M1 MCI360Compartment - Manual PDF

M1 MCI360
Operating Instruction for

MCI 360 – M1 Compartment Batcher
Important Note :
The Data’s indicated in this Operating Instruction may differ from plant to plant in accordance
with constant improvement, and we reserve all right to change or modify any parts at any time
without any prior notification.
Table of Contents
M1 MCI 360
Total Pages
01. Safety Instruction 02
02. Technical Data 03
03. Operating Instruction 50
04. Cable List 06
05. Spare Parts List 08
06. Recommended Spare Parts List 01
07. PLC Input / Output List 05
08. Control Panel General Arrangement 01
09. Control Panel Circuit Diagram 25
10. Junction Box & Connector Detail 05
11.3 Phase Induction Motor Fault Finding Procedure 03
12. Silo Level Meter 22
13. Moisture Meter 14
14. Phase Failure Relay 03

M1-MCI 360
ATTENTION!
All Electrical works and connections to be done by an Electrical Expert. Any work on the plant
may be performed only when the plant is switched off.
In case of the Plant is completely switched off during Maintenance and repair works, it must be
Safeguarded against unexpected Switching – On.
- Lock up Main Switching Equipment, Press Emergency Stop and Draw off the key.
In case of Disorder in Electric Supply (ie) Unbalanced Voltage, Single Phasing and
Over/Under Voltage, Please switch off the Plant immediately. And do not try to start. Ensure
that the problem is sorted out and then start the plant.
Use Voltage Insulated tools only, when working in electrical areas.
ELECTRICAL INSTALLATION
The cross section of the Incomer conducting cable for the power is on customer scope and
should be of 4*50 Sq mm Cu or 4*95 Sq mm Al.
Since earth plays very important role for accuracy of the plant, we request the customer to
provide proper earth to the structure and control panel of the plant.
D.G REQUIREMENT
The minimum capacity of the D.G provided by the customer should be 125 KVA and should
have 150% overload capacity.
POWER FAILURE
In the event of power failure, during the mixing cycle, the Pan Mixer can be started in Direct
on Line mode and that is why direct starting of mixer is provided and not for frequent
operation. Schwing Stetter does not take any responsibility at any circumstances if the above
facility is misused.
WELDING IN PLANT
If it is necessary to do Welding in the batching plant, kindly Switch Off the Control Panel
Power and Isolate the load cell from the weigher by tightening the transportation lock.
M1-MCI 360
PROTECTIVE AND SAFETY DEVICES
All Protective and safety devices are to be kept operative and must be repaired / replaced
immediately, in the event of failure. Bypassing the safety devices may result in heavy injuries
or even loss of lives.
No claim can be made in the event of Bypassing of any Protective / Safety Devices in the
control system. Schwing Stetter does not take any responsibility to such kind of activities
made.
We recommend to keep minimum spare parts available with you all times. Refer the
Recommended Spare Part List available in the manual.
REPLACEMENT OF ELCTRICAL ITEMS
The electrical life time of the Power and Control Contactors are 0.5 million operations at a
Constant Ambient temperature of 45 degree C. De-ration is applicable when operating at
higher temperature.
Any how considering the dusty atmosphere and to get best result we recommend to replace the
Contactors every 1, 20,000M 3 or 5000 Working Hours whichever is earlier and do not
replace the Contacts.
ADDITIONAL MATERIAL CONSUMPTION
Schwing Stetter does not take any responsibility in the event of misuse of materials (i.e.) taking
Cement instead of Fly ash / additional consumption of materials if batching done in manual
mode and no claim can be made. Material consumption in manual mode to be recorded by the
customer only.
M1 – MCI360
Technical Data
M1 MCI 360
Technical Data
Electric supply data
Supply Voltage:……………………………………………… 415 Volts

Permissible voltage fluctuation:……………………………… + / - 10 %
Frequency:……………………………………………………. 50 Hz
Connected Load:……………………………………………... 83 kVA
Operating Temperature:……………………………………… 5 – 40 deg C
Incomer cable requirement:…………………………………. 4*50 Sq mm Cu
D.G.Requirement:…………………………………………… 125kVA
Weigher data
Aggregate……………………………………………………. 2500 Kg
Cement………………………………………………………. 500 Kg
Water………………………………………………………… 250 Kg
Admixture……………………………………………………. 10 Kg
Aggregates …………………………………………………… 4 Components
Cement……………………………………………………….. 2 + 1 Max
Water…………………………………………………………. 1
Admixture……………………………………………………. 1 Component
M1 MCI360
Technical Data
Motor Details
Compressor Motor:……………………………………………… 2.2 kW / 3 HP

Sand Vibrator Motor..:…………………………………………....0.18kW /0.24 HP
Screw Conveyor Motor-1:………………………………………..11 kW /15HP
Screw Conveyor Motor-2 :(Optional)……………………………11 kW / 15HP
Fly Ash Screw Conveyor: (Optional)……………………………11 kW / 15HP
Cement Vibrator Motor..: ……………………………………....0.18kW /0.24 HP
Mixer Motor:……………………………………………………..37 kW / 50 HP
Skip Motor:……………..………………………………………..15 kW / 20 HP
Admixture Dosing Motor:………………………………………...0.75 kW / 1 HP
Admixture Discharge Motor : (Optional )……………………….0.75 kW / 1HP
Water Pump Discharge Motor:…………………………………...7.5 kW / 10 HP
Note:
All the above Motors are 3 Phase 415 V AC ± 10% , 50Hz, Otherwise Specified in the Drawing
All Contactor Coil Voltage - 220V AC 50Hz
All Relay Coil Voltage - 24V DC
All Solenoid Coil Voltage - 24V DC
All Indication Lamp Voltage - 24V DC
Skip Motor Brake Rectifier Input Voltage – 415V AC
All the Motor Protection Breakers and the Multi core Cables Provided by us are designed for
Constant Ambient temperature of 45° C. De-rating is applicable when operating at higher
temperature.
M1 MCI360
Technical Data
Panel Wiring Cable Color Code Details:
Red : 230 V AC
Black : Neutral
Blue : PLC Input side
Grey : PLC Output side
Orange : + 24 V DC
Violet : 0 V DC
White : Thermister Connecting cable
Brown : Before Incomer ie Power will be available even if incomer is in OFF
Load Cell Details:
Input Resistance : 350 Ohms ± 2 Ω

Output Resistance : 350 Ohms ± 2 Ω
Excitation Voltage : 10 V DC
Non-Linearity : < ± 0.025 %
Full Scale Output : 2 mV /V
Load Cell Wiring Details:
Red : Excitation (+ 10VDC)

Black : Excitation (0 V DC)
White : - Signal
Green : + Signal
MCI360 CONTROL SYSTEM
SCHWING STETTER INDIA PVT LTD.
MCI 360 CONTROL SYSTEM

USER MANUAL
1
INDEX
Page No
1.Introduction on MCI360 Control System 3
2.Scada Software
a. System Requirement and other information 4
b. Getting Started 5
c. Menu details 9
d. Master Details 9
e. Schedule Start 31
f. Plant Setup 32
g. Manual Operation 33
h. Generate Report 34
i. Divert Truck 45
j. Alarm Accept 46
k. Exit Software 46
l. Maintenance Schedule 46
m. Mimic screen text and graphical 46
n. Help Option 47
3,Features of MCI 360 48

4,Installation & UN installation of the software 50
2
1.Introduction On MCI360 Control System.
MCI 360 control system is one of the most sophisticated control systems in the world for
concrete batching plants. The main agenda was to bring down the workload of the
bathing plant operator.
This control system supports various batching plants ranging from schwing stetters M1 to
H6n.There are some new features available in the mci360 control system than our mci300
system.
The following are some additional features available in mci360 control system.
1. Schedule based batching

2. Maintanace schedule
3. Cement batching silo can be changed in between in case of silo empty
4. Automatic calibration and manual calibration available.
5. All kinds of statistical reports are available.
6. Slump measurement (optional)
7. PID control based batching (addition to the material in air control)
8. Automatic batching after power recovery
9. Centralized connection of load cell with plc
10. Common software for all stetter plants ranging from M1 to H6
11. Introduction of touch panel
12. Introduction of membrane keypad instead of control desk
13. Connectivity to USB camera (optional)
14. Customer credit locking system (optional)
16. Provision for slurry water batching
17. Introduction of authority based password control
18. Facility to divert the concrete from one customer to another (delivery docket)
19. Possibility for networking the plants (optional)
In the below chapters we will have a brief look on all the features and advantages of the
MCI 360 control system.
3
2.SCADA Software
a, System Requirements.
The control system is inclusive of computer this is for your information
1.P-IV processor 2.6 G Hz speed.

2.512 MB Ram
3.Loaded with win 2000 professional OS
4.Built in internal modem
5.Wincc Version 6 with spk3 & above
6.crystal tools and ms-tool with other components.
7.ie 6
8.Batching software
9.Communication Processor (5611)
10.win 2k spk4
4
b, Getting Started
After logging on to the windows press the batching software icon from the desktop to
initialize the SCADA software. The logon screen will appear on your screen as shown in
fig b1.0 enter the user name and password to logon to the software. The main screen will
appear on your screen as shown in fig b1.1 or b1.2 or b1.3 or b1.4 or b1.5 It will be
having the pictorial representation of the batching plant where we can monitor the exact
operation that is happening physically and a separate alarm window provided on top of
the screen where we can monitor the alarm status. There is additional facility where we
can always have a choice of selecting the main screen as per our plant requirement for eg
if you own an m1 plant with MCI 360 control system then you can choose that plant
graphical view on main screen it is given briefly in the following chapters. This software
is common software for all the plants ranging from M1 to H6 plants as given in the below
pictures.
5
Fig b1.0
Fig b1.1 (This screen sets for h3n skip type plant)
6
Fig b1.2 (This screen sets for h3n, h4n, h6n inclined conveyor with aggregate parallel
batching type plant)
Fig b1.3 (This screen sets for h3n, h4n, h6n inclined conveyor batching type plant)
7
Fig b1.4 (This screen sets for m1 compartment batcher type plant)
Fig b1.5 (This screen sets for m1 inline silo, H2, H1.25, H1 batcher type plant)
8
c, Menu Details
The following are the menus that available in mci360 control system.
1. Master menu
2. Schedule start
3. Manual operation
4. Plant setup
5. Generate report
6. Divert concrete
7. Exit
8. Alarm accept
9. Mimic screen
10. Maintenance schedule enable.
d, Master Details
1,Master menu
When we select the master menu the following screen appears in your pc as shown in fig
c1.0 following are available list of master details.
9
Fig c 1.0
1.Customer master
2. Site master
3.Truck master
4.Recipe master
5.Order master
6.Schedule master
7.User master
8.Maintenance master
1.Customer master:
The following are the fields available in customer master.
1.Customer code: This field is a mandatory field and it is capable of storing up to 15
character length of data and this field is the key identity and reference field of customer
details.
2.Customer name: This field is a mandatory field and it is capable of storing up to 30
character length of data and in this field we need to enter the name of the firm or an
individual.
10
3.Contact person: This field is an optional field and it is capable of storing up to 25
character length of data and in this field we need to enter the representative name of the
customer / client we deals with accounting in corporate office.
4.Customer Address: This field is a mandatory field and it is capable of storing up to
80-character length of data and in this field we need to enter the corporate address of the
customer.
5.City: This field is an optional field and it is capable of storing up to 15-character
length of data and in this field we need to enter the name of the city where this customer
corporate office is located
6.Pincode: This field is an optional field and it is capable of storing up to 6-character
length of data including center space in the pin code no and in this field we need to store
the pin code of the customer.
7.Phone: This field is an optional field and it is of character type it will also accept
character in case we need to enter “-“ in between no’s it is capable of storing up to 10
character length of data and in this field we need to enter the phone no of corporate
office.
Add Customer:
To add a new customer we need to enter in to master menu from main mimic screen by
clicking the master menu button and from the given options we need to choose the
customer master button then the below screen as shown in fig. C1.1 will appear on your
monitor.
Click on add button this will clear all old data’s from the screen and now start entering
the relevant data and press save to store the data.
11
Fig c1.1
Edit Customer:
To edit an existing customer we need to click the load customer code button and this will
list down the available customer in added or ascending order now choose the customer
code in which we need to perform the edit operation and then edit the required field and
press save button to store the data.
Delete Customer:
To delete a customer we need perform the same thing as we did for customer edit option
like choose the load customer code and select the customer code from the given customer
code field box and press delete button this will logically delete the customer but
practically the data will be retained for future reference of the system administrator.
Note: We can store customers up to disk limit which means unlimited and be sure to enter
all the mandatory data’s while storing the customer because those fields are very
important in the event of storing the cycle data, not entering those field could affect the
storage of cycle data.
12
2.Site master:
The following are the fields available in site master.
1.Customer code: This field is a mandatory field and it is capable of storing up to 15
character length of data and this field is the key identity and reference field of customer
details in the site master.
2.Site name: This field is a mandatory field and it is capable of storing up to 30
character length of data and in this field we need to enter the name of the construction
site where we are about to supply the concrete.
3.Contact person: This field is an optional field and it is capable of storing up to 25
character length of data and in this field we need to enter the representative name of the
customer / client or the name of the engineer who is available in the site.
4.Site Address: This field is a mandatory field and it is capable of storing up to 80-
character length of data and in this field we need to enter the exact location of the site by
km or postal address if available.
5.City: This field is an optional field and it is capable of storing up to 15-character
length of data and in this field we need to enter the name of the city where this site
located
6.Pincode: This field is an optional field and it is capable of storing up to 6-character
length of data including center space in the pin code no and in this field we need to store
the pin code of the site.
7.Phone: This field is an optional field and it is of character type it will also accept
character in case we need to enter “-“ in between no’s it is capable of storing up to 10
character length of data and in this field we need to enter the phone no of site engineer of
site office.
Add Site:
To add a new site we need to enter in to master menu from main mimic screen by
clicking the master menu button and from the given options we need to choose the Site
master button then the below screen as shown in fig. C2.1 will appear on your monitor.
Click on add button this will clear all old data’s from the screen and now select the
customer code which is listed in the customer entry box and then start entering the
relevant data and press save to store the data.
13
Fig c2.1
Edit Site:
To edit an existing site we need to click the load customer code button and this will list
down the available customer in added or ascending order now choose the customer
Code in which we need to perform the edit operation after that we also need to choose the
relevant site of the customer which is required to be modified and then edit the required
field and press save button to store the data.
Delete Site:
To delete a site we need to perform the same thing as we did for site edit option like
choose the load customer code and select the customer code from the given customer
code field box and this will list the sites which are available for that customer in the given
site box now press delete button this will logically delete the site of the customer but
practically the data will be retained for future reference of the system administrator.
Note: We can store sites up to disk limit which means unlimited and be sure to enter all
the mandatory data’s while storing the site because those fields are very important in the
event of storing the cycle data, not entering those field could affect the storage of cycle
data.
14
3.Truck master:
The following are the fields available in truck master.
1.Truck no: This field is a mandatory field and it is capable of storing up to 15
character length of data and this field is the key identity and reference field of truck
details.
2.Truck Id: This field is a mandatory field and it is capable of storing numeric data
and in this field we need to enter the id no or serial number, which are assigned to the
trucks.
3.Truck Capacity: This field is a mandatory field and it is capable of storing numeric
data and in this field we need to enter the capacity of the transit mixer drum in cubic
meter.
4.Truck Type: This field is a mandatory field and it is option-based field where we
need to choose any one between two given options. The options are transit mixer and
tipper.
5.Truck Driver: This field is an optional field and it is capable of storing up to 25-
character length of data and in this field we need to enter the driver name of the truck
6.Mid Position: This field is an optional field and it is capable of storing numeric
data and in this field we need to enter the required batching plant mixer gate ½ opening
time according to the transit mixer feeding chute opening. If no value given it will
consider the default value that is 0.Giving some value here will avoid spillage of the
material from transit mixer while discharging the material from the batching plant mixer
to transit mixer.
Add Truck:
To add a new truck we need to enter in to master menu from main mimic screen by
clicking the master menu button and from the given options we need to choose the truck
15
Fig c 3.1
Edit Truck:
To edit an existing truck we need to click the load truck no button and this will list down
the available truck in added or ascending order now choose the truck no in which we
need to perform the edit operation and then edit the required field and press save button
to store the data.
Delete Truck:
To delete a truck we need to perform the same thing as we did for truck edit option like
choose the load truck no and select the truck no from the given truck no field box and this
will list the truck details which are available, now press delete button this will logically
delete the truck details but practically the data will be retained for future reference of the
system administrator.
Note: We can store trucks up to disk limit which means unlimited and be sure to enter all
the mandatory data’s while storing the truck because those fields are very important in
the event of storing the cycle data, not entering those field could affect the storage of
cycle data.
16
4.Recipe master:
The following are the fields available in recipe master.
1.Recipe Code: This field is a mandatory field and it is capable of storing up to 15-
character length of data and this field is the key identity and reference field of recipe
details.
2.Recipe Name: This field is a mandatory field and it is capable of storing up to 25-
character length of data and in this field we need to enter the recipe or grade name.
3.Consistancy: This field is an optional field and it is capable of storing up to 15-
character length of data and in this field we need to enter the consistency maintained in
such grade of concrete.
4.Strength: This field is an optional field and it is capable of storing numeric data and
in this field we need to enter the strength maintained in such grade of concrete.
5.Aggregate1 Set weight: This field is an optional field and it is capable of storing
numeric data and in this field we need to enter the set weight assigned to the material that
is loaded in bin 1 of aggregate bins. If nothing is entered then it takes the default value,
which is 0.
which is 0.
which is 0.
which is 0.
which is 0.
which is 0.
11.Cement1 Set weight: This field is an optional field and it is capable of storing
is loaded in bin cement silo 1. If nothing is entered then it takes the default value, which
is 0.
is 0.
17
is 0.
is 0.
is 0.
16.Water1 Set weight: This field is an optional field and it is capable of storing
numeric data and in this field we need to enter the set weight of water that we are about
to use in the concrete. If nothing is entered then it takes the default value, which is 0.
17.Water2 Set weight: This field is an optional field and it is capable of storing
numeric data and in this field we need to enter the set weight of water2/ice that we are
about to use in the concrete. If nothing is entered then it takes the default value, which is
0.
18.Slurry Set weight: This field is an optional field and it is capable of storing
numeric data and in this field we need to enter the set weight of slurry water that we are
about to use in the concrete. If nothing is entered then it takes the default value, which is
0.
19.Silica Set weight: This field is an optional field and it is capable of storing
numeric data and in this field we need to enter the set weight of silica that we are about to
use in the concrete. If nothing is entered then it takes the default value, which is 0.
20.Admixture1 Sort1 Set weight: This field is an optional field and it is capable of
storing numeric data and in this field we need to enter the set weight of admixture type1
that we are about to use in the concrete. If nothing is entered then it takes the default
value, which is 0.
storing numeric data and in this field we need to enter the set weight of admixture type2
value, which is 0.
storing numeric data and in this field we need to enter the set weight of admixture2 type1
value, which is 0.
storing numeric data and in this field we need to enter the set weight of admixture2 type2
value, which is 0.
24.Mass Per Cu.Meter: This is an auto-generated field where it will calculate the sum
of all set weights and store in the hard disk.
18
Note: The set weights that we enter is for 1 cu.meter and the limit of each field is based
on the total capacity of the weigher that is defined in the plant setup maximum
calibration.
Add Recipe:
To add a new recipe we need to enter in to master menu from main mimic screen by
clicking the master menu button and from the given options we need to choose the recipe
Fig c 4.1
Edit Recipe:
To edit an existing recipe we need to click the load recipe code button and this will list
down the available recipe in added or ascending order now choose the recipe code in
which we need to perform the edit operation and then edit the required field and press
save button to store the data.
19
Delete Recipe:
To delete a recipe we need to perform the same thing as we did for recipe edit option like
choose the load recipe code and select the truck no from the given recipe code field box
and this will list the recipe details which are available, now press delete button this will
logically delete the recipe details but practically the data will be retained for future
reference of the system administrator.
Note: We can store recipe up to disk limit which means unlimited and be sure to enter all
the mandatory data’s while storing the recipe because those fields are very important in
cycle data.
5.Order master:
The following are the fields available in order master.
1.Order no: This field is a mandatory field and it is capable of storing up to 15
character length of data and this field is the key identity and reference field of order
details.
2.Order Name: This field is a mandatory field and it is capable of storing up to 25-
character length of data and in this field we need to enter the order name or reference of
order no.
3.Ordered Customer: This field is a mandatory field and it is a selectable field type
where we need to press the button next to that field and select the customer from the
given list.
4.Ordered For Site: This field is a mandatory field and it is a selectable field type
where we need to press the button next to that field and select the suitable or supplying
location or site for the customer from the given list
5.Ordered Recipe: This field is a mandatory field and it is a selectable field type
where we need to press the button next to that field and select the recipe that we are about
to batch to the site from the given list.
6.Truck No: This field is a mandatory field and it is a selectable field type where we
need to press the button next to that field and select the available truck from the given
list. Note: you can change the truck no in between the batching time also from the main
screen
7.Total Ordered Qty: This field is an optional field and it is capable of storing
numeric data and in this field we need to enter the total order placed by the customer and
the default value is 0
8.Total With This Load: This field is an optional field and it is capable of storing
numeric data and in this field we need to enter total load sent so far to the customer on
the particular order.
9Schedule Order: This field is a mandatory field and it is capable of storing numeric
data and in this field we need to enter the scheduled order for execution of the batching
sequence
10.Production Qty: This field is a mandatory field and it is capable of storing
numeric data and in this field we need to enter the production quantity by which the batch
completion has to be executed.
20
11.Aggregate Used: This field is an optional field and it is capable of storing up to 8-
character length of data and in this field we need to store the maximum aggregate used in
the concrete.
12.Cement Used: This field is an optional field and it is capable of storing up to 8-
character length of data and in this field we need to store the type of cement that we used
in the concrete.
13.Water Used: This field is an optional field and it is capable of storing up to 8
character length of data and in this field we need to store the water % we have used in the
concrete.
14.Admixture Used: This field is an optional field and it is capable of storing up to 8-
character length of data and in this field we need to store the type of admixture that we
are using in the concrete.
15.Pump Type: This field is an optional field and it is capable of storing up to 10-
character length of data and in this field we need to enter the type of supply whether it is
a pumping concrete or a supply
Add Order:
To add a new order we need to enter in to master menu from main mimic screen by
clicking the master menu button and from the given options we need to choose the order
fig c 5.1
21
Edit Order:
To edit an existing order we need to click the load order no button and this will list down
the available order in added or ascending order now choose the order no in which we
need to perform the edit operation and then edit the required field and press save button
to store the data.
Delete Order:
To delete a order we need to perform the same thing as we did for order edit option like
choose the load order no and select the order no from the given order no field box and
this will list the order details which are available, now press delete button this will
logically delete the order details but practically the data will be retained for future
reference of the system administrator.
Note: We can store order up to disk limit which means unlimited and be sure to enter all
the mandatory data’s while storing the order because those fields are very important in
cycle data in the case of order master it can result in batch hang or problem in starting the
batch.
6.Schedule master:
The following are the fields available in schedule master.
1.Schedule Id: This field is a mandatory field and it is capable of storing up to 15-
character length of data and this field is the key identity and reference field of schedule
details.
2.Schedule Name: This field is a mandatory field and it is capable of storing up to
25-character length of data and in this field we need to enter the Schedule name.
3.List Of Available Order: This field is a display field where by pressing the list of
orders button the available orders will be displayed and from that we can choose the
orders that we are about to schedule for the day.
4.Selected Orders: This field is a display where the selected orders from the order list
will be displayed. The order can be selected by pressing the button with the symbol “>”
and can be deselected by pressing the button with the symbol “<”.
5.Schedule Type: This field is a selecting option field where there will be 2 option
available “Normal” and Alternative” from which we need to select one. The normal type
of scheduling is nothing but the regular batching which means after completing the
scheduled order qty on production qty basis it will move to the next order where as in
alternative type after completing production qty batch it will move to next order.
Add Schedule:
To add a new schedule we need to enter in to master menu from main mimic screen by
schedule master button then the below screen as shown in fig.C6.1 will appear on your
monitor.
22
Fig c 6.1
Edit Schedule:
To edit an existing schedule we need to click the load schedule id button and this will list
down the available schedule in added or ascending order now choose the schedule id in
which we need to perform the edit operation and then edit the required field and press
save button to store the data.
Delete Schedule:
To delete a schedule we need to perform the same thing as we did for schedule edit
option like choose the load schedule id and select the schedule id from the given schedule
id field box and this will list the schedule details which are available, now press delete
button this will logically delete the schedule details but practically the data will be
retained for future reference of the system administrator.
Note: We can store schedule up to disk limit which means unlimited and be sure to enter
all the mandatory data’s while storing the order because those fields are very important in
cycle data in the case of schedule master it can result in batch hang or problem in starting
the batch.
23
7.User master:
The following are the fields available in user master.
1.User Name: This field is a mandatory field and it is capable of storing up to 15-
character length of data and this field is the key identity and reference field of user details
and to logon into the software.
2.Password: This field is a mandatory field and it is capable of storing up to 15
character length of data and in this field we need to enter the secrete password for login
user name. Note: If we forget the login password then it will be impossible to login to the
software.
3.Customer Master: This field is a selectable field and if this field is selected for the
user then that particular user have access to that level of area if not then the user can not
log in to that field area.
4. Site Master: This field is a selectable field and if this field is selected for the user
then that particular user have access to that level of area if not then the user can not log in
to that field area.
5. Truck Master: This field is a selectable field and if this field is selected for the
6. Recipe Master: This field is a selectable field and if this field is selected for the
7. Order Master: This field is a selectable field and if this field is selected for the
8. Schedule Master: This field is a selectable field and if this field is selected for the
9. User Master: This field is a selectable field and if this field is selected for the user
to that field area.
10. Material Inward: This field is a selectable field and if this field is selected for
the user then that particular user have access to that level of area if not then the user can
not log in to that field area.
11. Maintenance Master: This field is a selectable field and if this field is selected
for the user then that particular user have access to that level of area if not then the user
can not log in to that field area.
12. Material In Air: This field is a selectable field and if this field is selected for the
13. Coarse to Fine: This field is a selectable field and if this field is selected for the
14. Tolerance: This field is a selectable field and if this field is selected for the user
to that field area.
24
15. Empty Value: This field is a selectable field and if this field is selected for the
16. Jogontime: This field is a selectable field and if this field is selected for the user
to that field area.
17. Step time: This field is a selectable field and if this field is selected for the user
to that field area.
18. Discharge sequence: This field is a selectable field and if this field is selected for
19. Calibration: This field is a selectable field and if this field is selected for the user
to that field area.
20. Other settings: This field is a selectable field and if this field is selected for the
21. Mixer calibration: This field is a selectable field and if this field is selected for
22. Weigher capacity: This field is a selectable field and if this field is selected for
23. Generate Report: This field is a selectable field and if this field is selected for the
24. Manual Operation: This field is a selectable field and if this field is selected for
25. Divert Concrete: This field is a selectable field and if this field is selected for the
Add User:
To add a new user we need to enter in to master menu from main mimic screen by
schedule master button then the below screen as shown in fig.C7.1 will appear on your
monitor.
25
Fig c 7.1
Edit User:
To edit an existing user we need to enter the logged on user name and password by which
it will display all the level of access allotted to that user and we need to perform the edit
operation and press save button to store the data.
Delete User:
To delete a user enter user name and password and press delete to cancel the user.
Note: We can store user details up to disk limit which means unlimited and be sure to
enter all the mandatory data’s while storing the user because those fields are very
important in the event of login, not entering those field could result in authority block to
enter in to the software.
26
8.Inward Material:
The following are the fields available in Inward Material.
1.Aggregate 1: This field is an optional field and it is capable of storing numeric data
and this field will be automatically updated day wise when any data is entered. If nothing
is entered the value will be considered as 0
7.Cement 1: This field is an optional field and it is capable of storing numeric data
12.Water 1: This field is an optional field and it is capable of storing numeric data
13.Water 2 / Ice: This field is an optional field and it is capable of storing numeric
data and this field will be automatically updated day wise when any data is entered. If
nothing is entered the value will be considered as 0
14.Slurry: This field is an optional field and it is capable of storing numeric data and
this field will be automatically updated day wise when any data is entered. If nothing is
entered the value will be considered as 0
27
15.Silica: This field is an optional field and it is capable of storing numeric data and
this field will be automatically updated day wise when any data is entered. If nothing is
entered the value will be considered as 0
16.Admixture1 Sort1: This field is an optional field and it is capable of storing
numeric data and this field will be automatically updated day wise when any data is
entered. If nothing is entered the value will be considered as 0
Update and enter the material inward:

To inward a material we need to enter all the available details of material inward in to the
system manually and press save entering more then once in a day will update the record
based on the day in inward details
For reference see Fig c, 8.1
Fig c 8.1
28
9.Maintenance Master:
The following are the fields available in maintenance master.
1.Maintenance Id: This field is a mandatory field and it is capable of storing up to
15-character length of data and this field is the key identity and reference field of
maintenance details.
2.Maintenance Description: This field is a mandatory field and it is capable of
storing up to 25-character length of data and in this field we need to enter the detailed
description.
3.No Of Days Plant Run: This field is an optional field where we need to enter the
triggering date for the maintenance activity
4.Mixer Running Hours: This field is an optional field where we need to enter the
triggering mixer running hours of the plant
5.Production Quantity: This field is an optional field where we need to enter the
triggering quantity for the maintenance activity
Add Maintenance Schedule:

To add a new maintenance schedule we need to enter in to master menu from main mimic
screen by clicking the master menu button and from the given options we need to choose
the schedule master button then the below screen as shown in fig. C, 9.1 will appear on
your monitor.
Fig c 9.1
29
Edit Maintenance Schedule:
To edit an existing maintenance schedule we need to click the load maintenance id button
and this will list down the available maintenance schedule in added or ascending order
now choose the maintenance id in which we need to perform the edit operation and then
edit the required field and press save button to store the data.
Delete Maintenance Schedule:

To delete a maintenance schedule we need to perform the same thing as we did for
maintenance schedule edit option like choose the load maintenance code and select the
maintenance schedule code from the given maintenance schedule code field box and this
will list the maintenance schedule details which are available, now press delete button
this will logically delete the maintenance schedule details but practically the data will be
retained for future reference of the system administrator.
Note: We can store maintenance schedule up to disk limit which means unlimited and be
sure to enter all the mandatory data’s while storing the maintenance planner because
those fields are very important in the event triggering the maintenance schedule. This
maintenance schedule will pope up as per the duration specified.
30
e, Start Schedule
The following fig e1.0 shows what are all the details present in start schedule screen.
When we press the start schedule button another screen opens with in the first screen
where there will be a list schedule selection button and list box for schedule as well order.
In the schedule list box what ever the available schedules will be listed and on double
click of any one schedule among the listed will result in display of the available orders
for that schedule and all the related details like recipe, site etc will be displayed on the
respective display boxes.
In the schedule screen we can change the production quantity and we can also enter
returned quantity for production if any for the first order execution among the scheduled
order.
The Start schedule button can be used to start the schedule from the schedule.
Fig e 1.0
31
f, Plant Setup
The plant setup screen is the key or an important screen for any control system to go to
that screen we need to click the plant setup button from the first screen. The following
parameter settings are available in the plant setup screen.
1.Material In Air
2.Coarse to fine
3.Discharge sequence
4.Tolerance
5.Empty Value
6.Step Time
7.Gate Sequence
8.Jogontime
9.Calibration 1,2,3 & 4
10.Other Settings
11.Mixer Calibration
12.Weigher Maximum Weight
13.Other Settings 2
32
1.Material in air: This parameter is basically set to attain the accuracy level as per the IS
and DIN standards this is nothing but the controlling weight which need to be entered to
get the required batching weight and this is applicable only if the plant is set in material
in air mode.
2.Coarse to fine: This parameter is set to control the flow rate of the material to achieve
the accuracy as per the standards. This parameter is applicable only for aggregate and
water component.
3.Discharge sequence: This parameter is set to define the system when each and every
individual components has to be discharged in to the mixer excluding aggregate because
this component will be discharged first in to the mixer.
4.Tolerance: This parameter is set to define the system while batching in auto mode on
what tolerance level it has to accept the tolerance level of the targeted weight.
5.Empty Value: This parameter is set to define the zero value acceptance for each and
every weigher individually which will help in starting of the batch.
6.Step Time: This parameter is set to define the stability registering time for all the
components this is an integer type field where it has certain limitation settings like it has
1600 ms as lower limit and 5000 ms as upper limit.
7.Gate Sequence: This parameter is set to define the system on what sequence the
aggregate batching should be done. To set this parameter we need to enter the required
bin no and we need to press the set button to make this applicable.
8.Jogontime: jogontime is set to define the system opening or inching time for gate,
screw motor, water valve and admixture pump based on the time range the output of the
relevant component will be activated. The lower limit is around 500 ms and the
maximum range is around 5000ms.
9.Calibration 1,2,3 & 4: When we press the calibration button it will display all the
settings to calibrate weigher like aggregate, cement, water, silica, ice and admixture we
can calibrate the weigher in 2 mode 1 auto and 2 manual to calibrate the weigher in auto
mode we need to change the mode from manual by entering 1 and we should define the
characteristic as 2,filter settings as 2 Hz, milivolt offset value as 0, milivolt full scale
value 2.00 mV and decimal 2 for admixture only other then admixture for all components
is 0, module address starts from 384 to 424 for more information contact stetter
engineers, channel number as 1 or 2 refer with stetter engineer for more details on it.
Move zero is nothing but tare function to move zero value for individual weighers, set
zero to define the zero setting count to the PLC (contact stetter engineer before operating
this parameter), Theoretical Adjustment is the initial procedure for calibration, Adjust
weight maximum count to the PLC (contact stetter engineer before operating this
parameter), Send, this parameter set to transfer all the set details to the PLC and Mode to
define the system whether it is in auto or manual.
33
Calibration Procedure
Auto Mode:
Mode = 0
Set Characteristic value = 2
Set Filter Setting = 2 Hz
Set Milivolt offset value = 0
Set Milivolt fullscale value = 2.00
Set Module address = 384 (for aggregate & Cement weigher), 400 (for Water
& Admixture1 weigher), 416 (for Admixture2 & Ice weigher) and 424 (for Silica
weigher)
Set channel no = 1 (for aggregate, Water, Admixture 2 & Silica) and 2 (for
Cement, Admixture 1 & Ice).
Enter cumulative loadcell capacity in weight
Press send button to transfer entered data to the PLC
Press theoretical adjustment (this will display some value in gross weight)
After 5 seconds delay
Press move zero this will make the value to zero
Manual mode:
Mode = 1
Set Characteristic value = 2
Set Filter Setting = 2 Hz
Set Milivolt offset value = 0
Set Milivolt fullscale value = 2.00
Set Module address = 384 (for aggregate & Cement weigher), 400 (for Water
& Admixture1 weigher), 416 (for Admixture2 & Ice weigher) and 424 (for Silica
weigher)
Set channel no = 1 (for aggregate, Water, Admixture 2 & Silica) and 2 (for
Cement, Admixture 1 & Ice).
Enter weigher maximum capacity of the weigher
Press send button to transfer entered data to the PLC
Press set zero button
Place full standard weight on the weigher
Press adjust button
Now the system will display the weigher value
Calibration ends keep the weights and check again
10. Other Settings: There are various other basic settings like mixer off delay, skip-
traveling time, conveyor runtime etc the relevant fields will have relevant limit values.
11. Mixer Calibration: In this field we need to register the mixer low level value by
pressing the register button(while mixer is empty) and maximum value should also be
registered on same manner by pressing the register button(while mixer is full).
34
12. Weigher Maximum Weight: The value entered here will be very useful for validating
the recipe limit values if nothing is entered and saved from this parameter then we may
not be able to enter the recipe details.
13. Other Settings 2: The other settings 2 will have information like batching mode (flow
rate based or material in air mode), fault value for batching, dosing and discharging time
for all components variable based, by which the alarm is generated.
g, Manual Operation
There is an option available to operate the plant through computer manually. To operate
the plant manually through computer press manual button from the first screen then it
will display all the buttons in the main mimic screen through that we can operate all the
components from dosing to discharge.
35
h, Generate Report
The following are the reports that are available in the current control system,
1, Total Production Report

2. Customerwise Production Report
3. Sitewise Production Report
4. Recipewise Production Report
5. Truckwise Production Report
6. Total Consumption Report
7. Customerwise Consumption Report
8. Sitewise Consumption Report
9. Recipewise Consumption Report
10. Truckwise Consumption Report
11. Docket Reprint
12. Duplicate Delivery Note
13. Customerwise Material Consumption Report
14. Recipewise Material Consumption Report
15. Maintenance Detail Report
16. Hourwise Consumption Report
17. Customer Master Report
18. Site Master Report
19. Recipe Master Report
20. Truck Master Report
21. Order Master Report
22. Schedule Master Report
23. Inward Details Report.
1,Total Production Report:

This report basically gives you the statistics of total production taken for the period
mentioned as shown in fig h 1.1. The unit will be of cubic meter.
36
Fig h1.1
2.Customerwise Production Report:

mentioned as well depending on the customer code that you give as an input as shown in
fig h 2.1. The unit will be of cubic meter.
Fig h2.1
37
3.Sitewise Production Report:
mentioned as well depending on the customer code & site that you give as an input as
shown in fig h 3.1. The unit will be of cubic meter.
Fig h 3.1
4.Recipewise Production Report:

mentioned as well depending on the recipe code that you give as an input as shown in fig
h 4.1. The unit will be of cubic meter.
Fig h4.1
38
5.Truckwise Production Report:

mentioned as well depending on the truck no that you give as an input as shown in fig h
5.1 the unit will be of cubic meter.
Fig h5.1
6.Total Consumption Report:

This report basically gives you the statistics of total material consumed for the
period mentioned as shown in fig h 6.1. The unit will be of Kg.
Fig h6.1
39
7.Customerwise Consumption Report:
period mentioned as well depending on the customer code that you give as an input as
shown in fig h 7.1. The unit will be of Kg.
Fig h 7.1
8.Sitewise Consumption Report:

period mentioned as well depending on the customer code and site that you give as an
input as shown in fig h 8.1. The unit will be of Kg.
Fig h8.1
40
9.Recipewise Consumption Report:
period mentioned as well depending on the recipe code that you give as an input as
shown in fig h 9.1. The unit will be of Kg.
Fig h9.1
10.Truckwise Consumption Report:
period mentioned as well depending on the truck no that you give as an input as shown in
fig h 10.1. The unit will be of Kg.
Fig h 10.1
41
11.Docket Reprint:
This facility will be available only if you had gone for the additional optional
package to enable the 2nd printer option to print the delivery Chelan or docket as shown in
fig h 11.1 to enable this separate program has to written as per you docket format.
Fig h11.1
12.Duplicate Delivery Note:
This is an additional option given to print the delivery docket/autographic
record/batch details a duplicate copy in case of emergency requirement.
13.Customerwise Material Consumption Report:
This give the periodic summary report of material consumption based on the
customer as specified in fig h.13.1
Fig h13.1
42
14.Recipewise Material Consumption Report:
This give the periodic summary report of material consumption based on the
recipe as specified in fig h.14.1
Fig 14.1
15.Maintenance Detail Report:

This gives us the statistical report on pending and completed maintenance details
as per the data entered in master and triggered based on the master input.
16.Hourwise Consumption Report:
This gives us the statistical report on hour wise consumption. In the FROM hour
column we need to enter the time (24 hours / railway format) and in the TO hour column
we need to enter the TO time (24 hours / railway format) this will give you the clear
figure on how much material is consumed if you want to see for the next day then you
should click on the next day enable click box. Refer fig h16.1
43
Fig h16.1
17.Customer Master Report:
This gives us full details of existing customer data in the master file.
18.Site Master Report
This gives us full details of existing site data in the master file.
19.Recipe Master Report
This gives us full details of existing recipe data in the master file.
20.Truck Master Report
This gives us full details of existing truck data in the master file.
21.Order Master Report
This gives us full details of existing order data in the master file.
22.Schedule Master Report
This gives us full details of existing schedule data in the master file.
23.Inward Details Report.
This statistical report will give us full detailed information on materials that was
being in warded as on date and it is also periodic basis report retrieval.
44
i, Divert Truck
The divert truck option is given to redirect the returned quantity from one site to another
site. This is an html based link where it will prompt you for batch / docket no which you
need select on selecting the batch no it will display the related customer and site which
you can change as per your requirement for redirecting. Fig i1.0 will show clearly the
divert truck screen layout.
Note: In this particular screen we need to use mouse to move through the fields.
Fig i1.0
45
j, Alarm Accept
There is separate button given to reset or acknowledge all the generated alarms it is
available through out all the screen all you have to do is to press the button with the
mouse.
k, Exit Software
As similar to that of alarm accept there is separate button provided to close the software
all you have to do is to press the exit software button with the mouse and this will prompt
you a query stating whether you would like to quit the software if you press yes then it
will come out of the software.
l, Maintenance Schedule
There is a separate button provided to enable the visibility of pending maintenance
schedule all you have to do is to press that button this will enable a small list box on top
the screen next to the maintenance schedule enable button with the help of that button
you can view all the pending schedules of maintenance.
m, Mimic screen text and graphical:
There are 2 type of screen available for display in mci360 control system
1 mimic / main screen graphical
2 mimic / main screen text
1.mimic / main screen graphical: This is will give us a clear pictorial representation of the
batching plant and what ever operation take place in the batching plant will be reflected
in the screen
2.mimic / main screen text: In this screen we will be able to view the detailed information
of the batching plant in text based which means the targeted value and attained actual
along with the moisture all the other fields which are also available in mimic graphical
screen will be displayed here except image animation.
46
n, Help option:
In the help option we will be able to view the soft copy of the manual along with the
plant circuit drawings. Apart from that there is a provision for viewing the PLC IO status
is also provided as shown in fig n.1.0
Fig n 1.0
47
5, Features of MCI 360
The following are the available features of MCI 360 control system
1,scheduling the batches

2,simple touch panel and keypad operations
3,load cell connectivity direct to PLC
4,eacy to calibrate the weighers
5,Able to access the entire master details through html page (optional package)
6,Batch mode handling
7,Fault weight adjustment
8,Auto batch recovery on power failure
This software is designed to support all most 7 weighers
1.Aggregate
2.Cement
3.Water (supported with slurry as optional package)
4.Ice (optional package)
5.Admixture 1 (2 components)
6.Admixture 2(2 components optional package)
7.silica (optional package)
1, scheduling the batches
This feature will allow to schedule for the day in MCI 360 control system. we can
configure up to 9 schedules in this system. All the configuration is to be done as given in
earlier chapters please refer schedule master for more info. We can reassign the schedule
as per our requirement in the main screen
2,simple touch panel and keypad operations
There is a separate touch panel has been provided to view all the targeted and
achieved actual value and we can also view the alarm details as well along with the
facility to configure the moisture and water correction. We can tare all the weighers
3,load cell connectivity directed to PLC
Load cells are directly connected to the PLC this will totally eliminate the difference
in display both in touch panel as well as computer.
48
4,eacy to calibrate the weighers
As specified in the earlier chapter the calibration of the weighers are very easy. Please
refer the chapter calibration procedure of plant setup.
5,Able to access the entire master details through html page (optional package)
There is a separate option available which comes as an optional package to link as a page
with all the available masters can be used to update the data’s from LAN.
6.There is 2 mode of batching procedure available in MCI 360.Material in air mode and
PID control mode (flow based) to enable flow based batching we need to go to other
settings2 screen in plant setup and change all the mode to flow or material in air as per
our requirement by pressing the relevant button.
7.Fault weight to adjust the material in air weight calculation is also provided.
8.Time duration can be specified in the other settings 2 screen for all dosing and
discharges based on which the alarm will be displayed.
9.Auto batch recovery on power failure. MCI 360 control system goes to pause mode by
sensing the power failure and once when the power recovers the system retains all the
value and waits for operator to acknowledge by pressing auto pause key. When the auto
pause is released the batching starts to continue from where it has left.
49
Installation & Un installation of the software
To install the software first we need to make sure that the following software are installed
1.Win sp4
2.IE 6.0
if not the above software need to be installed.
After that we need to install the MS SQL server 2000 sp4 along with wincc sp4
Then we need to copy the mci360 setup to hard disk and extract converted.zip and
arun.zip to “c:” drive and also install the vb components which is available in the system
dump and go to converted directory and place the ssimci300 on the desktop as shortcut
To uninstall all we need to do is go to add remove programs of control panel and remove
all wincc related files.
50
M1 – MCI360
Cable List
Cable List for M1- MCI 360 Electronics & Automation Department
Cable From Cable To Comments

S.No. Size Of Cable Mtrs Name Ferrule No. Size Of Cable Mtrs Name FerruleNo.
1 4*50 Cu L1
or L2
4*95 Al L3 Supply line to
N control panel
PE by customer
2 4*2.5 15 X2M 11U 1M1 U

11V V Compressor
11W W
PE PE
X2M
3 4*1.5 18 1 21U 2M1 U Sand Vibrator 1
2 21V V
3 21W W
4 PE PE
X2M
4 4*1.5 18 5 22U 2M2 U Sand Vibrator 2 OPTIONAL
6 22V V
7 22W W
8 PE PE
5 4*1.5 16 X2M 23U 2M3 U Cement Vibrator

23V V
23W W
PE
6 4*2.5 30 X2M 31U 3M1 U

31V V Cement screw conveyor 1
31W W
PE PE
7 4*2.5 30 X2M 32U 3M2 U

32V V Cement screw conveyor 2
32W W
PE PE
8 4*2.5 30 X2M 33U 3M3 U

33V V Screw filler
33W W OPTION
PE PE
9 4*4 15 X2M 41U 4M1 U

41V V Skip motor
41W W
PE PE
10 4*2.5 14 X2M 51U 5M1 U Water Pump

51V V
51W W
PE PE
19.06.2006- Page 1 of 6
Cable List for M1-MCI 360 Electronics & Automation Department

11 7*6 10 X2M Brown 6M1 U1 Mixer Motor

Red V1
Grey W1
Blue W2
Black U2
White V2
PE PE
12 4*1.5 15 X2M 71U 7M1 U

71V V Admixture 1 dosing pump
71W W
PE PE
13 4*1.5 15 X2M 72U 7M2 U Admixture 2 dosing pump

72V V
72W W
PE PE
14 4*1.5 15 X2M 711U 7M11 U

711V V Admixture 1 Discharge pump
711W W
PE PE
15 4*1.5 15 X2M 712U 7M12 U Admixture 2 Discharge pump

712V V
712W W
PE PE
19.09.2006 - Page 2 of 6
Cable List for M1 - MCI 300 Electronics & Automation Department

17 7 * 0.34 25 MX1 X19.1
Blue 1 1&2 Loop Black Aggregate loadcell
Green 2 terminal box X19.1
Brown 3 3&4 Loop Red
Grey 4
White 6 Green
Pink 5 White
Shield 15
X19.1 1 Load Red Load cell aggregate

2 Cell Black
3 Green
4 White
5 Shield
18 7 * 0.34 25 MX2 X19.2

Blue 1 1&2 Loop Black Cement loadcell
Grey 4
White 6 Green
Pink 5 White
Shield 15
X19.2 1 Load Red Load cell Cement

2 Cell Black
3 Green
4 White
5 Shield
19 7 * 0.34 25 MX3 1 1&2 Loop X19.3

Blue 1 Black Water loadcell
Green 2 3&4 Loop terminal box X19.3
Brown 3 Red
Grey 4
White 6 Green
Pink 5 White
Shield 15
X19.3 1 Load Red Load cell Water

2 Cell Black
3 Green
4 White
5 Shield
19.06.2006 - Page 3 of 6

20 7 * 0.34 25 MX4 X19.4

Blue 1 1&2 Loop Black Admixture-1 loadcell
Grey 4
White 6 Green
Pink 5 White
Shield 15
X19.4 1 Load Red Load cell Admixturte-1

2 Cell Black
3 Green
4 White
5 Shield
21 7 * 0.34 25 MX5 X19.4

Blue 1 1&2 Loop Black Admixture-2 loadcell
Grey 4
White 6 Green
Pink 5 White
Shield 15
X19.4 1 Load Red Load cell Admixture-2

2 Cell Black
3 Green
4 White
5 Shield
19.06.2006 - Page 4 of 6
Cable List for M1 - MCI 300 Electronics & Automation Depatment

22 2*1 10 G1-F 2 2*1 X6:17 Gate1 Fine Open sensor

X2:5
23 2*1 10 G2-C 3 2*1 X6:18 Gate2 Corase Open sensor

X2:5

X2:5

X2:5

X2:5
27 18 * 1 5 X6
1 1 2Y1.1 X6:61 Gate1 Fine
2 2 2Y2 X6:62 Gate2 Coarse
3 3 2Y2.1 X6:63 Gate2 Fine
4 4 2Y3.1 X6:65 Gate3 Fine
5 5 2Y4.1 X6:67 Gate4 Fine
6 6 3Y31 X6:87 Cement Discharge
7 7 5Y4 X6:92 Water Pump Discharge
8 8 5Y3 X6:91 Water Gravity Discharge
9 9 7Y1 X6:81 Admixture 1 Sort-1
10 10 7Y11 X6:85 Admixture 1 Discharge
11 11 5Y1 X6:88 Water Dosing Coarse
12 12 5Y2 X6:90 Water Dosing Fine
13 13 3Y1 X6:93 Cement Blowoff-1
16 16 X2:5 24V +ve
17 17 X2:6 Second wires of all solinoid
18 18 Spare to be connected with 24V -ve
19.06.2006 - Page 5 of 6

28 9 6S33 1 2*1 X6:30 Mixer gate mid-position sensor

X2:5
29 9 S5 2 2*1 X6:33 Skip bottom sensor

X2:5
30 14 S2 3 2*1 X6:34 Slacksteel Sensor

X2:5
31 11 S4 4 2*1 X6:35 Skip Waiting position Sensor

X2:5
32 10 S3 5 2*1 X6:36 Skip Top Sensor

X2:5
33 9 6S31 6 2*1 X6:31 Mixer Gate open senor

X2:5
34 9 6S32 7 2*1 X6:32 Mixer Gate close sensor

X2:5
35 13 5S36 8 2*1 X6:29 Water scale gate open

X2:5
36 14 3S36 9 2*1 X6:28 Cement scale gate open

X2:5
37 15 4R1 12 2*1 X3:1 Skip Motor protection

4R1 13 X3:2 Skip Motor protection
38 10 6R2 12 2*1 X3:3 Mixer Motor protection

6R2 13 X3:4 Mixer Motor protection
39 15 6Y1 1 2*1 X6:75 Mixer Gate Open Solinoid

X2:6
40 15 6Y2 2 2*1 X6:76 Mixer Gate Close Solinoid

X2:6
41 15 3 2*1 10 Brake coil

4 11 Brake coil
42 10 Z1 7 2*1 X3:5 Hooter

Z1 8 X3:6 Hooter 230V Neutral
43 5 S6 9 2*1 X3:11 Skip bottom limit switch

12 S8 X3:10 Mixer cover limit switch
13 S7 10 2*1 X3:11 Skip Top limit switch
19.06.2006 - Page 6 of 6
M1 – MCI360
Spare Parts List

Schwing Stetter India Pvt. Ltd., Spare Part List
S.No. Designation Part Number Description Place ID

1 0S2 82500005 Emergency Push Button 1.06
82500131 Indication plate "EMERGENCY STOP"
2 S2 60573994 Slack Steel Rope Proxy Switch 4.10
3 S3 60573994 Skip Top Proxy Switch 4.11
4 S4 60573994 Skip Waiting Proxy Switch 4.10
5 S5 60573994 Skip Bottom Proxy Switch 4.10
6 S6 80000058 Mixer Door Limit Switch 1.04
7 S7 80000058 Skip Emergency Limit Switch 1.04
8 S8 80000058 Emergency Exit Door Bottom LimIt Switch 1.05
9 S9 80000058 Emergency Exit Door Top LimIt Switch 1.05
10 S10 60573994 Mid Position Sensor Switch 4.08
11 3S36 Water Balance Opened Sensor 4.06
12 5S36 Cement Balanced Opened Sensor 4.06
13 6S31 60573994 Mixer Opened Sensor 4.08
14 6S32 60573994 Mixer Closed Sensor 4.08
16 GC1 60573994 Gate1 Coarse Closed Sensor 4.02
22 GF1 60573994 Gate1 Fine Closed Sensor 4.02
28 0F1 60574460 1 Pole , 1A Miniature Circuit Breaker 1.04
8/4/2006 Page 1of 7 M1: MCI-360

29 1F1 80000075 2 Pole, 6A Miniature Circuit Breaker 1.08
38 3Q5 60575193 3 Pole, 25A Miniature Circuit Breaker 15.12
34 0Q1 8040 0088 Moulded Case Circuit Breaker, Incomer 150A 1.02
80400381 Under Voltage Trip 1.06
35 1Q1 80400336 Motor Protection Circuit Breaker 16.01
43 2K26 60574493 Power Contactor - 9A 18.02
8/4/2006 Page 2of 7 M1: MCI-360

60 R2K1 80000078 Double change over Relay module 5.02
61 R2K1.1 80000078 Double change over Relay module 5.02
8/4/2006 Page 3of 7 M1: MCI-360

100 MX1 80000383 Loadcell Interface Board - Aggregate 9.02
101 MX2 80000383 Loadcell Interface Board - Cement 9.10
102 MX3 80000383 Loadcell Interface Board - Water 10.02
103 MX4 80000383 Loadcell Interface Board - Amixture1 11.05
104 MX5 80000383 Loadcell Interface Board - Admixture2 10.10
105 Z1 80000076 Hooter 22.11
106 F 60574454 Fan and Filter Unit
107 60574456 Outlet Filter
108 60574455 Fan and Filter Sealing Frame
109 60572780 Terminal Box
8/4/2006 Page 4of 7 M1: MCI-360

110 80000080 Support Rail for Terminal Box
111 4U1 80000060 3 Phase Sequence / Unbalanced Relay 3.14
112 4F2 80000059 Skip Thermistor Protection Unit 13.06
113 6F2 80000059 Mixer Thermistor Protection Unit 14.09
114 T 80400343 Mixer Star/Delta Timer 22.04
115 1T1 80000123 Control Transformer, Pri: 415V, Sec: 230V,990VA 1.08
116 1T3 80000064 24V DC Power Supply Unit- 5A 1.14
117 60572431 Earth Terminal USLKG35
118 60571208 Earth Terminal USLKG16
119 60571190 Double Terminal block UDK4
120 60571192 End cover for UDK 4
121 60571177 Single Terminal UK5N
122 60571178 Neutral Terminal UK5N
123 60573389 Double Decker Termianl block UKK5
124 60573390 End cover for UKK 5
125 60571201 End Angle E/ALNS35
126 80000065 End bracket E/UK
127 80000066 Zack Strip - Un printed - Terminal Strip
128 60574266 Cable Gland PG9
130 60574268 Cable Gland PG13.5
135 60571317 Blanking Plug PG9
8/4/2006 Page 5of 7 M1: MCI-360

137 60571318 Blanking Plug PG13.5
140 60574276 Counter Nut PG9
142 60574278 Counter Nut PG13.5
147 60551049 Multi core cables 7x6 Sq.mm
148 60575449 Multi core cables 4x2.5 Sq.mm
149 60575447 Multi core cables 4x1.5 Sq.mm
153 80000098 Shielded Signal cables 2x0.34 Sq.mm
156 80000239 Braided Copper wire 20mm Dia
157 82500037 S7 CPU 314 2.02
158 82500039 Mounting Rail
159 82500040 32 Channel Digital Input Module 2.04
160 82500041 32 Channel Digital Output Module 2.06
161 82500042 8 Channel Analog Input Module 2.15
162 80400359 2 Channel SIWAREX 2.15
163 82500043 40 Pin Fronconnector
164 82500104 20 Pin Frontconnector
8/4/2006 Page 6of 7 M1: MCI-360

165 80400202 MICRO MEMORY CARD
166 80400231 CP 5611 CARD FOR COMMUNICATION
167 X6 8040 0112 HDD Connector 108 Pin (Assembly)
168 80400316 Membrane Keypad
169 80400317 Keypad Controller
170 80400362 TP170 Touch Panel
171 80400421 Communication Processor CP340
172 80400333 Keypad Enclosure
173 80400360 Interface Module IM 365
174 80400363 WIN CC 1024 Tag Run Time
175 3F5 80400479 Overload Relay 15.12
8/4/2006 Page 7of 7 M1: MCI-360

M1 – MCI360
Recommended Spare Parts List

Schwing Stetter India Pvt. Ltd., Recommended Spare Part List
S.No. Designation Part Number Description Qty

1 0F1 60574460 1 Pole , 1A Miniature Circuit Breaker 1.00
3 0Q1 80400088 Moulded Case Circuit Breaker, Incomer 160A 1.00

80400381 Under Voltage Trip 1.00
14 4U1 80000060 3 Phase Sequence / Unbalanced Relay 1.00
15 6F2 80000059 Mixer Thermistor Protection Unit 1.00
16 T 80400343 Mixer Star/Delta Timer 1.00
17 1T3 80000064 24V DC Power Supply Unit- 5A 1.00
18 82500037 S7 CPU 314 1.00
19 82500040 32 Channel Digital Input Module 1.00
20 82500041 32 Channel Digital Output Module 1.00
21 82500042 8 Channel Analog Input Module 1.00
22 80400231 CP 5611 CARD FOR COMMUNICATION 1.00
23 80400316 Membrane Keypad 1.00
24 80400317 Keypad Controller 1.00
25 80400362 TP170 Touch Panel 1.00
26 80400421 Communication Processor CP340 1.00
27 80400359 2 Channel SIWAREX 1.00
8/4/2006 Page 1of 1 M1: MCI-360

M1 – MCI360
PLC Input / Output List

PLC INPUT DETAILS - MCI-360 - M1
PLC INPUTS ADDRESS REFERENCE

COMPRESSOR MOTOR HEALTHY I4.0
SAND VIBRATOR 1 HEALTHY I4.1
SAND VIBRATOR 2 HEALTHY I4.2
CEMENT SCREW 1 HEALTHY I4.3
WEIGH BELT - PULL CHORD I4.4
WEIGH BELT - '0' SPEED SENSOR I4.5
ASC CONVEYOR - PULL CHORD I4.6
CEMENT SCREW 5 HEALTHY I4.7
CEMENT VIBRATOR HEALTHY I5.0

SKIP HEALTHY I5.1
SKIP UP FEEDBACK I5.2
SKIP DOWN FEEDBACK I5.3
WATER DISCHARGE PUMP HEALTHY I5.4
ICE SCREW HEALTHY I5.5
ICE VIBRATOR HEALTHY I5.6
MIXER MOTOR HEALTHY I5.7
MIXER MOTOR RUNNING FEEDBACK I6.0

MIXER GREASE PUMP HEALTHY I6.1
ADM-1 SORT1/2 DOSING HEALTHY I6.2
ADM-2 SORT 1/2 DOSING HEALTHY I6.3
ADM -1 SORT 1 DISCHARGE HEALTHY I6.4
WEIGHER BELT CONVEYOR HEALTHY I7.0

SPARE I7.1
SPARE I7.2
SPARE I7.3
SPARE I7.4
PHASE FAILURE ERROR I7.5
SKIP THERMAL OVERLOAD I7.6
MIXER THERMAL OVERLOAD I7.7
PLC INPUT DETAILS - MCI-360 - M1
PLC INPUTS ADDRESS REFERENCE

SPARE I8.0
GATE 1 FINE CLOSED SENSOR I8.1
GATE 2 COARSE CLOSED SENSOR I8.2
SPARE I8.4
SPARE I8.6
SPARE I9.0
SPARE I9.1
SPARE I9.2
SPARE I9.3
CEMENT DISCHARGE FLAP SENSOR I9.4
WATER DISCHARGE FLAP SENSOR I9.5
MIXER GATE 1/2 OPENED SENSOR I9.6
MIXER GATE FULL OPENED SENSOR I9.7
MIXER GATE CLOSED SENSOR I10.0

SKIP BOTTOM SENSOR I10.1
SLACK STEEL SENSOR I10.2
SKIP WAITING SENSOR I10.3
SKIP TOP SENSOR I10.4
SPARE I10.5
SPARE I10.6
SPARE I10.7
SPARE I11.0
SPARE I11.1
SPARE I11.2
SPARE I11.3
SPARE I11.4
SPARE I11.5
SPARE I11.6
SPARE I11.7
PLC OUTPUT DETAILS - MCI-360 - M1
PLC OUTPUTS ADDRESS REFERENCE

SPARE Q12.0
GATE 1 FINE OPEN Q12.1
GATE 2 COARSE OPEN Q12.2
SPARE Q12.4
SPARE Q12.6
SPARE Q13.0
SPARE Q13.1
SPARE Q13.2
SPARE Q13.3
SAND VIBRATOR 1 ON Q13.4
SAND VIBRATOR 2 ON Q13.5
SPARE Q13.6
SPARE Q13.7
SPARE Q14.0
SPARE Q14.1
SPARE Q14.2
CEMENT SCREW 1 ON Q14.3
SPARE Q14.6
CEMENT 1 BLOW OFF Q15.0

SPARE Q15.3
CEMENT VIBRATOR Q15.5
CEMENT DISCHARGE Q15.6
SPARE Q15.7
PLC OUTPUT DETAILS - MCI-360 - M1
PLC OUTPUTS ADDRESS REFERENCE

SKIP UP Q16.0
SKIP DOWN Q16.1
WATER DOSING COARSE Q16.2
WATER DOSING FINE Q16.3
WATER GRAVITY DISCHARGE Q16.4
WATER PUMP DISCHARGE Q16.5
ICE SCREW ON Q16.6
ICE VIBRATOR ON Q16.7
SPARE Q17.0
SPARE Q17.1
MIXER ON Q17.2
MIXER GATE OPEN Q17.3
MIXER GATE CLOSE Q17.4
ADM1 SORT 1 DOSING Q17.5
ADM1 SORT 2 DOSING Q17.6
SPARE Q17.7
SPARE Q18.0
ADM1 SORT 1DISCHARGE Q18.1
ADM1 SORT 2 DISCHARGE Q18.2
SPARE Q18.3
SPARE Q18.4
WEIGH BELT CONVEYOR ON Q18.5
SPARE Q18.6
SPARE Q18.7
SPARE Q19.0
SPARE Q19.1
SPARE Q19.2
SPARE Q19.3
SPARE Q19.4
AUTO BATCH HOOTER Q19.5
SPARE Q19.6
SPARE Q19.7
PLC ANALOG DETAILS - MCI-360 - M1
PLC ANALOG INPUTS ADDRESS REFERENCE

CEMENT SILO-1 LEVEL PIW 336
SPARE PIW 342
MOISTURE-1 PIW 346
MOISTURE-2 PIW 348
MIXER CURRENT PIW 350
AGGREGATE PIW 384

CEMENT PIW 384
WATER PIW 400
ICE PIW 400
ADMIXTURE-1 PIW 416
SPARE PIW 416
SPARE PIW 432
SPARE PIW 432
M1 – MCI360
Control Panel
General Arrangement
M1 – MCI360
Control Panel Circuit Diagram

M1 – MCI360
Junction Box & Connector Detail

M1 – MCI360
3 Phase Induction Motor

Fault Finding Procedure
M1 – MCI360
Silo Level Meter

M1 – MCI360
Moisture Meter
M1 – MCI360
Phase Failure Relay

Contact Us Here
SCHWING Stetter India Pvt Ltd., SCHWING Stetter India Pvt Ltd.,
Regd.Office & Works Sales & Service - Hyderabad
F71, Sipcot Industrial Park, House No.8-3-231/W/30/A
Irungattukottai, Plot No. 30A, WCHS
Sriperumpudur Taluk, Road No.2, Jubilee Hills,
Kanchipuram District, Hyderabad – 500 033
Tamil Nadu - 602 105 Phone: 91 – 40 – 23541783
Phone: 91 – 4111 – 256780 Mobile: 98480-37535
91 – 4111 – 256781 Telefax:91 – 40 – 22541782
Fax: 91 – 4111 – 256539 Email : schwinghyd@vsnl.net
Email : schwing@vsnl.com
SCHWING Stetter India Pvt Ltd., SCHWING Stetter India Pvt Ltd.,
Sales & Service -Mumbai Sales & Service - Bangalore
410-A, B-wing, Galleria, 179, Teacher’s Colony, 1st Block,
Hiranandani Gardens, Koramangala,
Powai, Mumbai – 400 076 Bangalore – 560 034
Phone: 91 – 22 – 25797735 Phone: 91 – 80 – 25633284
91 – 22 – 25797782 Telefax:91 – 80 – 51108396
91 – 22 – 25705247 Email : ssipl-balgalo re@schwingstetterindia.com
Fax: 91 – 22 – 25705260
Email : schwing1@vsnl.com
Other Service Centers
SCHWING Stetter India

Service - Kolkatta
SCHWING Stetter India Pvt Ltd., Contact No.98311 - 76526
Sales & Service – New Delhi
1105 – 1106,Ansol Towers,
38, Nehru Place, SCHWING Stetter India
New Delhi – 110 019 Service - Pune
Phone: 91 – 11 – 26440691 Contact No.98903 - 66646
91 – 11 – 26440692
Fax: 91 – 11 – 26440690
Email : schwingstetter@spectranet.com SCHWING Stetter India
Service - Ahmedabad
Contact No.98250 - 96208

M1 MCI360Compartment - Manual PDF

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M1 MCI360

Operating Instruction for

01. Safety Instruction 02

02. Technical Data 03

03. Operating Instruction 50

04. Cable List 06

05. Spare Parts List 08

06. Recommended Spare Parts List 01

07. PLC Input / Output List 05

08. Control Panel General Arrangement 01

09. Control Panel Circuit Diagram 25

10. Junction Box & Connector Detail 05

11.3 Phase Induction Motor Fault Finding Procedure 03

12. Silo Level Meter 22

13. Moisture Meter 14

14. Phase Failure Relay 03

Use Voltage Insulated tools only, when working in electrical areas.

PROTECTIVE AND SAFETY DEVICES

REPLACEMENT OF ELCTRICAL ITEMS

ADDITIONAL MATERIAL CONSUMPTION

Electric supply data

Supply Voltage:……………………………………………… 415 Volts

Compressor Motor:……………………………………………… 2.2 kW / 3 HP

Panel Wiring Cable Color Code Details:

Load Cell Details:

Input Resistance : 350 Ohms ± 2 Ω

Load Cell Wiring Details:

Red : Excitation (+ 10VDC)

MCI 360 CONTROL SYSTEM

3,Features of MCI 360 48

1.Introduction On MCI360 Control System.

1. Schedule based batching

The control system is inclusive of computer this is for your information

1.P-IV processor 2.6 G Hz speed.

Update and enter the material inward:

Add Maintenance Schedule:

Delete Maintenance Schedule:

1, Total Production Report

1,Total Production Report:

2.Customerwise Production Report:

4.Recipewise Production Report:

5.Truckwise Production Report:

6.Total Consumption Report:

8.Sitewise Consumption Report:

15.Maintenance Detail Report:

m, Mimic screen text and graphical:

5, Features of MCI 360

1,scheduling the batches

This software is designed to support all most 7 weighers

1, scheduling the batches

2,simple touch panel and keypad operations

3,load cell connectivity directed to PLC

Installation & Un installation of the software

if not the above software need to be installed.

Cable From Cable To Comments

2 4*2.5 15 X2M 11U 1M1 U

5 4*1.5 16 X2M 23U 2M3 U Cement Vibrator

6 4*2.5 30 X2M 31U 3M1 U

7 4*2.5 30 X2M 32U 3M2 U

8 4*2.5 30 X2M 33U 3M3 U

9 4*4 15 X2M 41U 4M1 U

10 4*2.5 14 X2M 51U 5M1 U Water Pump

Cable From Cable To Comments

22 21 10 G1-F 2 21 X6:17 Gate1 Fine Open sensor

23 21 10 G2-C 3 21 X6:18 Gate2 Corase Open sensor

24 21 10 G2-F 4 21 X6:19 Gate2 Fine Open sensor

25 21 12 G3-F 6 21 X6:21 Gate3 Fine Open sensor

26 21 10 G4-F 8 21 X6:23 Gate4 Fine Open sensor