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ZHENGZHOU SINOSUN MACHINERY

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Continuous Asphalt Mixing Plant Control System


Electric and weighing system Manual

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Safety Tips:
To ensure
the normal operation of the personal safety of staff
and equipment , in particular the following few requirements:

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ADD: 6-2002, JinCheng Business Tower, No.18 DongFeng Road,
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ADD: 6-2002, JinCheng Business Tower, No.18 DongFeng Road,
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1. Electrical system Instruction


1.1 Configuration of the system power
The electrical system uses a three-phase four-wire power supply system,
the rated voltage 380V, frequency 60Hz, equipment total installed capacity
of 90KW or so, it is recommended that the transformer capacity not less
than
125KVA, if the generator set power supply yourself, the output power of
the generator set is not less than 125KW. The power cord uses the VV - 3 *
50 +1* 25 copper cable. The power cord is greater than 50 meters
should be considered when the line losses.
Supply transformer or generator neutral point of the group to the ground,
the distance of the supply transformer or generator sets and equipment
is greater than 60m, the equipment installation at the repeated grounding,
grounding resistance less than 4. The ground polarity should be very indepth underground 2.5m above the ground line is to be connected reliably.
This product does not contain the lightning protection system. If necessary,
can be user installed. Lightning protection and grounding resistance is
less than 10. A metal shell must be grounded, the metal frame, base
metal components are connected into one body, the grounding resistance
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ADD: 6-2002, JinCheng Business Tower, No.18 DongFeng Road,
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is less than 10.
1.2 Component configuration
1. The whole system has a total current and voltage meter to show the
overall running situation. More than 37kW motor with a separate ammeter in
order to observe the operation of the load motor. Control voltage and the light
power control voltage and light voltage is220V.
2. Motor breaker as a short-circuit protection, thermal relay overload
protection.
3. Be the motor rated current Ied to select and tuning heating
element, la resistencia actual nominal del Iej debe estar cerca del
Ied, por lo general toma la Iej = (0,95-1,05) Ied
Cable into the electrical cabinet part of the cable wrapping should be
stripped, stripping the cable wrapping, pay attention not to damage the
wires, power line, any line of fire through the power distribution cabinet,
current transformer, each Fire Wire Crimping the terminal copper nose good
pressure to the knife fuse switch into the line-side power distribution
cabinet, pay attention to the wiring copper nose and switch connections are
tight, loose will cause the fever burned switches and wires. Zero line and
the zero line is securely connected with the line of fire together with nylon
cable ties to the power distribution cabinet.
Control system electrical components in the power distribution cabinets,
built-in circuit breakers, AC contactors, time relays, thermal relays,
current transformers, buttons, knobs, inverter, transfer switch, voltmeter,
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ammeter main components cloth counter tops.
1.3 Equipment start and stop sequence
1.3.1 Boot preparation:
Before the device is put into use the following preparations:
1. Sufficient materials, a variety of materials should be consistent with
construction requirements and in sufficient quantity;
2. The appropriate loader, and dump trucks and other machinery, tools,
etc.;
3. The ratio of the finished product, and the total output requirements,
calculate the yield of the bucket.
Operation timely inspections of agencies work, work in a variety of abnormal
conditions should be immediately removed or notification console downtime.
Confirm the various parts of the equipment on unmanned and loitering
items after opening bell tips.
1.3.2 The boot sequence:
Air Pump Throttle Off Wind drawing Fan Hot Elevator Dryer Drum
Tilted Belt conveyor Inclined belt conveyor Throttle on Oil Pump
Successful ignition Cold aggregate feed.
Temperature suitable material to the rear cylinder began after spray drying
asphalt;
Adjust to the speed of asphalt materials to meet the technical parameters of
the indicator;
Temperature regulation in the feed just dump the car when unloading with
temperature meter to measure the actual temperature.
Note: For oil burners, oil pressure at the time of ignition should be just below
the normal operating pressure and damper than normal working throttle;
unsuccessful if an ignition shall promptly closed oil circuit, and opened the
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door blown gale inside the furnace of the oil before re-ignition, especially hot
stove because of lighted mist into the system, preheated gasification, suffered
fire, easily "burst furnace." Successful ignition, adjust to the desired hydraulic
oil, adjust the throttle to the desired pressure, the burner can work.
1.3.3Shutdown sequence:
Fire Off Stopping feeding asphalt pump oil return hoist (half an hour
later) Hot finished aggregate door open Air pump Dryer Drum inclined
belt conveyor Tilted Belt conveyor stop Throttle off Wind drawing Fan.
2 Operating instructions
2.1 Operating System Profile
The automatic weighing system uses state-of-the-art control devices in the
world: Japan OMRON (Omron), programmable logic controller (PLC) as
the core control, color LCD touch screen (PC) as the user interface. The
whole system has a reasonable design, high reliability, accurate weighing,
the ease of user operation, intuitive features.
2.2 The main function of realization
1. The system set up automatic/manual mode. In automatic mode can
automatically complete the chain of start/stop processes, from equipment
layout and various quarters, you can choose the start and stop sequence
and delay time of batching scales, to ensure that material into the dryer
drum to ensure uniform mixing.
2. Cement level detection function can be displayed on the display the
number of tons of cement in the cement silo.
3. The display has technology process, modify parameters, recipe
management, statistical reports and printing capabilities of historical data
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storage.
2.3 Operating Instructions
The system is by from the weak power part, weak power part of the touch
screen, PLC, transmitter, force sensors, inverter, its wiring methods look
at electrical diagrams, electrical schematics attached.
The operation of this control system on the touch screen color LCD display.
Turn the power switch, the control system began to work.
2.3.1 Z h e n g z h o u S I N O S U N M a c h i n e r y C o . , L t d regards
to pay tribute to the screen.

First LCD touch screen display the first screen.


There are the greeting message to the user, the screen below the "Press to
enter" button, enter the second screen picture.
2.3.2 The second screen, the screen shows the process flow diagram
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of the entire system.

The second screen shows the process of the entire system, two touch
buttons on the screen, press the

button to the first screen, press the button

to the third screen.


2.3.3 The third screen images for the parameter input screen

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The screen mainly have two parts parameters, first part is the percentage
of parameters, the second part is the system parameters.
The percentage of parameters: enter the first pre-production, the percentage
of various ingredients in the percentage of the parameter box, and the
tonnage to be produced per hour, the system automatically generate the
traffic of each material per hour.
The system parameters: the zero is the value of automatic calibration of the
standard scale zero is automatically populated.
The tare weight is the value of zero is automatically populated by the
automatic calibration of the standard scales.
Flow slope is automatically filled in by the sub-scale calibration value
(school scale screen).When manually modify the flow slope by the formula:
New school factor = old school Coefficient (actual weight of material /
material weight)
After calculated, it will be regarded as the result of input data corresponding
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ADD: 6-2002, JinCheng Business Tower, No.18 DongFeng Road,
JinShui Zone, ZhengZhou City, P.R.China 450000
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box.
It is noteworthy that, when the work is in progress, come back to this screen:
the modifications of which the weight parameters, when the work is
stopped and then re-work to be valid, if certain parameters to be modified
during the operation of mixing work should be stopped, and to be
released after. It is noteworthy that, when the work is in progress, come
back to this screen: the modifications of which the weight parameters, when
the work is stopped and then re-work to be valid, if certain parameters to
be modified during the operation of mixing work should be stopped, and to
be released after stirring the spices of the dryer drum, and then return to this
screen to modify the parameters.
The

button on the touch screen to the "process" screen, press the

button ,turn to the monitor screen.


2.3.4

The

fourth

screen

to

the

monitor

production

screen

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Flow bar graph: red stick picture shows the settings for flow bar graphs,
green stick picture shows the actual flow rate bar graph.
Set the flow: The hours of each ingredient in the production set production.
The actual flow: each ingredient in the production hours of practical
production.
Speed output: the output of the motor operating frequency of each
ingredient production.
Operation mode: display the ingredients of the motor current operating
mode, automatically or manually.
Speed running: the actual feedback, the speed of the motor in the
ingredients weighing the actual operation.
Weight signal: belt weigher scale body under heavy pressure sensor
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ADD: 6-2002, JinCheng Business Tower, No.18 DongFeng Road,
JinShui Zone, ZhengZhou City, P.R.China 450000
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measured weight display new number values.
Speed tracking: in the automated production, the ingredients motor
frequency directly to the speed of running for the starting speed.
Powder on the upper limit: the powder metering tank weighing more
than the value, and stop feeding butterfly and dragon action to the powder
metering tank.
Powder on the lower limit: the powder metering tank weight is below
the value, start to the powder measure tank. Feeding butterfly and spiral
action.
Press the bottom left of the screen

button on the screen can be

switched t o the third screen, namely, parameter setting, Press the bottom
right of the screen

button on the screen can be switched to the

production of the cumulative screen.

2.3.5 Cumulative report screen


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Equipment in the normal production process,show the cumulative quantity of


each ingredient.

2.3.6 School scale screen


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The screen is the correction belt batching machine zero parameters and
flow slope parameters.
Schools weighing options: To select need to adjust the belt batching
machine.
Weight signal: Select ingredients belt conveyor weight signal.
Speed signal: Select ingredients belt conveyor speed signal.
Automatic zeroing: scales before the calibration must be zero, if you find
zero biased in use, ready to be zero in the course.
Note: zero in the manual mode of operation stage, adjust the manual output
values so that the inverter to run around 15HZ. Click on the automatic
zeroing button, turn red, the belt conveyor in one minute automatic zero,
when the one minute time zero data is automatically written to zero
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parameters of the selected belt weigh. Automatic zero and automatic reset
.The calibration of flow slope:
Click to clear the nominal, and then in manual mode to tune the Motor to
run in the 15-30HZ, cleared the nominal weight of the back data
automatically with the movement of those materials to accumulate. When
materials reach about 8 tons, the batching machine stops running,
unloading the materials of finished products warehouse, to the scale
measurement, and then measured the weight input to the actual weight, last
press school scales determine, the program automatically calculates the
flow slope.
2.3.7 Recipe screen

Up formula: Select the above set of query


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formula. Down formula: Select the next set of
query formula.
Save formula: The current system is running the formula data into the
formula database, the current formula to the query formulation.
Select formula: Data in the current query formulation data set to the recipe
data for the current system is running, Query formulation to the
current formula.
3. The common electrical fault and approach
3.1 Discrimination and maintenance of the equipment failure
If this system appear failures, through found the weight signal and speed
signal to determine point of failure where the initial judgment.
If the weight signal is wrong, check the following equipment:
The mechanical part of the scale body: to check whether the scale body
stuck, especially spiral scales cross reed parts should be inspected regularly
to clean up.
Wire and cable: The signal line is intact, the wiring is correct, the connectors
for reliable contact.
Linear power supply: power supply is whether normal.
If the speed signal is wrong, you can check the following equipment: Inverter
output voltage is correct, the wiring is reversed with the interface box, and
the connection is solid.
When the weight signal and speed signal are normal, check the following
failure for the operation, the solution is as follows:
(1) At boot time, manually is normal and automatic is abnormal.

Set incorrectly, parameters table tare, slope, speed slope, speed intercept
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is correct; manual tracking is whether the value in normal operation.
(2) At boot time manually is normal automatically when running at the
fastest speed. The insurance bolts screw from, and the scale box is stuck.
(3) The measurement is incorrect
View the tare of the parameters total table, the slope is correct; scale box
object stuck or product materials required to cleanup.
(4) Measured is the half of the actual feeding amount.
View the tare of the parameters total table, the slope is correct; with zero
material is in normal working.
(5) Running abrupt pause
Large piece of material stuck, at the same time the motor current
increases, sometimes the motor and drive roller running belt does not
move, can be the discharge port of the material door open wider, clean up
the card material.
(6) Circuit fault
A. For broken circuit;
B. Whether there is a short circuit and ground;
C. Polarity is reversed;
D. The connection sequence is normal, whether bobble connection and
wrong connection then;
E. Whether the circuit parameters is fit for
(7). Three-phase motor failure
A. Mechanical transmission part if there are problems;
B. The power supply is normal, the capacity is adequacy, power is
normally sent to the motor;
C. The electrical wiring is correct;
D. Whether the motor winding is broken circuit;
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E. The motor insulation resistance is less than 0.5 M.
(8). Breaker, thermal relay trip
A. Mechanical transmission parts are jam, whether is load;
B. The motors if there are problems;
C. Whether the current is exception;
D. The breaker and the heating element setting value is whether correct;
E. The breaker and thermal relay contacts are whether burning severe, and
the contacts are good.
(9) The contactor and relay is not pull
A. Power supply is normal.
B. The loop string of breaker, thermal relay, contactor, relay contacts, limit
switch action is correct, protected themselves contact is normal contacts.
C. The coil is whether burned.
4. The daily inspection and periodic maintenance
4.1 Routine inspections
1. It should be in inspection daily at any time.
2. The inspection means visual, listening, hands touch, ammeter, voltmeter
and thermometer.
3. Check the contents:
(1) Electrical equipment operating temperatures higher than 40, should
consider dissipate heat, such as cabinet doors is open;
(2) Whether the condensate phenomenon of electrical equipment, leaking
traces;
(3) Whether the odor in the air, smoke phenomenon;
(4) Electrical equipment vibration is for smooth, the action sound is normal,
whether abnormal noise, any abnormal sound;
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(5) Electrical equipment operating parameters (current, voltage, etc.) is
within the nominal range, deviated from the normal is larger;
(6) Whether the normal action of electrical equipment, instrument display is
normal;
(7) Live electrical equipment, instrumentation fixed firmly, and interfered with
the machinery and equipment;
4.2 Regular maintenance
1. Equipment arrived in the site, the power at full load to run the day after,
shall conduct a comprehensive inspection, after follow the user environment,
weeks or a month on electrical equipment, periodic inspection.
2. The only professionally trained person to carry out maintenance and
replacement of the device.
3. Not the screws and washers and other metal left in the device, otherwise
the risk of damage to the equipment.
4. Check the main content
(1) The main circuit terminal screws are loose, whether there is poor contact,
alignment line of the main circuit overheating traces;
(2) Control terminal screws are loose;
(3) Power cables, control cables, and cabinet wires with or without injury,
especially in contact with the metal surface epidermis cut traces;
(4) Whether the damage of the insulation of the electrical equipment,
insulated copper wire nose bandage belt is off, the insulation which there is
doubt, may be the appropriate level of ohmmeter, the motor windings
insulation resistance at room temperature should be not less than 0.5 M;
(5) Comprehensive cleaning of dust on electrical equipment (outdoor
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exposed part).
4.3 The Long-term Disabled Precautions
(1) The switch disconnected the transformer power strip to the supply of
equipment, power distribution room.
(2) The distribution cabinet breaker is turned off, knife fuse switch pull
down.
(3) A variety of operating knobs, and the change-over switch convert to the
stop position, then press the emergency stop button, key button pull out.
(4) The distribution room air-conditioning power cord from the outlet, the
interior lighting switch is turned off.
(5) The distribution cabinet door lock and reliable, the introduction of cable at
should be mouse proof processing.
(6) Check the motor terminal box, screw is complete, fixed, whether solid, the
rubber is complete.
(7) Check the limit switch, the body with or without damage, loose, pin out
connector tape wrapped good.
(8) Check the thermal resistance, fixed reliability, wiring cover is tightened,
the rubber is complete; wiring mouth down.
(9) Check from the motor terminal box, magic valves, heat resistance, and
other various live electrical equipment cable, fixed and reliable, to prevent
water running down cable into the device.
(10) The power distribution room windows are whether closed reliable, and
the door lock.
4.4 Note the boot next year
(1) Check the motor terminal box, magic valves, etc. all kinds of live electrical
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equipment are damaged, water phenomenon.
(2) Examine the various field of electrical equipment cable, fixed reliability,
with or without injury, joints wrapped good.
(3) Examine the various operating devices(breaker, button, knob,
etc.)operation is flexible.
(4) Examine the various terminals, connectors are whether the corrosion
phenomenon.
(5) Main circuit terminal screws are loose, whether there is poor contact.
(6) Control terminal screws are whether loose.
(7) Whether the insulation of the electrical equipment damage, copper nose
insulating tapes is off.
(8) For the motor, you should remove the cable from the motor terminals (to
prevent voltage string of shake table to the other devices), using a 500V
ohmmeter (shake table) insulation resistance of measuring motor winding
phases, with the relative shell insulation resistance, room temperature, the
insulation resistance shall be not less than 0.5 M.
(9) On the electrical components, cabinets, equipment (outdoor exposed part)
on the dust comprehensive cleaning.
5. Electrical Safety Precautions
(1) The electrical equipment is not installed in the environment containing
explosive environment, otherwise there is danger of causing an explosion.
(2) It must have a qualified professional personnel for maintenance, repair,
otherwise there is a risk of electric shock.
(3) Do not mount power distribution cabinet temporary equipment, then the
maintenance power, should pay attention to a machine configuration a knife;
(4) Maintenance of equipment must be cut off the power, and supervised,
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can be carried out; in the maintenance of rotating equipment such as
auger, conveyor, mixing tank, should pay particular attention to this,
otherwise life is in danger; supply loop containing the charger equipment
such as inverters, switching power supply, maintenance must charge light
is completely extinguished before the operation.
(5) When the power is off, all power is disconnected (double circuit power
supply should be special attention to this point), not with a load of wind up;
have to pull the knife melt (visible breakpoints); experience electricity; person
responsible for the care (or hang Someone work, DO NOT TURN ON
"brand), after the overhaul, be notified before transmission.
(6) Not to promote live working, but must live working should be noted: the
professionals before operation; someone guardianship; tools insulated
qualified; fastened cuffs, with gloves; disconnect the wires, the first off the
line of fire, energize, the first zero line.
(7) During the operation should be preceded by ringing the bell sounding,
warning device next to the staff note that non-hazardous before operation,
boot device, if occur over current protection, please re-confirm the wiring is
correct, electrical equipment before transmission to run.
(8) Prohibits the operations can not control equipment.
(9) On power case, do not touch the terminals, otherwise an electric shock
hazard.
(10) Magic valves, limit switch, PLC,touch

screen,

variety

of

instrumentation, control circuit terminals and other equipment, the wiring


should pay special attention to the voltage level, or there is risk of damage to
the equipment.
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(11) The exposed part of terminals attention should be paid to the insulation
problem, part of the treatment with insulating tape tied, electric shock,
explosion, damage to the equipment.
(12) Equipment metal casing must be earthed, metal supports and basic
metal structures as an overall, the grounding resistance less than 10.

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