Phoenix RTS2010 Control System Operator Manual

Phoenix Transworld Ltd, Viaduct Works, Canon St, Leicester LE4 6GH
Tel: +44 (0) 870 750 5022 • Fax: +44 (0) 870 750 5033 • sales@phoenixtransworld.com
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Index

Page 1 Index

Page 2 Starting the Asphalt Plant

Page 3 Starting to Mix

Page 4 Faults during Mixing

Page 5 Shutting the plant down

Page 6 Home page

Page 7 Plant Status

Page 9 Recipe

Page 10 Production Schedule

Page 11 Alarms

Page 12 Inflights

Page 13 Totals

Page 14 Plant Setup

Page 15 Variables

Page 16 Skip Status

Page 18 Skip Configuration

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Starting the Plant

1. Start all motors in correct sequence and ensure Bitumen is

circulating.

2. If in manual control, set Exhaust Fan speed to approx. 60% or 6 –

10 on the Dryer pressure gauge. Increase the speed if Dust is
emitted from the burner end of the Dryer.
Alternatively set the Exhaust Fan control to Auto.

3. Light the Burner by pressing the button on the desk and warm the
dryer/bag filter for a minute or two on low flame.

4. Start the feeders as required and set the “Gang Control” which
controls the speed of all the feeders to about 40%.

5. Adjust the burner to approx. 30% using the ▲ and ▼ buttons on the
controller with the controller set to Man (manual) using the
Manual/Auto button (upper left button on burner controller).

6. Wait until the dryer discharge temperature stabilises and adjust the
burner to achieve the required temperature (150 0C?)

7. When ready to Mix press the “Start Mixing” button on the display
screen after first setting up a job to mix as per the following pages
in this Manual.

For the Control System to operate in Auto you require the following to
be correct.

1. Mixer running

2. Door limits to be operational on Mixer (open & closed), Aggregate

discharge door (closed), Bitumen discharge door (closed) and
Filler discharge door (closed)

3. All three scales must be approximately zero (lower than the “tare
limit”) but do not need to exactly zero as the system internally auto
zeros as it mixes

4. System switched to “Auto” on the desk

5. Skip must be under the mixer (if installed)

The skip must be driven in manual mode past the “Zero Reset”
switch and returned to the Mixer position before selecting “Auto”
when the power has been turned off.
The counter stop positions are not operative in manual mode!!!

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Start Mixing

Initially, if the mixer is cold or the first start of the day, the Mixer capacity
should be limited to 60 or 70% for ten batches until it warms up.

See page 7 for information on changing the batch size.

First a job has to be installed into the production Schedule (see page 9).

To start mixing, check that the Auto/Manual switches on the desk are in Auto.

Press the “Start Job” button on the display to start mixing. The system will
now start weighing up the required amounts as per the installed recipe.

Note The first batch will not drop out until you confirm that it can be released
by pressing the flashing “Batch Ready” button on the desk or the button
on the display, which will be flashing when it is ready to discharge from
the mixer.

Any alarms during weighing will be noted by a bleeping sound, which can be
read and acknowledged by pressing the “Alarm Mute” button on the “Alarm”
window.

Mixing will continue until the load is complete.

To top up the bin from another if one hot bin runs empty, press the “Top Up”
button on the desk then press the required bin button on the desk control.
You can also jog a sticking bin door by pressing and releasing the “Top Up”
button.

To stop a mix before the load is complete, press “Stop Job” on the display.
The batch being weighed will complete mixing and the job will then stop.

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Faults During Mixing

Weigh Door/Mixer Door Fault

This alarm will be generated if a weigh door (Aggregate, Bitumen, Filler) does
not close and reach the limit switch.
The control system will not start unless all the scales and mixer door are
closing the closed limits.
A quick check of the Mix Status screen on the control system will indicate if
the limits are correct or not.
The bar below the Aggregate, Bitumen and Filler weight displays turn Green
when the doors are not reaching the closed limit to show that they are open.

Open and close the weigh hopper doors to make the door indicator bar turn
Green when opened.

The Mixer will have the word “Mixing” in red when the Aggregate door is
opened.

Mixer Door fault will be generated if the door does not Open or Close on
either limit (two are fitted).

Weigh Door fault will be generated if the door does not Open or Close in the
pre-set fault time or close on the limit.

Bitumen Pump Stopped

The bitumen pump is stopped by the control system if the weight in the
Bitumen Scale is higher than a value as set in the Variables list (normally
150kg).
This is to stop the scale overflowing if the weigh valve does not close.

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Shutting the Asphalt Plant down

1. Stop the Feed Section and allow the material to be fully discharged
from the Dryer whilst reducing the burner flame, as less heat is
required.

2. Stop the Burner when the dryer is empty

3. Reverse the Bitumen Pump and open the Bitumen Weigh Valve
manually from the desk for at least two minutes to suck bitumen
from the Bitumen Valve to Plant pipe work.

4. Stop the Bitumen Pump and close the Bitumen Tank feed valve

5. Leave the Dryer running for at least 15 minutes to allow it to cool

down.

6. Clean the Mixer with at least two 500kg dry batches of material
which is left in the mixer for a couple of minutes each batch.

7. Empty the hot bins through the mixer using the manual controls.

8. Stop the remaining motors.

9. Grease the screen daily with three shots of SHELL HD2 or

equivalent grease in each bearing.

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Home Page

This is the screen displayed when first powering up the control desk.
It has four user selectable touch screen buttons, “Plant”, Main Menu”, “Setup”
and “?”.

The “Plant” button take the user directly to the main status screen.

The “Main Menu” button takes the user to a further selection of buttons for
access to other pages.

The “Setup” button is used to access a password-protected page for Time and
Date adjustment as well as other operations normally accessed by an
authorised engineer.

The “?” button will display a page that has all the Phoenix Transworld Ltd
contact details.

The buttons down the left hand side are used to directly access various pages
to be described later in this manual.

The “Menu” button links to the same “Main Menu” page as described above.

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Plant Status Page

The above screen is used to monitor the operation of the weighing and mixing
sequence.

The “Skip” buttons are only displayed if a mixed material storage system is
installed.
Also the Batch Elevator under the Aggregate scale is only displayed on
machines with a Batch Elevator.

The “Mix Time” and “Mix Size” can be accessed and changed by touching the
touch screen on the respective digits and using the numeric keyboard, which
pops up in a window.

Always press “Enter” to save the new value.

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Numbers out of range will not be permitted.

The “Start/Stop Job” button is used for starting and stopping a loaded job.

If for any reason a job needs to be deleted abruptly before ending i.e. stopped
before it has finished by switching to “Manual”, the “Reset” button is used to
cancel the job.

By touching the screen over any material bin, the page will go to the “Recipe”
page.
By touching the screen at the top right hand corner over “Recipe/Job No.” the
page will go to the “Schedule“ Page.

If any of the Weigh Scales are touched on the screen, the page will go to the
“Inflight “page.

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Recipe Page

The recipe page is used for entering and viewing the material recipes to be
mixed.
An unlimited number of recipes can be saved, each with a unique name and
number.

To enter a new recipe, choose a number by touching the “Recipe Number”

data field on the screen to bring up the numeric keyboard.
Choose a name by touching the centre of the “Recipe Name” box and using
the alphanumeric keyboard in the window.

Then enter the recipe % for each material, Bin 1 being the smallest material.

All the individual % must add up to exactly 100% or the recipe will not save
and the error total will be displayed.

Press the “Save Recipe” button to save it.

The “Delete Recipe” button can be used to delete individual recipes.

You can send the recipe direct to the “Production Schedule” page by pressing
one of the “Job #” buttons.

The “Plant” button will take you back to the Main Plant Page.
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Schedule Page

The schedule page is used to load the recipe and amount to be mixed in
tonnes.

It has six separate fields that can be used in any order for loading up
production before it is required if numerous recipes are being mixed in any
one day.

The “Job No.” can be any number, which refers to the job and is changed by
touching the data field in the usual way.

The “Recipe No.” is then selected which will display the name given when
saved.

The “Tonnes Required” is then needed. It can be any amount to one decimal
place.

If the “Tonnes Completed” is not at zero then the “Reset” button must be used
to zero it before starting.

When the job is installed and ready to mix, press the “Load” button next to the
job to be mixed to load it into the “Plant Page” ready to be mixed.

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Alarms Page

The alarm page can be accessed at any time via the “Menu” button.

Also the alarm window will pop up when any new alarm occurs to prompt the
operator and to make him aware of the problem.

If the alarm is accepted it will go from Red to Yellow if it is still occurring.

Non-essential alarms will reset automatically when they are rectified.

Other alarms such as those concerned with weighing etc., will only clear if
accepted first.

The “Plant” button returns the operator to the Plant Page.

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Inflights Page

The “Inflights Page” displays and records the weight of the material “inflight”
between the storage hopper door and the weigh scale.

This “inflight” material will cause inaccurate weighing if not compensated for
and the control system automatically calculates for weighing errors and
displays the amount on the right hand column.

During initial commissioning the amount in the right hand column must be
noted and entered in the left hand column “Initial Inflights”.

When the control system is powered up, the previous days “Inflights” are lost
and these initial inflights are used to ensure that the first few batches are
accurate.

They will not always be the same as the “Actual Inflights” but only need to be
approximate.

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Plant Totals Page

The Plant Totals page displays two totals.

The Daily total can be re-set each day to record all automatically mixed
materials.

The “Print Totals” button will print a record of the totals.

“Reset Daily Totals” will reset the daily total to zero.

The “View Log Files” button displays all production logged to the CF card
which is fitted into the side slot.
It looks jumbled due to the fact the file is designed to be viewed by Windows
Excel” and is comma deliminated.

The files may be down loaded to a PC via the USB socket at the base of the
terminal.
The files are dated with a new one opened each day.

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Plant Setup Page

To access the Plant Setup page, the “Logon” button is pressed and the
alphanumeric keypad window is displayed.

Type in “manager” for the “username”, and press “Enter”.

Then type in “admin” again as the “password” and press enter again.

You will now be logged in and will stay logged in until the “Log-Off” button is
pressed

The “Plant Setup” page is to be used by an authorised engineer to adjust the

control system properties.

UNAUTHORISED ADJUSTMENT OF THESE VARIABLES CAN RESULT IN

MAJOR CONTROL SYSTEM MALFUNCTION.
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Variables Page

The above security screen may or may not be displayed when accessing this
page. If the “manager” username and “admin” password has been already
used as above, the page will be directly accessed without security.

The “Plant Variables” page is to be used by an authorised engineer to adjust

the control system properties.

UNAUTHORISED ADJUSTMENT OF THESE VARIABLES CAN RESULT IN

MAJOR CONTROL SYSTEM MALFUNCTION.

The “Simulator” button is used to enable the “Simulator” which allows

simulated mixing to take place for training purposes.

All motors must be isolated and the plant must be empty before using it as it
ignores the actual weight on the scales. The compressor must be running
though as it uses the doors on the plant to operate.

The “Print Variables” button sends a print of the entire system configuration to
the printer. It is very necessary to keep a hard copy of these settings.

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Skip Status Page

To select either “Skip Manual” or “Skip Auto”, the button in the centre of the
silo is pressed.

The skip destination can be selected from either the “Plant Status” page or
from this page by pressing the respective destination button.

The “Skip Door Open” delay time and “Skip Up” delay time are set from this
page and are not under password control for ease of operator access.

If a change is made to a delay time, the “Save” button must be pressed to

confirm the change and to save the change to non – volatile memory.

The blocks are illuminated when correctly selected to show destination and
final position of the skip car.

The Up and Down counts are displayed at each end of the track as the skip
car is positioned by a 400 pulse per revolution encoder which is fitted to the
winch shaft with a Zero reset switch at a mid point in the track.

The winch is controlled and stopped depending on the number of counts to

each position.

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Please note.

To initialise the skip position counter each time the control system has
powered up, “Skip Manual” must be selected and the skip car must be run in
manual control past the “Zero” switch on the track mid point.

When “Skip Manual” is selected, the counter positioning control will not
stop the skip automatically and great care must be used when reaching
the stop positions.
The Up or Down button must be released early to allow for the Skip car
to stop.

If the skip car was parked above the “Zero” switch, it will be enough just to run
the Skip car to an area near the mixer stop position.

“Skip Auto” can then be selected and after pressing “Up” the car can be
allowed to run up to a selected stop position and then return to the mixer
position automatically.

Alternatively, if the Skip car is parked under the mixer, the Skip car will need
to be sent Up in Manual control until it passes the “Zero” switch position, then
bring the Skip car back down the track until close to the Mixer stop point.

“Skip Auto” can then be selected and after pressing “Up” the car can be
allowed to run up to a selected stop position and then return to the mixer
position automatically.

If the Hot Storage system is not to be used, by either lifting the bottom track or
opening the lower section of track, a “Track Down” limit switch will open and
signal to the control system that it will operate in “Direct Load” mode which
does not require the Skip car under the Mixer before the Mixer Door will open.

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Skip Config Page

The above security screen may or may not be displayed when accessing this
page. If the “manager” username and “admin” password has been already
used as above, the page will be directly accessed without security.

The “Skip Config” page is used to configure the control system for the
installed skip system.

The “Skip Up Check” and Skip Down Check” timers are used to ensure that
the “Zero” switch and Encoder is working.
They must be set to a time just longer than the time taken to travel from the
furthest point to the “Zero” switch in each direction.

The “Encoder Speed Set” detects for an out of control skip and must be set a
little higher than the highest “Encoder Speed” figure displayed whilst the Skip
car is travelling.

The “Set Stop” counter positions must only be adjusted by persons who
understand what they are doing.

“Save” must be pressed to save any adjustments to the non – volatile

memory.
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