Setup and Operation Guide

Transcription

1 Rapidmix 400CW Setup and Operation Guide Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 1)

2 Table of Contents Index Machine Setup Calibration Prerequisites 5 Materials Required for Setup 6 Setup of legs 7 Raising the Machine 8 Securing the Support Legs 9 Lowering the Machine 10 Erecting the Silo 11 Building the Ramp 13 Connection of the Water Supply 14 Prerequisites 16 Aggregate Static Calibration 17 Aggregate Material Calibration 18 Silo Screw Static Calibration 20 Silo Material Calibration 21 Manual Operation 23 Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 2)

3 Table of Contents Index Automatic Operation Starting the Machine 26 Loading a Recipe 27 Starting the Batch 28 Running the Batch 29 Stopping the Batch 30 Software Creating a Recipe 31 Receiving Stock 32 Finding Settings 33 Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 3)

4 Machine Setup Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 4)

5 Machine Setup Prerequisites 1. Machine must be set-up on level ground. 2. Note: Never Setup on uneven ground. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 5)

6 Machine Setup Materials Required for setup Item Description Quantity A Sheet of wood 2400mm x 1200mm (8 x 4 ) 6 B Block of wood 600mm x 200mm x 200mm (2 x 8 x 8 ) 20 C Sheet of wood 600mm x 600mm x 13mm (2 x 2 x 1/2 ) 20 D Spirit Level 1 E Loading Shovel 1 A B C D E Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 6)

7 Machine Setup Setting the legs 1. Place Wood under the 4 Jacking legs. 2. Place wood under 8 support legs. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 7)

8 Machine Setup Raising The Machine 3. Start the generator (see generator manual). 4. Push the green button to start the hydraulics. 5. Push (toward machine) levers 1 & 2 to raise the front of the machine Push (toward machine) levers 3 & 4 to raise the back of the machine Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 8)

9 Machine Setup Securing The Support Legs 7. Remove pin to lower legs. 8. Lower Legs 9. Replace pin after legs are lowered. 10. Leg should be securely in place. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 9)

10 Machine Setup Lowering The Machine 11. Pull (away from machine) levers 1 & 2 to lower the front of the machine Pull (away from machine) levers 3 & 4 to lower the back of the machine Press the red button to stop the hydraulics. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 10)

11 Machine Setup Erect The Silo 1. Remove pins from conveyor. 2. Press the green button. 3. Push (toward machine) lever 6 until conveyor is fully extended Replace the pins which where removed at Step 1. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 11)

12 Machine Setup Erect The Silo 5. Push (toward machine) lever 7 to raise the Silo Check wire ropes do not get tangled or caught on anything on the machine. 7. Insert pins to secure Silo. 8. Press the red button to stop the hydraulics. 9. Install conveyor supports. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 12)

13 Machine Setup Building The Ramp 1. Place items A as show on page 5 against the side of the machine. 2. Place material for ramp against machine. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 13)

14 Machine Setup Connecting the Water Supply 1. Connect water supply to water tank. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 14)

15 Calibration Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 15)

16 Calibration Prerequisites Item Description Quantity A Tandem Dump Truck 1 B Portable Scale 0-250kgs (0-400 lbs) 1 C Access to portable or public scale 1 D Containers for Cement 2 A B C D Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 16)

17 Aggregate Calibration Static Calibration 1. Enter the Max Capacity of the Aggregate Weigh Belt. 2. Remove the weight from the scale. 3. Enter the total amount of weight (kg/lb) used to calibrate the machine. 4. Press the Zero button. 5. Add the Calibration Weights to the weigher. The weighs must be placed equally over the weigher. 6. Press the span button. 7. If no error messages appear then press the save button, however if Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 17)

18 Aggregate Calibration Material Calibration 1. Switch into Automatic. 2. Weigh and record the empty truck. 3. Position empty truck under the GOB hopper. 4. Navigate to the Material Calibration Screen. Click Settings. 5. On the next screen click on Aggregate Material Calibration. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 18)

19 Aggregate Calibration Material Calibration 6. Enter the appropriate values into Agg Calibration Time and Agg Calibration Speed. 7. Press Start Calibration. 8. Collect Aggregate in truck. 9. Weigh filled truck on scales 10. Subtract the empty truck weight value from the full truck weight. 11. Record this weight in the Sample Weight column of textboxes. 12. Record the totaliser weight in the Calculated Weight column of textboxes. 13. Repeat steps 6-12 until three consistent samples are recorded. 14. After recording the values, click the Calculate button and the Calculated MCF and Average textboxes will have values now. If you are satisfied with the calibration then click on the Applied MCF textbox and enter the value which is in the Calculated MCF textbox. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 19)

20 Silo Calibration Static Calibration 1. Enter the Max Capacity of the Screw Weigh Screw. 2. Remove the weight from the scale. 3. Enter the total amount of weight (kg/lb) used to calibrate the machine. 4. Press the Zero button. 5. Add the Calibration Weights to the weigher. The weighs must be placed equally over the weigher. 6. Press the span button. 7. If no error messages appear then press the save button, however if there are error messages, close the software and restart. 8. Repeat steps 1-7 for screw 2. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 20)

21 Silo Calibration Material Calibration 1. Switch into Automatic. 2. Weigh empty containers 3. Connect Silo Calibration chutes to the output of the cement weigh screws. And place containers under the chutes. 4. Navigate to the Material Calibration Screen. Click Settings. 5. On the next screen click on Silo Material Calibration. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 21)

22 Silo Calibration Material Calibration 6. Enter the appropriate values into Silo Calibration Time and Silo Calibration Speed. 7. Press Start Calibration. 8. Collect Powder in container. 9. Weigh filled container on scales. 10. Subtract the empty container weight value from the full container weight. 11. Record this weight in the Sample Weight column of textboxes. 12. Record the totaliser weight in the Calculated Weight column of textboxes. 13. Repeat steps 6-12 until three consistent samples are recorded. 14. After recording the values, click the Calculate button and the Calculated MCF and Average textboxes will have values now. If you are satisfied with the calibration then click on the Applied MCF textbox and enter the value which is in the Calculated MCF textbox. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 22)

23 Manual Operation Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 23)

24 Future Addition Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 24)

25 Automatic Operation Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 25)

26 Automatic Operation Starting The Machine 1. Start the generator. (See generator manual) 2. Re-set each emergency stop. 3. Re-set Emergency Stop. 4. Check E-stop lights are on. 5. Start Compressor 6. Allow air pressure to build up. 7. Switch into Automatic. 8. Press the green start plant button. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 26)

27 Automatic Operation Loading A Recipe 1. If a Recipe has not yet been created, see page # to create a recipe. 2. To get to the Recipe Page, Click the Recipes button on the navigation bar. 3. Using the Recipe ID selection box select the recipe you wish to use. 4. Check the Recipe has been correctly been selected. 5. Click the Load button at the right of the Recipe textboxes. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 27)

28 Automatic Operation Starting the Batch 1. Load a Recipe (Shown on Previous Page) 2. Enter a Target Weight 3. Enter a Production Rate 4. Press the Start Infeeds button on the Control Panel Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 28)

29 Automatic Operation Running the Batch Navigation Bar Manual Weighing PLC connection indicator Exit Application Minimise Application VSD connection Indicator Separate TPH reading for each screw. As there are two screws but only one product, the screen displays two actual values, and one target value. Separate TPH target for each product As there are two products but only one weigh belt, the screen displays two target values, and one actual value. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 29)

30 Automatic Operation Stopping The Batch Under normal circumstances the batch will end when the Actual Weight (2), is equal to the Target Weight (1). However if you wish to stop a batch before the target is reached, pressing the red button below Start Infeeds (3) will stop the plant in its normal shutdown procedure. Pressing the emergency stop button (4) will force all infeeds, belts and the mixer to stop immediately, and they will have to be emptied manually before automatic production can begin again Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 30)

31 Software Creating A Recipe 1. Navigate To Recipes Screen. 2. Click Insert New 3. A new Recipe ID will be created and all the textboxes will show no value. 4. Click on each of the values and insert the correct value. 5. If no value is to be entered against any product, a 0 must be entered. Deleting A Recipe 1. Select the Recipe to delete using the Recipe ID selection box 2. Click the Delete Button Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 31)

32 Software Receiving Stock Note: Screen may vary 1. Click the Add button for the product required. 2. A dialog box will pop up, enter the amount of stock to add. 3. Another dialog box will pop up, enter the Docket Number / Code, if there is no Docket Code then enter N/A. Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 32)

33 Software Finding Settings Admix Admix Pump Start Speed Admix Pump Low Tolerance Admix Pump High Tolerance Admix Pump OS Tolerance Shutdown Time Delay Admix Material Low Alarm Time Delay Aggregate Aggregate Bin Low Tolerance Aggregate Bin High Tolerance Aggregate Bin Material Low Alarm Time Delay Aggregate Bin Outside Tolerance Shutdown Time Delay Aggregate Bin 1 Moisture Aggregate Bin 2 Moisture Time Delay before Tare or Aggregate Weigh Belt Aggregate Weigh Belt Totaliser Drop out Value Aggregate Weigh Belt Output in TPS (Tonnes per Second) Aggregate Weigh Belt Output in TPH (Tonnes per Hour) Mixer Audible Sounder Timer Shutdown Mixer Time Delay In-flight Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 33)

34 Software Finding Settings Out Loading Conveyor Start Out-Loading Conveyor Time Delay Stop Out-Loading Conveyor Time Delay Start Gob Hopper door after Aggregate Feeder Gob Hopper Door Open Time Gob Hopper Door Closed Time Water Pump Water Pump Start Speed Water Pump Low Tolerance Water Pump High Tolerance Water Pump Material Low Alarm Time Delay Water Pump OS Tolerance Shut Down TD Silo Silo Low Tolerance Silo High Tolerance Silo Material Low Alarm Time Delay Silo OS Tolerance Shutdown TD TD before tare of Silo Weighed Screw Silo Weighing Totaliser Drop Out Value Silo Feeder Output TPS (Tonnes Per Second) Silo Feeder Output TPH (Tonnes Per Hour) Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 34)

35 Software Finding Settings Timer Silo Start Sequence Time Delay Silo Stop Sequence Time Delay Water Pump Start Sequence Time Delay Water Pump Stop Sequence Time Delay Admix Pump Start Sequence Time Delay Admix Pump Stop Sequence Time Delay Automated Control Systems - Rapidmix 400CW - Setup Instruction Manual - Issue 2 (Page 35)