Pneutrol International Limited Rapid 600C User manual

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Rapid 600C
Continuous Mixing Plant
User Manual
Pneutrol International Limited,
5 Caulside Drive,
Antrim,
Co. Antrim,
N. Ireland.
TEL: [phone]
FAX: [phone]
03/11/2015

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Contents
1: GENERAL INFORMATION..........................................................................................................4
1.1: System Hardware......................................................................................................................4
1.2: System Software Standard Features..........................................................................................5
2: SYSTEM SET-UP...........................................................................................................................6
2.1: Standard Navigation bar: ..........................................................................................................7
3: RUNNING INFORMATION:.........................................................................................................8
3.1 Running Screen –Manual Controls:........................................................................................10
4: STATISTICS:................................................................................................................................14
4.1: Production Summary: .............................................................................................................15
4.2: Stock: ......................................................................................................................................17
4.3: Trucks: ....................................................................................................................................18
4.4: Drivers: ...................................................................................................................................19
4.5: Delivery Supplier:...................................................................................................................20
5: RECIPE SCREEN: ........................................................................................................................21
5.1: View/Edit Recipes: .................................................................................................................22
5.1.1: Calibrate Recipes:............................................................................................................23
5.2: Recipe Groups:........................................................................................................................28
6: CUSTOMERS: ..............................................................................................................................29
7: SETUP:..........................................................................................................................................30
7.1: Plant Setup:.............................................................................................................................31
7.1.1: General Variables: ...........................................................................................................32
7.1.2: Drives:..............................................................................................................................33
7.1.3: Times: ..............................................................................................................................34
7.1.4: Drain Times: ....................................................................................................................35
7.1.5: Alarm Times:...................................................................................................................36
7.1.6: Tolerances:.......................................................................................................................37
7.1.7: Rates:................................................................................................................................38
7.1.8: Drive Comms Control:.....................................................................................................39
7.1.9: Cement Calibration..........................................................................................................40
7.2: Material Setup:........................................................................................................................44
7.3: Supplier Setup:........................................................................................................................45
7.4: Moisture Setup:.......................................................................................................................46
7.5: Printer Setup: ..........................................................................................................................48
7.6: IO Status: ................................................................................................................................50
7.7: Users: ......................................................................................................................................51
8: CHARTS:.......................................................................................................................................52
8.1: Historical Chart:......................................................................................................................53
8.2: Real Time Flows Chart:..........................................................................................................55
9: MANUALS:...................................................................................................................................57
10: BACKUP DATABASE:..............................................................................................................58
11: REMOTE LAPTOP.....................................................................................................................59
11.1: Remote Viewing on Laptop:.................................................................................................60
11.2: Laptop Assuming Main Control of Plant:.............................................................................61
12: DIAGNOSTICS/ALARMS:........................................................................................................64
12.1: Alarms Screen:......................................................................................................................64
13: REMOTE ACCESS:....................................................................................................................65
13.1: Modifying Network Providers’ APN Settings:.....................................................................67
14: SHUTDOWN SYSTEM:.............................................................................................................69
15: USEFUL INFORMATION: ........................................................................................................69
15.1: Pausing The System:.............................................................................................................69
15.2: Emergency Stop:...................................................................................................................70
15.3: Safety Pull Switches .............................................................................................................71

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15.4: Mixer Castell Interlocking System .......................................................................................73
15.5: How To Reset VSD’s............................................................................................................75
15.6: Compressor...........................................................................................................................76
15.7: Pneumatic Valve Box Lubricators/Air Pressure Setup.........................................................78
15.8: HMI.......................................................................................................................................79
15.9: How to Calibrate Moisture Probes........................................................................................80
15.10: Admix Dispenser ................................................................................................................82
15.11: Hydraulic Controls..............................................................................................................83
15.12: What to Do If You Have a Problem?..................................................................................84
16: APPENDIX 1 –Best Practice/Regular Checks ...........................................................................85
17: APPENDIX 2 –Full Alarm List..................................................................................................86
18: APPENDIX 3 –Troubleshooting Guide......................................................................................90

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1: GENERAL INFORMATION
The Control System and Software have been designed and developed specifically for the control of
Concrete Batching Plants. The Hardware that is housed inside our Control Panel has been chosen
for its reliability in operation and for flexibility in different applications.
The software is 'Customised' for each plant and is therefore suitable for all types of plants and
plant layouts.
1.1: System Hardware
CONTROLLER: - ALLEN BRADLEY Micrologix Processor.
- Uses Industry Standard Ladder Logic Programs.
- CSA Certification to Class 1 Division 2.
- Battery-backed up memory for protection of program and data.
- Can be expanded to take in 256 additional discrete I/O
- Built-in LCD with backlight allows you to view controller and I/O status
TERMINAL: - Exor eTOP 15” touch screen operator interface
- 16.2M colours, providing XGA 1024x768resolution display
- Energy efficient LED display
- Displays all plant data.
- Displays plant operation on screen.
PRINTER: - Able Systems Ltd Ap1400V Thermal Panel Printer
- Robust design with added protection for harsh environments
- Mechanism life of 13 million print lines
- Print speed of 80mm/sec
- Flexible connectivity

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1.2: System Software Standard Features
1. STORAGE OF RECIPES: Each recipe will contain the details regarding a specific blend of
materials, which is the amount of each of the aggregates, cement, water and additives if required.
There is no limit to the number of recipes the system can store.
2. PASSWORD PROTECTION: Information in the memory of the computer can be protected by a
password code to prevent any unauthorised person deleting, changing or resetting stored data.
3. STOCK CONTROL: Materials in stock and material usage are stored in memory on the HMI.
These may be displayed as required to give daily or monthly totals for each material used in the
plant and stock levels remaining.
4. NO FEED: Should a bin be empty or material be bridged in the bin then an alarm message will
be given.
5. PRINTER: The system printer is used to print a ticket on demand or automatically given the
parameters input for print detail.
6. PLANT ALARMS: An alarm message will be placed in an alarm log and displayed on the
monitor. A printout will be given of any/all alarm faults together with a date and time.
Alarm messages are given for specific faults e.g.
‘Mixer not running’
The operator may therefore rectify the problem quickly and so save on plant 'Down Time'.
An audible and/or visual alarm is also available where the operator may be a considerable
distance from the Control Panel.
Once the alarm has been initiated the operator may push the alarm accept button at the control
panel once to cancel the audible/visual alarm. He must then push the alarm accept button again
to continue batching once the fault has been rectified. Also the operator may rectify an alarm
when in the alarm screen using option "F1: ACCEPT ALARMS".
7. MONITOR:
Displays Selection Menus.
Displays recipes
Displays mix tolerances
Displays alarms
Displays plant Inputs and Outputs.
Displays running screen.
Displays a variety of stock and production reports
Displays customer information

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2: SYSTEM SET-UP
When the generator is started, the UPS and HMI will automatically be turned on. During the
course of normal use, if the HMI is not being used, it will automatically go into sleep mode. There
is a small LED in the top right hand side of the HMI which alerts the user to the following:
Red –Power is on, but the HMI is turned off
Amber –Power is on, but the HMI is in sleep mode
Green –Power is on and the HMI is on
When the HMI is powered on, the following Log On screen will appear:
Enter user name and password to log onto the system. This will launch the running screen of the
continuous mixing plant and highlight the following as sown below in the figure:
Conveyor status
Mixer status
Drive speed
Material loads across the system
Tons per hour target

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2.1: Standard Navigation bar:
The navigation bar (shown above) appears at the top of all screens in the system except for the
reports screens.
View Alarms. In order to view alarms, hold down the ‘alt’ key and press 1.
View Running Screen. In order to view the running screen, hold down the ‘alt’ key and
press 2.
View Silo Screen. In order to view the silo control, hold down the ‘alt’ key and press 3.
View Recipes. In order to view the recipes, hold down the ‘alt’ key and press 4.
View Plant Setup. In order to view system setup, hold down the ‘alt’ key and press 5.
You also can enter any of the navigation bars by just touching them on touch screen or by
left clicking the mouse over them.

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3: RUNNING INFORMATION:
After the HMI is powered up, the running screen is the default, home screen, which allows the
operator to oversee the entire continuous mixing process.
The Auto/Manual selector switch in the top right of the screen, lets the user know which control
mode the plant is currently in.
A graphical representation of the plant is shown in the running screen. The running screen has
weight indicator boxes around the weigh hoppers which show the actual weight in each hopper.
The current live drive speeds are also shown.
In the top left hand corner of the running screen the following information is displayed:
Load Qty (Tns) –actual batched quantity versus the target
Agg/Cem Qty Rate (Tns/Hour) –actual quantity rate in tons per hour versus the target rate
Target % - Percentage of each material being used in the current recipe. Calculated from the load
quantity and target tons per hour rate.
Actual % - Percentage of each material being used in the current recipe, calculated from the
amount of material leaving the hoppers and feeders (continuously updated.)
Actual Kgs or Lbs/s –Displays the actual flow rate per second of each material
Batched (Tns) –Displays how many ton of material have been utilized
Water Adjust %–this allows the user to change the water target percentage in real time.
To the bottom left of the Running Screen the Start, Abort, Hold and Shutdown buttons are
displayed.
When the Start button is pressed, a dialogue box as shown below pops up on screen:

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A close up of this dialogue box is shown below:
The user can select the recipe, customer, site and truck using the drop down menus. After
selecting these 4 options the user enters the quantity to be batched and the batching rate (in tons
per hour). We will look at how recipes, customer information, site details and truck information
are entered later in this manual. After a load has been completed, the same details will
automatically appear in the start dialogue box. Al the user will need to do is press “Start”.

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The second button along the bottom of the screen is the Abort button. When this button is
pressed, the system immediately stops what it is doing and resets its automatic program –any
material already weighed up will have to be discharged from the system manually by the operator.
This buttons function is primarily used to reset the program, but in case of emergency if the
wrong mix has been setup or started, this button can be used to minimise the amount of material
produced in error.
Beside Abort is the Hold button, this button does exactly what it says, when this button is
pressed the entire plant will pause what it is doing and wait until its pressed again to taken off
hold. The mixer and outloading conveyor will continue to run, but the aggregate belts feeding the
mixer and also the cement filling/emptying process will pause. A large, red ‘HOLD’ warning
appears below auto/manual toggle switch on the running screen.
The last button in this row is the Shutdown button, this button is used to shutdown the plant
when in the middle of a production run. For example, if the user has started the plant off making
25 tons of material, the shutdown button can be pressed at anytime, this will ensure the plant
stops producing any further material and shuts the system down in an orderly fashion as it would
do if it had reached its 25 ton target, ensuring the outfeed belt and mixer are totally drained out
and empty of material.
3.1 Running Screen –Manual Controls:
At any point the user can chose to turn the plant into manual control as shown below by selecting
the auto/manual switch in the top right corner: