized, with a COM port for the PLC
4. A license for the Apex software that includes the Loadout module

Hardware Installation
The installation of the Loadout controller (PLC) consists of wiring your various gate controls and devices to the
appropriate input and output relays. A standard 120V AC power source is required. A terminal wiring strip is provided
for wiring connections. If possible, wire to keep the original equipment intact to provide a backup. A licensed electrician
is required to install the Loadout controller. JWS technicians are not licensed electricians.

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Hardware Installation (Continued)
Loadout Controller Wiring Sets

SG – Slow Gate
This is for use in two-position gates, as the slow position (not fully open). It is assumed that turning ON the
power to this gate will OPEN the gate, and turning OFF the power to this gate will CLOSE the gate.

FG – Fast Gate
This is used to fully open the gate at the bottom of the silo. One-position gates will wire FG but not SG. It is
assumed that turning ON this output will OPEN the gate, and turning OFF this output will CLOSE the gate.

CMP – Loadout Complete

Typically wired to timer connected to a horn, the power to this will be turned ON when Loadout is complete.

LL – Low Level
The Apex software assumes that if the power to this input is ON, then the silo level is low.

SEL – Silo Selected

The Apex software assumes that if the power to this input is ON, the corresponding silo is selected for Loadout.

CT – Counter Pulse
The Apex software will increment the corresponding silo’s inventory each time the power to this input is ON.
Note: It may be useful for the electrician to block this signal if the reject chute is currently open.

CS – Counter Selected
The Apex software assumes that if the power to this input is ON, the corresponding silo is selected to be filled.

DG – Dump Gate
This is used to open the gate at the bottom of the weigh-hopper to load material onto the vehicle. It is assumed
that turning ON this output will OPEN the gate, and turning OFF this output will CLOSE the gate.

GC – Gate Closed
Weigh Gate (Upper Gate) Closed Limit Switch. If this input is ON,

SLG – Slug Feeder Gate

It is assumed that turning ON this output will OPEN the gate, and turning OFF this output will CLOSE the gate.

SLF – Slug Feeder Control Signal

The Apex software assumes that turning ON the power to this input will prevent the Slug Feeder Gate from
opening outside of the Apex software.

SLA – Slug Feeder Abort

This is used by third party controls. If the power to this input is turned ON, the Apex Loadout will abort so that
the Slug Feeder Gate can be opened by third party controls.

SLC – Slug Feeder Closed

The Apex software assumes that if the power to this input is ON, the Slug Feeder Gate is open, and therefore
Loadout will not continue.

JH – Jumper Hot
To use this configuration within the Apex software, the power to this input must always be ON.

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Hardware Installation (Continued)
Command Set 1: Platform Scale

This is for loadout lanes with a platform scale underneath the silos.
The scale weight for this configuration is the total vehicle weight.
With no vehicle on the scale, the scale instrument is at zero.
Apex can handle up to five silos per loadout controller for this configuration.

1 2 3 4 5

SG/FG

Output Points
0 1 2 3 4 5 6 7 8 9 10 11
SG FG SG FG SG FG SG FG SG FG CMP
Silo 1 Silo 2 Silo 3 Silo 4 Silo 5

Input Points (If the Loadout Controller will receive a different pulse for each silo being loaded)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
LL LL LL LL SEL SEL SEL SEL SEL LL CT CT CT CT CT
#1 #2 #3 #4 #1 #2 #3 #4 #5 #5 #1 #2 #3 #4 #5

Input Points (If the Loadout Controller will receive one pulse for all silos)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
LL LL LL LL SEL SEL SEL SEL SEL LL JH CT CS CS CS CS CS
#1 #2 #3 #4 #1 #2 #3 #4 #5 #5 #1 #2 #3 #4 #5

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Hardware Installation (Continued)
Command Set 2: Weighhopper

This is for loadout lanes with a hopper separate from the storage silo, located underneath the silo.
The scale weight for this configuration is the weigh-hopper weight.
When the weigh-hopper is empty, the scale instrument is zero.
Apex can handle up to three silos per loadout controller for this configuration.

1 2 3

SG/FG

DG

Output Points
0 1 2 3 4 5 6 7 8 9 10 11
SG FG DG SG FG DG SG FG DG CMP
Silo 1 Silo 2 Silo 3

Input Points (If the Loadout Controller will receive a different pulse for each silo being loaded)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
GC LL GC LL SEL SEL SEL GC LL CT CT CT
Silo 1 Silo 2 #1 #2 #3 Silo 3 #1 #2 #3

Input Points (If the Loadout Controller will receive one pulse for all silos)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
LL LL LL LL SEL SEL SEL GC LL JH CT CS CS CS
Silo 1 Silo 2 Silo 3 #1 #2 #3

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Hardware Installation (Continued)
Command Set 3: Negative Weigh

This is for loadout lanes where the entire weight of the silo is read into the scale indicator.
The scale weight for this configuration is the total silo weight, thus the weight decreases as the silo is emptied.
When the silo is empty, the scale instrument is at zero.
In order to prevent material from being added into a silo during a drop, Apex must control the Slug Feeder.
Apex can handle up to two silos per loadout controller for this configuration.

SLG

1 2

SG/FG

Output Points
0 1 2 3 4 5 6 7 8 9 10 11
SG FG SLG SG SLF FG SLG SLF CMP
Silo 1 #2 #1 Silo 2

Input Points (If the Loadout Controller will receive a different pulse for each silo being loaded)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
SLA SLC SLA SLC SEL SEL CT CT
Silo 1 Silo 2 #1 #2 #1 #2

Input Points (If the Loadout Controller will receive one pulse for all silos)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
SLA SLC SLA SLC SEL SEL JH CT CS CS
Silo 1 Silo 2 #1 #2 #1 #2

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Software Configuration
The Apex Loadout module works with other programs in the Apex software. Therefore, Loadout configuration includes
settings in several different locations within the Apex software. These way these settings are configured will determine
Apex Loadout behavior. Only settings that determine Apex Loadout behavior are included.

Bins/Silos/Stockpiles

Status
Active – This Bin/Stockpile is available
Out of Service – This Bin/Stockpile is not available

Inventory Unit
When viewing Bin/Silo Inventory, what unit of measure is used

Capacity
The quantity (in the inventory unit) that the Bin/Stockpile can contain

Last Qty fields

The amount of material in the Bin/Stockpile
The quantity that has been filled into it
The quantity that has been loaded out

Fill Unit
The unit of measure to be used when filling the silo

Fill Increment
The amount of material (in the fill unit) that has been loaded per pulse on the PLC

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Software Configuration (Continued)
Bins/Silos/Stockpiles (Continued)

Bin Scale Type

The corresponding Command Set in the Hardware Setup used for this Bin/Silo/Stockpile

Weight Scale No
The scale to be used for weighing when using Apex Loadout via this Bin/Silo/Stockpile

Load Off Scale

Enables loading a vehicle partially off-scale (Platform Scale only)
Note: The vehicle must be completely on the scale when Loadout is initiated
Note: This will generate a ‘Vehicle is in Position’ confirmation on every drop

Default No of Drops
The default number of drops that will be utilized when loading out of this Bin/Silo/Stockpile

Maximum Drop
The maximum amount of material to be loaded in a single drop
For weigh hoppers, this is the maximum amount the weigh hopper can hold

Weighhopper Freefall
The amount of material (lb or kg) loaded into the weigh-hopper after the power to the gate has been turned off

Bin Low Level

This is used to indicate on the Bin/Silo Inventory screen when the level of the Bin/Silo is low
For negative weigh, this will warn the operator when attempting Loadout

Auto Learn
Default – Use value in Load Stations
Yes – Change Freefall Values based on scale readings and Adjustment Factor
No – Do not automatically change free-fall Values
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Software Configuration (Continued)
Bins/Silos/Stockpiles (Continued)

Adjustment Factor
This determines how much Apex Loadout will change the free fall amount when learning
EX: If set to 4, the difference in free-fall is divided by 4 before being applied

Settle Time
The amount of time in tenths of a second to wait for the scale to settle before trying to get the weight
This is used to stop a scale weight reading from bouncing and becoming inaccurate

Max Load Time

The amount of time the gate can be held open before loadout is aborted

Slow Gate Control

Close/Open – Gates close completely, then open to slow position
Fast to Slow – Gates move from Fast position to Slow position, without closing first

Product
The product currently in the Bin/Silo/Stockpile

Free-fall Weights
Default – The amount of material loaded into the vehicle after the power to the gate has been turned off
Minimum – The lowest amount the free-fall can be adjusted to
Last Adjust. – The amount the free-fall was adjusted by on the last loadout

Top Off Mode

If checked, Apex will open the gate for the amount of time specified in ‘Open Time’
This is done until the difference between the current and target weights is less than the ‘Default’ Free Fall
If Auto Learn is used, Apex will change Freefall Values based on scale readings and Adjustment Factor

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Software Configuration (Continued)
Load Stations

Load Out Type

Automatic (JWS) – Loadout is controlled by Apex
Automatic (Other) – Loadout is controlled by a third party system
Manual Loading – Loadout is not performed automatically

Dump Gate Timer

Used if the Dump Gate on a weigh-hopper silo is controlled by a timer

Dump Timer Interval

The number of seconds the Dump Gate will remain open when controlled by a timer

Batcher Time Interval

Used by negative weigh silos
The number of seconds the Slug Feeder Gate should be held open so that it can be emptied

Auto Learn
Default – Use value in System Configuration
Yes – Change Freefall Values based on scale readings and Adjustment Factor
No – Do not automatically change free-fall Values

Adjustment Factor
This determines how much Apex Loadout will change the free fall amount when learning
EX: If set to 4, the difference in free-fall is divided by 4 before being applied

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Software Configuration (Continued)
Load Stations (Continued)

Control Set
The corresponding Command Set in the Hardware Setup used for this Bin/Silo/Stockpile

Load Out Model

LO-100 – Koyo DirectLogic PLC
LO-200 – Allen Bradley MicroLogic PLC

Control Scale No.

The scale ID setup for connecting to the PLC

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Software Configuration (Continued)
Load Stations (Continued)

Bin Information
Bin/Silos/Stockpiles assigned to this Load Station.
Note: The No. column corresponds to the Silo # defined in the Control Sets

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Software Configuration (Continued)
Workstations

Loadout requires a Default Load Station to be defined in the Workstation.

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Software Configuration (Continued)
System Configuration

Default Target Type

If using a scale set to Gross minus Tare, (Gross Scale Type) is used – Otherwise, (Net Scale Type) is used
Default Gross – By default, the target amount to be loaded into the vehicle is the Gross weight
Default Net – By default, the target amount to be loaded into the vehicle is the Net weight
Gross Only – Only the Gross weight of the vehicle can be used as a target
Net Only – Only the Net weight of the load can be used as a target

Auto Initiate Loadout

Yes – Loadout will automatically start when ‘Start Loadout’ is pressed from the Ticketing screen
No – Loadout will only start when ‘Start Loadout’ is pressed from the Loadout screen
The Loadout screen is brought up when pressing ‘Start Loadout’ from the Ticketing screen

Pause Before Start Loading

Yes – A confirmation box will show before loadout starts
No – Loadout begins immediately after ‘Start Loadout’ is pressed

Auto Drop (Multiple Drops)

Yes – Each drop will start automatically
No – A confirmation box will show between each drop

Drop Time Interval

If Auto Drop is set to Yes, this is the number of seconds between each drop

Auto Print Ticket After Drops

Yes – The ticket will automatically be printed when Loadout is complete
No – The ticket will be printed manually

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Software Configuration (Continued)
System Configuration (Continued)

Print / Save Timeout

If Auto Print Ticket After Drops is set to Yes, this is the maximum number of seconds to wait for the scale to
settle before printing/saving the ticket

Auto Message
Used with Apex automated loadout (New installations use OPC in favor of Apex automation)
Yes – Apex will look for Device I/O messages during loadout (this can affect accuracy)
No (recommended) – Apex will not look for Device I/O messages during loadout

Auto Timeout
Used with Apex automated loadout (New installations use OPC in favor of Apex automation)
The number of seconds to wait for events, such as the driver to initiate loadout, scale to settle, etc.

Auto Actuator Count

Used with Apex automated loadout (New installations use OPC in favor of Apex automation)
The number of times the actuator must be turned on before automated loadout begins
EX: If the actuator is a cord, and this is set to 2, the cord must be pulled 2x

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Software Configuration (Continued)
System Configuration (Continued)

Auto Learn
Yes – Change Freefall Values based on scale readings and Adjustment Factor
No – Do not automatically change free-fall Values

Adjustment Factor
This determines how much Apex Loadout will change the free fall amount when learning
EX: If set to 4, the difference in free-fall is divided by 4 before being applied

Maintain Silo/Bin Inventory

Set to Yes if a Silo Inventory Pulse will be received on the PLC

Scale Read Speed

This setting is no longer in use.
Weights are captured into a buffer, where recent weights are retrieved and the buffer is cleared.
Too many scale readings (usually over 20, but depends on system specs) can cause buffer overflow errors.

Load While In Motion

For Platform Scales, if set to Yes, Loadout will not check for Motion before starting a Drop

Validate Product In Silo/Bin

If set to Yes, a confirmation message will appear if attempting to begin Loadout for a Product different than the
one set on the Bin/Silo/Stockpile

Force Save or Print After Loading

If set to Yes, the operator is prevented from clearing the ticket after Loadout has started

Allow Switching Load Stations

If set to Yes, Apex will automatically switch the Load Station when choosing a Silo/Bin

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Software Configuration (Continued)
Vehicle Types

The Weight Calculation section of this document shows how Default, Federal, or Off Road is determined.

Weights will come from the Vehicle Type only if they are 0 on the actual Vehicle, where Drops Information will always
come from the Vehicle.

The Vehicle Type can be used to overwrite data in existing vehicles.

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Software Configuration (Continued)
Vehicles

The Weight Calculation section of this document shows how Default, Federal, or Off Road is determined.

Max GWV
The maximum total weight for this Vehicle

Max Net
The maximum weight of material that can be loaded onto this Vehicle

Target Gross
The target total weight of this vehicle

Target Net
The target weight of material to be loaded onto this Vehicle

Minimum Tare
The lowest acceptable Tare Weight value for this Vehicle

Tare Weight
The current empty weight of this Vehicle

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Software Configuration (Continued)
Vehicles (Continued)

Auto Drop (Multiple Drops)

Default – System Configuration value is used
Yes – Each drop will start automatically
No – A confirmation box will show between each drop

No. of Drops
The number of drops that will be given for this vehicle
Note: If using multiple components, this number must equal the total Component No. of Drops

Component Count
Total number of components of this vehicle
Note: Each container that will be loaded (usually including the vehicle itself) is a component

Component No. Of Drops

Number of Drops for this particular Component
EX: A Tri-Axle vehicle is a component, and its trailer is a component (2 components will be loaded)

Calculate Drops As
Equal Sized Drops – Target Net is divided by Total Drops to find the Target Drop Net Weight
Percentage By Drop – Percent/Weight fields will be populated with the percentage of each drop
Quantity Entered – Percent/Weight fields will be populated with the weight of each drop

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Weight Calculation
Weights will be calculated based on the following items. If #1 cannot be calculated, then we go to #2, etc.
Fields used depend on the Weight Type identified at the beginning of the process.

Weight Types
1. If a Dispatch Order is used, use Default, Federal, or Off Road depending on selection
2. If an Order is used, use Default, Federal, or Off Road depending on selection
3. Use Default, Federal, or Off Road depending on Customer selection

Tare Weight
1. If Platform Scale, and Scale Weight is > 0 when Loadout is started, use scale weight
2. If vehicle’s current tare is > vehicle’s minimum tare, use vehicle’s current tare

Maximum Gross Weight

1. Lowest of the following:
a. Dispatch Order Maximum Gross, if > 0
b. Order Maximum Gross, if > 0
c. Customer Maximum Gross, if > 0
d. Vehicle Maximum Gross, if > 0
e. Destination State’s Maximum Gross, if > 0
f. Source State’s Maximum Gross, if > 0

Maximum Net Weight

1. Lowest of the following:
a. Dispatch Order Maximum Net, if > 0
b. Order Maximum Net, if > 0
c. Customer Maximum Net, if > 0
d. Vehicle Maximum Net, if > 0
2. Vehicle Type Maximum Net, if > 0
3. (Vehicle Maximum Gross – Vehicle Current Tare), if > 0
4. (Vehicle Type Maximum Gross – Vehicle Current Tare), if > 0

Note: Maximum Net weight is then recalculated. If Maximum Net Weight is > (Maximum Gross Weight – Current
Tare Weight), (Maximum Gross Weight – Current Tare Weight) is used.

Target Gross Weight

1. User Target Gross, if > 0
2. (User Target Net + Vehicle Current Tare), if User Target Net > 0
3. Vehicle Maximum Gross Weight, if > 0
4. Vehicle Type Maximum Gross Weight, if > 0

Note: Target Gross Weight is then recalculated. If Target Gross Weight is > Maximum Gross Weight, Maximum
Gross Weight is used.

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Weight Calculation (Continued)
Target Net Weight
1. User Target Net, if > 0
2. (User Target Gross – Vehicle Current Tare), if User Target Gross > 0
3. User Drop Target Net, if > 0
4. Dispatch Order Target Net, if > 0
5. Vehicle Target Net, if > 0
6. Vehicle Type Target Net, if > 0
7. (Vehicle Target Gross – Vehicle Current Tare), if > 0
8. (Vehicle Type Target Gross – Vehicle Current Tare), if > 0
9. (Vehicle Maximum Gross – Vehicle Current Tare), if > 0
10. (Vehicle Type Maximum Gross – Vehicle Current Tare), if > 0

Note: Target Net Weight is then recalculated. If Target Net Weight is > Maximum Net Weight, Maximum Net
Weight is used.

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Operation
Ticket Screen

The Apex Ticketing screen operates the same way, with the addition of a Loadout button at the top of the screen, used
to open the Loadout Control. You can also access this screen by pressing F11 on they keyboard.

When customizing the screen, depending on how Loadout will be used, it may be beneficial to add fields. Some of the
fields that can be added to the screen include:

Field Number Description

232 Bin/Silo/Stockpile
255 Bin/Silo/Stockpile Label
253 Load Station
254 Load Station Label
260 / 262 Maximum Net / Maximum Net (ton/mton)
640 / 641 Maximum Gross / Maximum Gross (ton/mton)
730 Target Gross
731 Target Tare
732 Target Net
261 / 263 User Target Net / User Target Net (ton/mton)
621 / 622 User Target Gross / User Target Gross (ton/mton)
681 / 682 User Target Alt-Net / User Target Alt-Net (ton/mton)
679 / 680 Batch Drop Size / Batch Drop Size (ton/mton)
372 Total Drop Count
568 - 577 Target Drop Weight (Drops 1-10)
578 - 587 Target Drop Weight (ton/mton, Drops 1-10)
696, 700, 704, 708 Vehicle Component Label (Components 1-4)
697, 701, 705, 709 Vehicle Component Drop Count (Components 1-4)
698, 702, 706, 710 Vehicle Component Drop Weight (Components 1-4)
699, 703, 707, 711 Vehicle Component Drop Weight (ton/mton, Components 1-4)

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Operation (Continued)
Loadout Control Screen

Bin
The silo that will be opened to load material into the vehicle
This can be input on the ticketing screen to default when this window is pulled up

Drops
The number of drops that will be used to load material into the vehicle
This can be input on the ticketing screen to default when the window is pulled up
If this is not changed on the ticketing screen, it is defaulted from the Vehicle itself

Target Type
This is defaulted from the System Configuration values for the ‘Default Target Type’ settings
If this is set to one of the ‘only’ options, it will be read-only

Target Weight/Quantity
This will be Gross or Net, depending on Target Type
Weight is in lb or kg, where Quantity is in ton or mton

Progress Bar
Progress bars will fill with green with progress towards Drop and Total (Loadout) completion

Drops Screen
The drops screen shows current and projected totals for drops, and will recalculate drop targets after each drop

Note: All 3 screens in the Loadout Control can be hidden individually, and the size/position of the popups can be
changed as well. This is done through the WorkstationID.Sta file, found in the Apex\Company_ID folder.
EX: C:\CAI\JWS\Apex\1\1.Sta

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Operation (Continued)
Edit Drops

The Edit Drops window can be accessed from the Loadout Control via Loadout>Edit Drop Weights (or CTRL+E).

Weights for each drop, up to 10 drops, can be entered here to replace system calculated drop weights. These weights
can be entered in as lb/kg, or ton/mton, with the other column automatically calculating.
EX: Entering 1000 LB will change Tons to 0.50.
EX: Entering 2.00 Tons will change LB to 4000.

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Operation (Continued)
Bin/Silo Inventory

Inventory for each silo will increment (based on the Fill Increment in the Bin/Silo/Stockpile screen) each time a pulse is
received on the PLC (based on Counter Select or specific Silo Pulse). Alternatively, if a Receive load is done against a
bin/silo, inventory will increment based on the amount of the ticket.

Inventory will decrease based on the amount of each ship ticket against a particular bin/silo.

It may be useful to create a new bin/silo, named Ground Loading, and hide it from this screen.

Window positions, silo sizes, silo order, etc. can be configured through the WorkstationID.Sta file, found in the
Apex\Company_ID folder.
EX: C:\CAI\JWS\Apex\1\1.Sta

In the picture above, the yellow line is based on the Low Level, configured in the Bin/Silo/Stockpile screen. The
percentage is based on the current amount in the Silo, as well as the capacity (also set in the Bin/Silo/Stockpile screen).

The current silo levels can be adjusted manually via right clicking this window, and clicking on ‘Edit Silo Quantity’.

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