plant control system · Control System Belt Weigher 1 ASI-Master GT32 Belt Weigher 2 Belt Weigher 3 RS 422 RS 422 RS 232 AD20 AD20 AD20 RS 422 Touchscreen K2 Control Board. K2 Automation

plant control system

Project: Quarry Plant Sibiu / Romania

Project: Quarry Plant Schmidt Basalt / Germany

Project: Quarry Plant Braszowice / Poland

Project: Quarry Plant Bologa / RomaniaProject: Quarry Plant Dunabogdany / Hungary

Project: Quarry Plant Sheleiki / Russia

K2 Automation GmbHUntere Brettachtalstr. 27D-74626 Bretzfeld-Geddelsbach

Telefon +49 7945 / 94 29 9-0E-mail: [email protected]

K2 Automation GmbHUntere Brettachtalstr. 27D-74626 Bretzfeld-Geddelsbach

Telefon +49 7945 / 94 29 9-0E-mail: [email protected]

Project: Quarry Plant Lüptitz / Germany

Project: Quarry Plant Stara Zagora / Bulgaria

Project: Quarry Plant Slupiec / Poland

Project: Quarry Plant Großsteinberg / Germany

Project: Quarry Plant Viryvskij Karier / Ukraine Project: Quarry Plant Nesselgrund / Germany

K2 Automation GmbH

Untere Brettachtalstr. 27 Werner-von-Siemens-Str.D-74626 Bretzfeld-Geddelsbach D-03229 AltdöbernTel.: 07945 / 94299 – 0 Tel.: 03 54 34 / 66988 - 0 Fax.: 07945 / 94299 – 20 Fax.: 03 54 34 / 66988 - 20

Quarry Plant Sibiu (Romania)

Plant Control System

Operation Manual

K2 Automation GmbH - 2 -

1. Contents

1. Inhaltsverzeichnis.................................................................................................................... 22. General Overview.................................................................................................................... 33. Controlling the Plant................................................................................................................ 4

3.1.Using the System............................................................................................................... 43.2.Touch-Screen Operation ................................................................................................... 43.3.Keyboard Operation........................................................................................................... 4

4. Selesting a Machine................................................................................................................ 55. Starting, Getting Empty and Stopping the Plant ..................................................................... 76. Starting and Stopping of specific Machines ............................................................................ 97. Failure Looking and Clearing................................................................................................. 108. Pages for Parameters of the Plant or Machines ................................................................... 129. Overview of Parts of the Plant .............................................................................................. 1410. General Information to the Parameters ............................................................................... 1611. Specifics on Parts of the Plant ............................................................................................ 17

11.1 Level Measurement in the Silos:.................................................................................... 1811.2 Current Measurements................................................................................................... 1911.3 Beltweighers:.................................................................................................................. 20

12. Sections of the Plant ........................................................................................................... 2112.1 „Primary Crusher “.......................................................................................................... 2112.2 „Second Crush .............................................................................................................. 2112.3 „Third Crush“.................................................................................................................. 22

13. Manual Operation ............................................................................................................... 2313.1 Manual Operation at the Contol Cabinet ....................................................................... 2313.2 Manual Operation via Control System ........................................................................... 23

14. Popup-Menue ..................................................................................................................... 2414.1 Getting .......................................................................................................................... 2414.2 Menue Error List ............................................................................................................ 2414.3 Menue Interfaces („Schnittstellen“)................................................................................ 2714.4 Menue „Über“ ................................................................................................................ 2814.5 Menüpunkt „Ende“.......................................................................................................... 28

15. Controls .............................................................................................................................. 2915.1 General ......................................................................................................................... 2915.2 Page of Parmeters for the Controls ............................................................................... 30

Erstelldatum 27.07.2005 - Doku_Werk.sdw - Technische Änderungen vorbehalten -


2. General Overview


Picture 1 General Structure of Operating,, Viewing and Controlling

Operator

ProcessControl System

Belt Weigher 1ASI-Master

GT32

Belt Weigher 2

Belt Weigher 3

RS 422

RS 422RS 232

AD20 AD20

AD20

RS 422

Touchscreen

K2 Control Board


3. Controlling the Plant

3.1.Using the System

The Controlsystem could either be used by „Touch Screen“ or „Keyboard“ operation.Selecting a machine on the right edge of the screen several buttons for switching „ON“ and „OFF“ areoccuring. Using these buttons you can also reach the page for „PARAMETERS“.

3.2.Touch-Screen Operation

For operating you have only to „TIP“ the symbols on the screen.After that following menues areoccuring.If there is no „Touch Screen“ available, the system could also be used by „Mouse“ operation.

3.3.Keyboard Operation

Key OperationBild↑ Page before

Bild↓ Next Page

→| Next Element

[Umsch]+[Tab] Previous Element

↑ Previous Element

↓ Next Element

[ENTER] Display the buttons of the machine or verify the actual commands

q Removing the actual text of failure from the screen

[Esc] Several uses or longer operation stops program

[ALT]+[F4] Closing program

Table: Using Controlmasks



4. Selesting a Machine

Using the keys ↑, ↓, [Enter], [Esc] or →| (Tab) the cursor occurs, a lightblue marker, on thedisplay. The key →| or the cursor will bring you to the followig machines.Confirming by [Enter] on the right edge of the screen the different buttons of that machine willoccure. Using „Touch Screen“ operation only a soft tip to the wanted machine is necessary.

Moving the cursor to the button „PARAMETER“ the page of parameters is displayed havingused [Enter] .Erstelldatum 27.07.2005 - Doku_Werk.sdw - Technische Änderungen vorbehalten -


The page of parameters (here for example a conveyor belt including a „Belt Weigher“ Pos.13)shows all necessary parameters of that specific machine.In addition you can see the actual„I/O“ operation of that machine in the moment.



5. Starting, Getting Empty and Stopping the Plant

Starting a part of the plant automaticly you have to select one of the buttons [Schotteranlage] or[Edelsplittanlage] or [Vorbruchanlage] .After tipping the button [Start] out of the list the warning for starting begins. After aprogrammable time of warning the machines are starting operation in a fixed kind for yourspecific plant. During starting the specific machine occures yellow, green in normal operation. PhisicalParameters like cuurent, feeding rate or filling hights are renewed all the time. Starting a part of the plant the machines are switched on against the direction of material flow.Stopping the plant regularly by tipping „LEERFAHRT“the machines will be stopped after aprogrmmable time for emptying the plant in order of the material flow.

Using the emergency stop „SOFORT STOP“ all machines are switched off immediately,excepted the crushers and oilpumps (they are stopping regularly), including material on allbelts, screens and other machines.Don´t use this function in normal operation, it´s only foremergency purposes.



Using the button „LEERFAHRT“ the system starts emptying the plant. The material feeding intothe plant is switched off and every machine stops after its specific programmable time. Duringthis kind of operation the machine occures in orange.Just before switched off machines, which are not allowed to be switched on again, are darkgrey.



6. Starting and Stopping of specific Machines

During automatic operation (when the plant is running regularly) every machine could bestopped and started again. Doing this you have to select the specific machine by keyboard ortouch screen and the list of buttons occur for switching on or off. You have to be aware nowthat every machine is chained to the other depending on the material flow. Switching off forexample conveyor belt pos. 13 immediatly the feeders pos. 11 and pos.12 will be stopped.If any machine has got a failure ( to much current or a revolving signal of a belt is missing) thesame mechanism will operate and overfilling of machines will be prohibitted.

If there is machine driven by a frequency converter you will have in addition the buttons more„MEHR“ or less „WENIGER“. Using this buttons you can change frequency by 1% steps. Thedisplayed percentage shows the frequency of the electric motor within its programmed limits.Showing 0% for example means that the motor is going with its lowest allowed frequency of 5Hz when it´s programmed and 100% means 80 Hz for max. speed, when selected.



7. Failure Looking and Clearing

To get proper operation of the plant good working sensors and machines are necessary.On a not working plant however on the overview on the screen no changes in color of thedifferent machines are allowed to occur. If there is any the sensors and limiting switches haveto be proved on correct working. If there is a failure detected or the system realizes a wrong kind of operation the identifiedmachine gets „RED BLINKING“. In addition on the bottom of the screen the detailed descriptionof the failure occurs. Using „q“ on the keyboard the actual failure disappears and the nextbefore will be displayed.

Warning: Using „q“ only the text disapears. To eliminate the failure and going to properoperation again you have to be in the correct picture of the plant and press the button„STÖRUNG QITTIEREN“

Take Care: After having eliminated the failure the machine has to be switchted on again. Inthe example above you have to „TIP“ to the screenig machine Pos. 29 and to use button„START“on the right hand side of the screen. (NO TIME WARNING WILL TAKE PLACE; THEMACHINE STARTS IMMEDIATLY).



In our example down there for an overload of an electric motor, the input „Overload“ is active(red ) and the output for switching the conveyor belt Pos. 35.2 is not activated (grey). Going to the page for „PARAMETERS“ for Pos. 35.2 you can verify this.

If there is after a failure no blinking of the botton „Störung qittieren“so it is only a information (for example:material missing) ,which disapears by himself or could be eliminated by pressing„Q“.



8. Pages for Parameters of the Plant or Machines

General:

On every page of parameters you can find informations like following:

Inputs: electrical Inputs of that specific machine or part of the plant If the Input is active, it means its physical description is right, so the field of that

Input gets colored (for example red, green, yellow ) If unactive: grey

Outputs: Outputs are like Inputs



Parameter: Adjustable physical values for running the plant or the different machines. All values will be stored, when switching the system off. For changes you have to use a password. After changes you have to use thebutton „Speichern“ for veryfying.

Parameters for Adjusting: Adjusting analog signals:Analog signals are measured either in 0V...10V or 0mA...20 mA.

Analog I/O are converted into numbers between 0 and 4095. Doing adjusting you are verifying the physical amount to electronicalsystem. So the left two numbers are the „MIN“and the right twonumbers are the „MAX“ of the range. Figures between are linearised.

On analog signals you have got always two more parameters „Time for conversion (Abtastzeit)“and „Nr. of time for conversion (Abtastungen bis Aktualisierung). First is for how often it shouldbe measured, second for how many measurements the average should be calculated andtransfered to the system. These parameters are shown on the page of overview and at thepage of parameters.

Information Bringing in „0“ to one of these figures, the analog measurement is switched offand on failure of an sensor the system could be used further on, but without control of thatmeasurement.



9. Overview of Parts of the Plant

The momentary kind of operation of the system shows a figure.

0 (OFF): Plant „OFF“, every machine is „OFF“1 (HAND): Manual operation, is used for setting up and test purposes only

If selected manually Every machine could be switched on individually, Warning: No Safety Requirements Active For Professionel PeopleOnly .

2 (AUTOMATIC): Automatic Operation:Using „START“ the system starts and operatesautomatically and all safety requirements are active

3 (LEERFAHRT): the plant is stopped regularly .Every material is feeded out. After thatoperation it finishes with „0“ (OFF)



Every part of the plant has got it`s own controlvoltage and a seperate key for „Manual/Automatic“ operation located at the control cabinet, several control fuses , its own warningsystem and emergency switches. The „I/O“s off that you can see at the page off parameters. The general „I/O“s, which do not respond to a specific machine are shown at the page part ofthe plant, for example the traffic lights at the primary crusher.



10. General Information to the Parameters

Every machine has got it`s time counter, when it was switched on. Starting time is that time which has to be over until the previous machine could be started.Physical measurements will also take place after that time . The emtying time („LEERFAHRTZEIT“) is necessary to empty the previous machine withmaterial. If there is a move control sytem it could be activated by „DREHWÄCHTERÜBERWACHUNG“ON or OFF (0/1).The pages of paramters are showing the I/O`s of that machine in the moment. Grey means„NOT“, colored means „YES“. On the pages of parameters you can also find the actual figures for every necessaryparameters for that specific machine.

To change figures there, you have to go by „TAB“ to the specific field and press „ENTER“. Thepassword now is „sibiu“ Confirming by „ENTER“. You are now able to change parameters. With „BACKSPACE“ the old value is away ,the newinserted and with „ENTER“ finisched. Confirming by button „SPEICHERN“and „ENTER“ again.The same is also possible by touch screen handling. Leaving with „ESCAPE“ to be back on the main picture. .



11. Specifics on Parts of the Plant

The complete quarry plant exists out of 3 parts, which are seperated by buffers.

The parts are as following:

Part Description Machines

1

Primary Feeder Pos.2; Primarycrusher Pos.3, FeederPos.4; Belt.Pos.5, Pos.10; magnetic beltPos.5.1; flapps P6, P8; screen P7

2 Secound crush feeders P11, 12; belts P13, P16, P18, P22,P23, P24, P25, P26; crusher P15incl.oilpumps P15.1; screen P17; flappsP16.1, P19.1, P19.2, P20, P21.1, P21.2;drive P26.1

3 Third crush feeders P27; belts P35.2, P35, P35.1, P38,P41, P42, P43, P43.1, P44, P45, P46;crushers P28, P32, P34 incl. oilpumpsP28.1, P32.1, P34.1; screens P29, P36,P39; flapps P29.1, P37, P40

Dividing in three gives you the advantage beeing able to operate parts of it when one was goinginto failure or has to be repaired.

In principal feeders for material flow have to be started manually to be sure now that crushingbegins.



11.1 Level Measurement in the Silos:

The level in the buffersilos is measured by echo sensors.The sensors are giving analog signalsto the control system, where they are needed for control purposes.On the monitor the silos are displayed in different colors to be able to realize very fast thepresant situation of the plant.

Buffersilo

Color Level OperationRed Silo full (e.g. 99%) On running plant the material feeders will be stopped,

when reaching that level (i.e. Feders Pos.11 and 12).Attention: The Level (i.e.99%) has to be selected in thatway that the remainig material in the plant can be addedinto the silo.

Orange Silo nearly full (e.g. 95%) On running plant the material feeders will be switched onagain below this level

Yellow Silo nearly empty (e.g. 10%)

Emptying buffer silo will be stopped

Grey Silo empty (z.B. 0%)



11.2 Current Measurements

Controlling the amount of material which is on the screens or in the crushers the current ofmotors is measured, and as a analog signal ( 4-20 mA) connected to the control system. Thecurrent measurement is necessarry for different operations explained below.

Examplel Screen Pos.7Current Description Operation15,0 A Current

MINMIN(Driving Crash)

The value of current should be current of empty machine minus10%. A driving crash is controlled, when the actual measurementgoes below that value, and the machine is switched off. Adetailed failure text occurs on the screen.During starting„MINMIN“ is ignored.

30,0 A Current MIN(Materialfeeding„ON“again)

The material feeding will be switched on again automaticly, whenit was switched off in order of to high current. (Current MAX)

35,0 A Current MAX(Overload ,Stop Feeding)

Is the current going above „MAX“ the feeding is stopped, whichmeans material feeder before is switched off. In order of no loadon the machine the current will go down below „MIN“ and thefeeding is switched on again automaticly.



11.3 Beltweighers:

The amount of material on the conveyor belts P5and P13 is measured by belt weighers ofK2Automation. The electronic GT 32 (measuring device) is located in the control container. Theresults of measurement (capacity of feeding) are transferred to the contolsystem and are usedas „MIN;MAX;MAXMAX“.

Example Beltweigher P5 with basic parameters Feedrate Description Operation

130 t/h Capacity MIN (StartFeeding again)

The material feeding to the belt with the weigherstarts again (e.g. vibrating feeder ).

180 t/h Capacity MAX Only for information 200 t/h Capacity MAXMAX (Stop

Feeding)Above 200t/h the conveyor belt is in overloadoperation MAXMAX.The material feed is stopped in order to provideany damage for secure operation.



12. Sections of the Plant

12.1 „Primary Crusher “

The primary crusher section is built out of following machines: the vibration feeder P2 with traffic light the primary crusher P3 with grease pump P3.1 the feeder P4 the belts P5 (including weigher ), P10 the screening machine P7 the hand flaps P6, P8

On starting that part of the plant the machines are switched on in its logical manner (exceptvibrating feeder ). For material flow the vibrating feeder has to be started seperatly using thebutton on the screen.

The traffic light is working like following:„Green“:

vibrating feeder P2 works in its proper range (filling heights) and material could befilled into the bunker

„Red“: vibrating feeder P2 is switched off or the filling hight in the bunker is above MAX.

No material filling is allowed. „Red blinking“:

a failure in that part of plant occured and was not verified now (quitted)

12.2 „Second Crush

The second crush area exists out of following machines: the vibrating feeders P11,P12,P14 the crusher P15with oilpump P15.1 the belts P13 (incl.belt weigher ), P16, P18, P22, P23, P24, P26 the screening mashine P7 the manual gates P16.1, P19.1, P19.2, P21.1, P21.2 the drive for belt P26.1

On starting that part of the plant the machines are switched on automtically (exepted feederrRinnen P11, P12, P14) in it`s logical manner. The feeders for material flow have to be switchedon seperately by tipping the the relevant buttons on the screen. eingeschaltet werden.



12.3 „Third Crush“

The third crush area exists out of following machines: the feeders P27, P31, P33 the crushers P28, P32, P34 with oilpumps P28.1, P32.1, P34.1 the conveyor belts P35.2, P35, P35.1, P38, P41, P42, P43, P43.1, P44,

P45, P46 the screening machines P29, P36, P39 the manuanl gates P29.1, P37, P40

On starting all machines are switched on automaticly in it`slogical manner (exepted feederP27). For feeding material the feeder P27 has to be started seperately by tipping its button.



13. Manual Operation

13.1 Manual Operation at the Contol Cabinet

To get manual operation active you have to switch the key switches into manual mode(„SCHOTTERANLAGE, EDELSPLITTANLAGE, VORBRUCHANLAGE“).

With another switch you can choose either random operation or secure chained operation („Hand entriegelt“).

On secure chained operation on a failure the machines befor are switched off. On randomoperation nothing is switched off.

13.2 Manual Operation via Control System

There is another possibility for manual switching machines via computer.To go on you have tochange on the pages of parameters of parts of the plant „BETRIEBSZUSTAND“ from „0“ to„1“and beeing stored.

Leaving page of parameters you can see the information „HAND“ for manual operation.

Now you are able to switch on every machine for itself, however any software control forsecurity reasons is NOT don now.

For switching „ON“ or „OFF“ you have to TIP only the relevant buttons.

To go back into automatic mode you either have change „BETRIEBSZUSTAND“ into „0“ or TIP„SOFORTSTOP“.



14. Popup-Menue

14.1 Getting

You will get „POPUP“ ether using right mouse key orpress„Shift + F10“ at once Followingwindow on the screen is opned.

14.2 Menue Error List

Here ( „FEHLERLISTE“) you can find every failure which happened during production, e.g.current overload, belt security switch, Emergency switch off. The occuring and the confirmationare stored on a database, including the times. Which errors should be shown can selected.You can choose a specific time interval (day, week, month, dates), a intresting machine (beltP13, screen P7) or for kind of failures.



Below the table you can see several statistics, e.g. how often the system was started, no. Offailures, total running time of the control system and total error time.

Using button „DRUCKEN“ on a connected printer the error list could be printed out. Using button „FEHLERTEXTE“ you are in a new window were changes on „error textes“ couldbe made.



On that mask you define error no., name of machine and two textes for description and furtherinformation. In addition you can tell the sytem if the machine itself should also blink red and inaddition an acoustic warning is necesarry.



14.3 Menue Interfaces („Schnittstellen“)

Using that command you get a window for configuration,where the interfaces could be defined,which are necessary for control system. For the plant in sibiu two interfaces are necesarry:

1.) Control System As the device („GERÄT“) you have to chooseAls the control board „µP5“ of K2 AutomationGmbH. The board is connected to the interface board type „MOXA“ with RS422. Followingsettings have to be done:

- Baudrate: 57600; Databits: 8; Parity: none; Stopbits: 1The interface „COM1 - COM9“ depends on the settings of the operating system and could be

defined by the device manager or hardware settings.

2.)BeltweigherAs the device(„GERÄT“)you have to choose the multi belt weigher of K2 Automation „GT32“.The multi belt weigher is connected to the internal RS232 interface. The settings have to bedone like following:

- Baudrate: 9600; Datenbits: 8; Parity: none;Stopbits: 1 „COM1-COM9“ see above.



14.4 Menue „Über“

Calling for that you will get general informations of the control system e.g. version of programand date of manufacture.

14.5 Menüpunkt „Ende“

Über diesen Menübefehl wird das Visualisierungsprogramm beendet.



15. Controls

15.1 General

The filling height of the crushers P15, P28, P32 and P34 and the Silo 1 (32/200) is controlled bya variation of frequency ( e.g. 30-80Hz ) to have more or less material flow into the crushers orsilo.Doing this you can keep the filling height on wanted level for best working of the crushers andbest kind of stone crushed. In addition you get best performance of the plant with highestoutput.

The controls can be activated by using the corresponding buttons. Switching on they will beginwith the starting frequency.

During all the time of operation there will be calculated after a selectable waiting time(„TOTZEIT“) a new setting for the frequency converters and brought to them.



15.2 Page of Parmeters for the Controls

The kind of operation of the controls can be changed by varying the parameters. The parameter for MIN. and MAX. settings gives you the borders for example for the frequency,which is necessary for the physically possible range of operation of the specific machineWARNIG: Don`t go to high or to low. Otherwise the machine could be destroyed. Thebeginning setting is the setpoint for starting.The calculation for a new setting is done with several mesurements to avoid calculations with asingle extreme measurement. The number mesurements which should be used is preselectableby parameters. The time interval for measurements is dedicated by the „AKTUALISIERUNGSZEIT“. Themeasurements are starting after the waiting time („TOTZEIT“), to assure that the measurementis done when the change of material flow has reached the measuring point. For the calculation for the new setting the difference between wanted and actual measuredvalue is taken and multiplied by the amplifying factor(„AUFWÄRTSVERSTÄRKUNG/ABWÄRTSVERSTÄRCKUNG“). The amplifying factor „AUFWÄRTSVERSTÄRCKUNG“is used, when the wanted setting ishigher than the actual measured and on opposit the „ABWÄRTSVERSTÄRKUNG“.


Documents

plant control system · Control System Belt Weigher 1 ASI-Master GT32 Belt Weigher 2 Belt Weigher 3 RS 422 RS 422 RS 232 AD20 AD20 AD20 RS 422 Touchscreen K2 Control Board. K2 Automation