Quality Changes the World

Concrete
Batching Plant

HZS60

Safety, Operation and Maintenance Manual

HZS60 Concrete Batching Plant

HZS60 Concrete Batching Plant

Safe, Operation and Maintenance Manual

WARNING
Read and follow the safety precautions and instructions in this manual and on the machine
decals. Failure to do can cause serious injury, death or property damage. Keep this
manual with the machine for reading and future reference.

Safety, Operation & Maintenance - October, 2014

 HZS60 Concrete Batching Plant

SANY GROUP
SANY Automobile Manufacturing CO.,LTD
SANY Industry Town,
Economic and Technological Development Zone,
Changsha, Hunan, China 410100

http://www.sanygroup.com

Tel: 0086-10-60738666
Fax: 0086-10-60738831

© 2012 by SANY Group. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as described
herein. All information included within this publication was accurate at the time of
publication. Product improvements, revisions, etc., may result in differences between your
machine and what is presented here. SANY Group assumes no liability. For more
information, contact SANY Group.

Safety, Operation & Maintenance - October, 2014

HZS60 Concrete Batching Plant

EXEMPTION CLAUSES
Specific declaration
Concrete batching plant is a large bathcing plant integrating material storage,
measurement, and mixing with high productivity. It is suitable for most constructions,
such as airport, road, harbor and bridge projects. Applications other than the specified
range are excluded from the scope. Sany assumes no liability for any consequence
acused by any unauthorized applications.

Sany assumes no responsibility for consequences caused by the following factors:

● ● Misuse of the concrete batching plant due to failure to observe the information
provided hereunder in this manual;

● ● Unauthorized restructuring or modification to the concrete batching plant;

● ● Use of non-genuine parts, untested or unapproved parts or tools;

● ● Consequences caused by nonconforming maintenance on the mixing plant.

● ● Consequences caused by unauthorized startup after the mixing plant has been locked.

● ● Machine failure or damage resulted from natural disasters (such as earthquake,

typhoon, etc.), wars and other force majeure.

Sany cannot anticipate all potential hazards that may occur on work site. Therefore,
operators and owners shall attach great importance to the issue of safety.

Local government may impose higher standards for use of the concrete batching plant.
If local regulations have conflicts to the safety rules described herein, whichever stricter
applies.

Obligations of SANY
● ● Be responsible for providing qualified products and correct documents.

● ● Abide by after-sales service commitment and keep a record for all maintenance work
and repair work.

● ● Provide training for batching plant operators and service persons as required.

Obligations of owners or authorized personnel

● ● Only trained personnel who fully understand the Parts Book and the Operation and
Maintenance Manual are allowed to operate and service the concrete batching plant.

● ● Make sure that the batching plant operator and service person are qualified for this

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 HZS60 Concrete Batching Plant

job and know their related responsibilities.

● ● Regularly inspect the safety awareness of related persons at work.

● ● Should any fault threatening safety occurs, shut down the concrete batching plant
immediately.

● ● Sany service personnel have the right to carry out safety inspection to the concrete
batching plant when required.

● ● Besides the checks specified by Sany, local laws and regulations on the concrete
batching plant shall also be boserved.

● ● Ensure timely maintenance and repair of the concrete batching plant.

Obligations of all operating personnel

● ● Any abnormalities that could bring potential hazards or inproper opertaion of the
concrete batching plant should be reported to your supervisor. The abnormalities
should be corrected timely if possible.

● ● All workers around the concrete batching plant must know and obey all warning
signals, and be alert to safety of oneself and others.

● ● All operators must know the operating items and procedures.

● ● Be alert to any hazardous situation and immediately inform operator and singnalman
of the hazards such as voltage cables, irrelevant people and worse ground condition.

Obligations of managers
● ● Make sure that the operator has been trained and fully understand the provision of
the Satety, Operation and Maintenance Manual. The operator must be healthy and
licensed. Otherwise he/she is not allowed to operate the concrete batching plant.

● ● Make sure that the operator has good sense, cooperation awareness and psychological
quality, or he/she is not allowed to operate or service the concrete batching plant.

● ● Make sure that the signalman has good visibility and hearing ability, knows standard
command signals and can give signals clearly and correctly. The signalman shall also
have enough experience to recognize hazardous factors and timely tell the operator
to avoid the hazards.

● ● Make sure that the assistant person can positively identify the model and working
condition of the concrete batching plant and choose a suitable one.

● ● Make sure that each operating person of a project shall bear certain safety
responsibilities and has been required to timely report unsafe factors to the supervisor.

Safety, Operation & Maintenance Manual - January, 2015

HZS60 Concrete Batching Plant Contents

Contents
1 Preface
1.1 Introduction............................................................................................................1-3
1.2 Use, Storage and Structure of the Manual.............................................................1-5
1.2.1 Suggestions about use...................................................................................1-5
1.2.2 Storage of the manual....................................................................................1-5
1.2.3 Structure of the manual..................................................................................1-5
1.2.3.1 Preface..................................................................................................1-5
1.2.3.2 Safety....................................................................................................1-5
1.2.3.3 System functions...................................................................................1-6
1.2.3.4 Operation..............................................................................................1-6
1.2.3.5 Maintenance.........................................................................................1-6
1.2.3.6 Trouble shooting...................................................................................1-6
1.2.3.7 Specifications........................................................................................1-6
1.3 Machine Information..............................................................................................1-7
1.3.1 Data plate.......................................................................................................1-7
1.3.2 Naming regulation of the concrete batching plant..........................................1-7
1.3.3 Naming regulation of the mixer......................................................................1-7
1.4 Contact Information................................................................................................1-8

2 Safety
2.1 Safety - General.....................................................................................................2-3
2.2 Icons and Symbols.................................................................................................2-4
2.3 Safety Symbols and Safety Notes.........................................................................2-5
2.3.1 Locations of safety symbols on the concrete batching plant..........................2-5
2.3.2 Safety Symbols and Safety Notes..................................................................2-6
2.4 Introduction..........................................................................................................2-10
2.4.1 Intended use.................................................................................................2-10
2.4.2 Scope of Responsibilities.............................................................................2-11
2.4.2.1 Responsibilities of users.....................................................................2-11
2.4.2.2 Responsibilities of the operators.........................................................2-11
2.5 Operation and Use...............................................................................................2-13
2.5.1 Operation and use as directed.....................................................................2-13
2.5.2 Operation and use not as directed...............................................................2-15

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Contents HZS60 Concrete Batching Plant

2.6 Requirement of the operator................................................................................2-16

2.6.1 Candidates and requirements......................................................................2-16
2.6.2 Operation responsibility................................................................................2-17
2.6.3 Protective equipment of workers..................................................................2-17
2.7 Special danger and handling of the batching plant..............................................2-20
2.8 Safety Requirements before, during and after operation..................................2-22
2.8.1 Safety requirements before operation..........................................................2-22
2.8.2 Safety requirements during operation..........................................................2-24
2.8.3 Safety requirements after operation.............................................................2-26
2.9 Safety Protection Devices....................................................................................2-27
2.9.1 Inspection switch..........................................................................................2-27
2.9.2 E-STOP button.............................................................................................2-28
2.10 Electrical Safety..................................................................................................2-30
2.11 Safety operation of the aggregate storage..........................................................2-31
2.12 Safety operation elevator....................................................................................2-32
2.13 Safety operation of mixer....................................................................................2-33
2.14 Conclusion..........................................................................................................2-34
2.14.1 Test on your knowledge..............................................................................2-34
2.14.2 Conclusion..................................................................................................2-34

3 System Functions
3.1 General Overview..................................................................................................3-5
3.2 Aggregate storage.................................................................................................3-6
3.2.1 Basic structure of steel structure aggregate storage......................................3-7
3.2.2 Function instruction........................................................................................3-7
3.2.3 Aggregate weighing........................................................................................3-8
3.3 Powder silo............................................................................................................3-9
3.3.1 Silo-top filter...................................................................................................3-9
3.3.2 Pressure safety valve...................................................................................3-11
3.3.3 Rotating resistance type material level indicator..........................................3-12
3.3.4 Silo body.......................................................................................................3-13
3.3.5 Overhaul ladder............................................................................................3-14
3.3.6 Powder delivery pipe....................................................................................3-14
3.3.7 Aeration pad.................................................................................................3-14
3.3.8 Manual butterfly valve..................................................................................3-15
3.3.9 Leg...............................................................................................................3-15

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HZS60 Concrete Batching Plant Contents

3.4 Upper box componetn..........................................................................................3-15

3.4.1 Bag dusting..................................................................................................3-16
3.4.2 Powder weighing..........................................................................................3-16
3.4.2.1 Basic structure of the Powder weighing..............................................3-16
3.4.2.2 Function instruction of the Powder weighing......................................3-16
3.4.3 Water weighing.............................................................................................3-17
3.4.3.1 Basic structure of the Water weighing.................................................3-17
3.4.3.2 Function instruction of the Water weighing.........................................3-17
3.4.4 Liquid additive weighing...............................................................................3-18
3.4.4.1 Basic structure of the liquid additive weighing....................................3-18
3.4.4.2 Function instruction of the liquid additive weighing.............................3-18
3.5 Lower frame component.....................................................................................3-19
3.5.1 Air compressor.............................................................................................3-19
3.5.2 Mixing system...............................................................................................3-20
3.5.2.1 Instruction of SANY mixer...................................................................3-20
3.5.2.2 Structure of the mixer..........................................................................3-21
3.5.2.3 Working principle of the mixer.............................................................3-21
3.5.2.4 Main parts of the mixer.......................................................................3-22
3.6 Discharge device.................................................................................................3-30
3.7 Conveying System...............................................................................................3-30
3.7.1 Belt weigher..................................................................................................3-30
3.7.1.1 Basic structure of the belt weigher......................................................3-30
3.7.1.2 Reducer of the belt weigher................................................................3-32
3.7.2 Elevator........................................................................................................3-34
3.7.2.1 Basic structure of the elevator............................................................3-34
3.7.2.2 Reducer of the elevator.......................................................................3-34
3.7.3 Screw conveyor............................................................................................3-36
3.7.4 Pneumatic delivery.......................................................................................3-38
3.8 Liquid Supply System..........................................................................................3-38
3.9 Additive supply system........................................................................................3-39
3.9.1 Additive container.........................................................................................3-39
3.9.1.1 Basic structure of the additive container.............................................3-39
3.9.1.2 Function instruction of the additive container......................................3-39
3.9.2 Additive pump...............................................................................................3-40
3.10 Pneumatic System..............................................................................................3-40
3.10.1 Basic structure of the pneumatic system....................................................3-40

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Contents HZS60 Concrete Batching Plant

3.10.2 Function instruction of the pneumatic system............................................3-41

3.10.3 Working principle of the pneumatic system................................................3-41
3.10.4 Main parts of the pneumatic system...........................................................3-42
3.11 Control Room and Electric Control System.........................................................3-42
3.11.1 Control room...............................................................................................3-42
3.11.2 Electrical control system.............................................................................3-43
3.11.2.1 Control process of the concrete batching plant..................................3-43
3.11.2.2 Structure and principle of the control system ....................................3-45
3.11.2.3 Control of electronic measuring system.............................................3-47
3.11.2.4 Control of power driving system........................................................3-48
3.11.2.5 Hardware of the control system.........................................................3-49
3.11.2.6 Software of the control system...........................................................3-49
3.11.2.7 Control software system function instruction......................................3-50

4 Operation
4.1 Preparation and Precautions before Operation.....................................................4-5
4.1.1 Inspection before operation............................................................................4-5
4.1.1.1 Parts inspection of the concrete batching plant....................................4-5
4.1.1.2 Inspection of electrical units of the concrete batching plant..................4-7
4.1.1.3 Inspection of the software system.........................................................4-8
4.1.2 Selection and qualification of operators.........................................................4-9
4.1.3 Precautions during operation.......................................................................4-10
4.1.3.1 Basic requirement...............................................................................4-10
4.1.3.2 Precautions.........................................................................................4-11
4.2 Quick Start Operation Guide of the Concrete Batching Plant Control System....4-13
4.3 Operation and Application of Monitoring System.................................................4-17
4.3.1 Time parameters definition and setting........................................................4-17
4.3.1.1 Time parameters definition..................................................................4-17
4.3.1.2 Time parameters setting.....................................................................4-18
4.3.1.3 Automatically disable the material (Yes/No)........................................4-19
4.3.2 Sandstone batching interface and button functions.....................................4-20
4.3.2.1 Information instruction.........................................................................4-20
4.3.2.2 Button function....................................................................................4-21
4.3.3 Water, cement feeding interface and button function...................................4-22
4.3.3.1 Cement weighing system....................................................................4-22
4.3.3.2 Water weighing system.......................................................................4-23

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HZS60 Concrete Batching Plant Contents

4.3.3.3 Additive weighing system....................................................................4-23

4.3.4 Production process control and prompt function..........................................4-25
4.3.4.1 Production process control buttons.....................................................4-25
4.3.4.2 Production task queue display window...............................................4-26
4.3.4.3 Other information................................................................................4-26
4.3.5 Debugging....................................................................................................4-27
4.3.5.1 Instrument parameter..........................................................................4-27
4.3.5.2 Aggregate weighing setting.................................................................4-30
4.3.5.3 Stripper set..........................................................................................4-31
4.3.5.4 Other setting.......................................................................................4-31
4.4 Operation and Application of Management System.............................................4-32
4.4.1 Guidelines to functions of the management system.....................................4-32
4.4.2 Guidelines for the operation of system management menu.........................4-33
4.4.2.1 Data backup........................................................................................4-33
4.4.2.2 Data restore........................................................................................4-34
4.4.2.3 Database management function.........................................................4-35
4.4.2.4 System setup......................................................................................4-36
4.4.2.5 User management, login and cancellation..........................................4-38
4.4.3 Guidelines for recipe menu operation..........................................................4-39
4.4.3.1 Recipe manage...................................................................................4-39
4.4.3.2 Recipe view.........................................................................................4-41
4.4.3.3 Steps for deleting the login information of operator............................4-42
4.4.4 Guidelines for task menu operation..............................................................4-42
4.4.4.1 Steps for increasing production tasks.................................................4-42
4.4.4.2 Steps for viewing production tasks.....................................................4-43
4.4.4.3 Steps for modifying production tasks..................................................4-43
4.4.4.4 Steps for deleting production tasks.....................................................4-44
4.4.5 Guidelines for the operation of delivery manage menu................................4-44
4.4.5.1 Delivery order information...................................................................4-44
4.4.5.2 Modify of delivery order.......................................................................4-45
4.4.5.3 Delivery order printing.........................................................................4-45
4.4.6 Guidelines for inventory management menu operation................................4-46
4.4.6.1 Inventory management.......................................................................4-46
4.4.6.2 Material storage information (maintenance).......................................4-47
4.4.7 Guidelines for truck mixer management menu operation.............................4-47
4.4.7.1 Input, modify and deletion of truck mixer information.........................4-47

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Contents HZS60 Concrete Batching Plant

4.4.7.2 View and printing of truck information.................................................4-49

4.4.7.3 Shift of drivers.....................................................................................4-50
4.4.8 Guidelines for report management menu operation.....................................4-52
4.4.8.1 Manufacture dates report....................................................................4-52
4.4.8.2 Consumption report............................................................................4-53
4.4.8.3 Statistical report..................................................................................4-55
4.4.9 Guidelines for data management menu operation......................................4-57
4.4.9.1 Customer data management..............................................................4-57
4.4.9.2 Employee data management..............................................................4-59
4.4.9.3 Silo management................................................................................4-61
4.4.9.4 Batching plant data management.......................................................4-62
4.4.9.5 Construction part management...........................................................4-64
4.4.9.6 Pouring method maintenance.............................................................4-65
4.5 Production Operation and Other Setting..............................................................4-67
4.5.1 Production operation....................................................................................4-67
4.5.1.1 Automatic operation............................................................................4-67
4.5.1.2 Manual production operation..............................................................4-68
4.5.2 Washing operation.......................................................................................4-69
4.5.3 Shutdown Procedures..................................................................................4-70
4.5.4 Invoking method of the software..................................................................4-70
4.5.5 Setting of printer...........................................................................................4-71
4.5.6 Operation of system restore.........................................................................4-73
4.6 Other Operation...................................................................................................4-75
4.6.1 Other Operation............................................................................................4-75
4.6.2 Operation of winch (elevator).......................................................................4-75
4.6.2.1 Opreation of the elevator steel wire rop..............................................4-75
4.6.2.2 Proximity switch of the elevator..........................................................4-82
4.6.2.3 Other precautions of the elevator........................................................4-86
4.6.2.4 Special statement...............................................................................4-87
4.6.3 Operation of mixer........................................................................................4-87
4.6.3.1 Delivery of the mixer...........................................................................4-87
4.6.3.2 Transport of the mixer.........................................................................4-87
4.6.3.3 Installation of the mixer.......................................................................4-88
4.6.3.4 Drive of the mixer................................................................................4-89
4.6.4 Operation of the air compressor...................................................................4-90
4.6.4.1 Preparation and installation of the air compressor..............................4-90

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HZS60 Concrete Batching Plant Contents

4.6.4.2 Operation of the air compressor.........................................................4-91

4.6.5 Operation of additive pump..........................................................................4-93
4.6.5.1 Startup of additive pump.....................................................................4-93
4.6.5.2 Disassembly and assembly of additive pump.....................................4-95

5 Maintenance
5.1 Preparing for Maintenance.....................................................................................5-5
5.1.1 Before maintenance.......................................................................................5-5
5.1.2 After maintenance..........................................................................................5-7
5.2 Precautions during Maintenance...........................................................................5-7
5.2.1 Precautions of producing operation................................................................5-7
5.2.2 Precautions during operation of liquid and air delivery...................................5-8
5.2.3 Precaution during oil selection.......................................................................5-9
5.3 Daily maintenance.................................................................................................5-9
5.3.1 Daily inspection..............................................................................................5-9
5.3.2 Replacement of wearing parts......................................................................5-13
5.3.3 Inspection and maintenance intervals..........................................................5-14
5.4 Maintenance of Main Parts..................................................................................5-16
5.4.1 Maintenance of the mixer.............................................................................5-16
5.4.1.1 Inspection and adjustment before operation.......................................5-16
5.4.1.2 Motor of the transmission system.......................................................5-20
5.4.1.3 Transmission system..........................................................................5-24
5.4.1.4 Shaft end sealing................................................................................5-35
5.4.1.5 Liner plate assembly...........................................................................5-42
5.4.1.6 Mixing device......................................................................................5-43
5.4.1.7 Discharging device..............................................................................5-45
5.4.1.8 Upper cover of the mixer.....................................................................5-47
5.4.1.9 Electrical control system.....................................................................5-48
5.4.1.10 Monthly inspection of the mixer..........................................................5-48
5.4.2 Maintenance of measuring system...............................................................5-50
5.4.2.1 Weighing sensor.................................................................................5-50
5.4.2.2 Replacement of five-pore junction box/signal inverter ST-001............5-52
5.4.2.3 Weighing instrument...........................................................................5-53
5.4.2.4 Maintenance of measuring system.....................................................5-54
5.4.3 Maintenance of belt conveyor......................................................................5-59
5.4.3.1 Helical-bevel gear reducer..................................................................5-59

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Contents HZS60 Concrete Batching Plant

5.4.3.2 Turnabout drum...................................................................................5-63

5.4.3.3 Maintenance of the belt conveyer.......................................................5-64
5.4.4 Maintenance of elevator...............................................................................5-67
5.4.4.1 Precautions before maintenance........................................................5-67
5.4.4.2 Replacement the steel wire rope........................................................5-67
5.4.4.3 Adjustment of brake motor..................................................................5-68
5.4.4.4 Maintenance of elevator......................................................................5-69
5.4.5 Maintenance of the powder silo....................................................................5-71
5.4.5.1 Silo-top filter core................................................................................5-71
5.4.5.2 Level gauge........................................................................................5-79
5.4.5.3 Aeration pad........................................................................................5-80
5.4.5.4 Maintenance of powder silo................................................................5-81
5.4.6 Maintenance of screw conveyor...................................................................5-84
5.4.6.1 Installation of screw conveyor.............................................................5-84
5.4.6.2 riving head and seal in end bearing....................................................5-86
5.4.6.3 Replace middle hanging shaft assembly............................................5-86
5.4.6.4 Maintenance of screw conveyor.........................................................5-88
5.4.7 Maintenance of control room........................................................................5-88
5.4.8 Maintenance of aggregate storage discharging system...............................5-89
5.4.8.1 Discharge gate of aggregate storage bin............................................5-89
5.4.8.2 Discharge gate of aggregate weighing hopper...................................5-90
5.4.9 Maintenance of addtive pump......................................................................5-91
5.4.9.1 Anti-freezing measure.........................................................................5-91
5.4.9.2 Pump needs check as followings periodically.....................................5-91
5.5 Maintenance of Liquid and Air Supply System.....................................................5-92
5.5.1 Liquid supply system....................................................................................5-92
5.5.1.1 Impeller of water pump and mechanical seal......................................5-92
5.5.1.2 Bearing of water pump........................................................................5-93
5.5.2 Air supply system.........................................................................................5-94
5.5.2.1 Air compressor....................................................................................5-94
5.5.2.2 Pneumatic triplet...............................................................................5-100
5.5.2.3 Solenoid valve...................................................................................5-104
5.5.2.4 Spherical vibrator..............................................................................5-106
5.5.2.5 Pneumatic cylinder............................................................................5-107
5.6 Maintenance of Control System.........................................................................5-109
5.6.1 Computer ........................................................................................
. 5-109

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HZS60 Concrete Batching Plant Contents

5.6.2 Monitor....................................................................................................... 5-111

5.6.3 UPS power.................................................................................................5-112
5.7 Maintenance of Lubrication System...................................................................5-113
5.7.1 Lubrication part of the batching plant.........................................................5-113
5.7.2 Lubrication for main parts...........................................................................5-114
5.7.2.1 Lubrication of the mixer.....................................................................5-114
5.7.2.2 Lubrication of the screw conveyor....................................................5-120
5.7.3 Grease for centralized lubrication...............................................................5-121
5.7.3.1 Replenishment of bearing lubricant greases.....................................5-121
5.7.3.2 Replenishment of lubricant grease at the shaft end seal..................5-121
5.8 Warranty Clauses of the Concrete Batching Plant.............................................5-122
5.8.1 General.......................................................................................................5-122
5.8.2 Detailed regulations....................................................................................5-123

6 Troubleshooting
6.1 Troubleshooting of the Mixer..................................................................................6-3
6.2 Troubleshooting of the Mixer Motor.......................................................................6-6
6.3 Troubleshooting of the Screw Conveyor................................................................6-8
6.4 Troubleshooting of the Air Compressor..................................................................6-9
6.5 Troubleshooting of the Belt Conveyor..................................................................6-11
6.6 Troubleshooting of the Elevator...........................................................................6-12
6.7 Troubleshooting of the Motor...............................................................................6-13
6.8 Troubleshooting of the Weighing Instrument.......................................................6-14
6.9 Troubleshooting of the Industrial Process Computer...........................................6-17
6.10 Troubleshooting of the Additive Pump................................................................6-20
6.11 Troubleshooting of the Pneumatic System.........................................................6-22
6.12 Troubleshooting of the Lubrication System.........................................................6-25
6.13 Troubleshooting of the Electrical Control System...............................................6-26
6.14 Other Common Faults and Troubleshooting Methods........................................6-27

7 Specifications
7.1 Specifications of Concrete Batching Plant.............................................................7-3
7.2 Specifications of Mixer...........................................................................................7-5

8 Appendix
8.1 Schematic Electric Diagram of the Mixer...............................................................8-3

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Contents HZS60 Concrete Batching Plant

8.1.1 Schematic electric diagram of the mixer 1.....................................................8-3

8.1.2 Schematic electric diagram of the mixer 2.....................................................8-4
8.1.3 Schematic electric diagram of the mixer 3.....................................................8-5
8.1.4 Schematic electric diagram of the mixer 4.....................................................8-6
8.1.5 Description of electrical component symbols of the mixer.............................8-7
.

X Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Preface

Preface
1 Preface
1.1 Introduction..............................................................................................................1-3
1.2 Use, Storage and Structure of the Manual..............................................................1-5
1.2.1 Suggestions about use...................................................................................1-5
1.2.2 Storage of the manual....................................................................................1-5
1.2.3 Structure of the manual..................................................................................1-5
1.2.3.1 Forward.................................................................................................1-5
1.2.3.2 Safety....................................................................................................1-5
1.2.3.3 System functions...................................................................................1-6
1.2.3.4 Operation..............................................................................................1-6
1.2.3.5 Maintenance.........................................................................................1-6
1.2.3.6 Trouble shooting...................................................................................1-6
1.2.3.7 Specifications........................................................................................1-6
1.3 Machine Information................................................................................................1-7
1.3.1 Data plate.......................................................................................................1-7
1.3.2 Naming regulation of the concrete batching plant..........................................1-7
1.3.3 Naming regulation of the mixer......................................................................1-7
1.4 Contact Information.................................................................................................1-8

Safety, Operation & Maintenance - October, 2014 1-1

Preface HZS60 Concrete Batching Plant

WARNING
Always read the Safety section of this
manual before attempting to operate
this equipment. Failure to do this could
result in machine damage, personal
injury or death.

1-2 Safety, Operation & Maintenance - October, 2014

HZS60 Concrete Batching Plant Preface

1 Preface
1.1 Introduction
Thank you for choosing SANY concrete
batching plant. We will provide you with
high quality products and super after-sales
service.

SANY Heavy Industry Co., Ltd. is a leading

enterprise engaging the research and
development of engineering construction
machinery, providing first class products
both in China and across the world.
Cement concrete batching plant is a
large batching plant integrating material
storage, measurement, and mixing, with
high productivity. The batching plant is
equipped with JS1000B forced twin-shaft
mixer as the main supporting engine, and
it boasts a concrete-discharging height
of 3.6m~3.8m, capable of mixing various
concrete. The plant may be used in
places requiring engineering construction
concrete, such as, building project,
highway, port, wharf, and bridge, etc.
“SANY” provides you with top products,
qualities, and services.

The manual provides you with a brief

introduction to SANY concrete batching
plant, including principle, performance
parameters, technical features, structure,
safety in operation, and maintenance, etc.,
as well as information on safety, operation
instructions, transportation, lubrication,
and maintenance.

For using the plant in a better way, read

through the instructions carefully before
operation, in order to:

a) Help you understand the structure and

functions of the batching plant;

Safety, Operation & Maintenance - October, 2014 1-3

Preface HZS60 Concrete Batching Plant

b) Avoid equipment failure due to

improper operation;

c) Improve the reliability;

d) Prolong the service life;

e) Reduce repair expense and down time.

The user should carefully maintain and

properly use the concrete batching
plant. SANY shall not be liable for any
consequences resulting from violation of
the following provisions:

a) Carefully read through the operation

manual before using the plant, and operate
as required.

b) Only use the batching plant for purposes

in the scope specified in the operation
manual, but not any other purpose without
authorization.

c) All operators must be skilled workers

that have received training and keep
emotionally stable, clear-headed, and
nimble in response.

d) Do not engage unskilled technicians to

repair or disassemble the batching plant.

e) All technical maintenance tasks must

be carried out in accordance with the
requirements of the operation manual.

f) Information, technical specifications,

and drawings & tables in the manual must
be collected according to information and
data available during the compilation. No
further information will be provided on
changes, so consult the company directly.

g) If the user doesn’t strictly observe

regulations of the manual during operation,
or he’s bold to revamp the equipment, or
because of carelessness, the manufacturer
is not respond to any result.

1-4 Safety, Operation & Maintenance - October, 2014

HZS60 Concrete Batching Plant Preface

h) When you need to operate the

machine beyond safety regulations,
please consult with manufacturer or
agent firstly.

1.2 Use, Storage and Structure

of the Manual
1.2.1 Suggestions about use

a) This manual is suitable for the device

which is attached to.

b) Keep the internality of this manual.

If this manual is damaged, lost or
unreadable, you must immediately request
a replacement copy from your SANY
distributor. If you sell the equipment, be
sure to give this manual to the new owner.

1.2.2 Storage of the manual

This manual provides direction of correct

use of the machine. Always keep this
manual nearby in the control room to refer
to it conveniently.

1.2.3 Structure of the manual

1.2.3.1 Preface

This section provides an overview of

what is covered in the rest of this manual,
including machine label information and
SANY contact information.

1.2.3.2 Safety

This section covers basic safety

information relating to operation and
maintenance. Always read this section of
this manual before attempting to operate
this equipment. Failure to do this could
result in machine damage, personnel
injury or death.

Safety, Operation & Maintenance - October, 2014 1-5

Preface HZS60 Concrete Batching Plant

1.2.3.3 System functions

This section provides an overview

of storage system, weighing system,
conveying system, liquid supply system,
air supply system, mixing system and etc
function systems on your equipment. It is
important to study and become familiar
with all controls and systems before
proceeding with any operations safely.

1.2.3.4 Operation

This section provides the basic operating

procedures for the job. It is important
to study and become familiar with all
procedures before performing any
operations with the equipment.

1.2.3.5 Maintenance

This section provides all general

maintenance and repair procedures.
It is important to study and become
familiar with all repair and maintenance
procedures before performing any repair or
maintenance operations on the equipment.

1.2.3.6 Trouble shooting

This section outlines common malfunctions

and fault diagnostic procedures for the
equipment operating system. Basic
mechanical, hydraulic and electrical
system troubleshooting is included.

1.2.3.7 Specifications

This section provides technical

specifications and performance information
of systems or parts. Some information
presented in this manual may vary from
your machine due to design changes.

1-6 Safety, Operation & Maintenance - October, 2014

HZS60 Concrete Batching Plant Preface

1.3 Machine Information

1.3.1 Data plate

The serial numbers and model numbers

on the components are the only numbers
that your SANY distributor will need when
ordering replacement parts or requiring
assistance for your equipment. You can
find the information on the data plate as
shown in Fig. 1-1, and it is located on the
door of the control room as shown in Fig.
1-2 .

1.3.2 N a m i n g r e g u l a t i o n o f t h e
concrete batching plant
H Z S XXX X

Model number

Theoretical productivity m 3/h

Twin-shaft horizontal mixer

Concrete batching plant Fig. 1-1 Data plate

Concrete

Models instruction of the concrete batching

plant: V, K and T denote batching plant with
elevator bucket. Others denote common
concrete batching plant. H denotes Data plate
environmental protection concrete batching
plant.
Example: HZS120—— denotes a concrete
batching plant with twin-shaft horizontal
mixer. Its theoretical productivity is
120m 3/h. Fig. 1-2

1.3.3 Naming regulation of the mixer

J S XXX

Norminal volume, L
Twin-shaft horizontal
Mixer

Example: JS1000——denotes twin-shaft

Safety, Operation & Maintenance - October, 2014 1-7

Preface HZS60 Concrete Batching Plant

horizontal mixer with 1000L nominal

volume.

1.4 Contact Information

Thank you for purchasing a SANY product.
In the event that you should need to
contact us for any reason, you can reach
us as follows:

Issue department: Documentation,

Standards and Service Department, SANY
Mixing Plant R&D Institute.

Address: SANY Industry Town, Economic

and Technological Development Zone,
Changsha, Hunan, China

Post code: 410100

Tel: 0086-10-60738666

Fax: 0086-010-60738831

E-mail: crd@sany.com.cn

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HZS60 Concrete Batching Plant Safety

Safety
2 Safety
2.1 Safety - General.....................................................................................................2-3
2.2 Icons and Symbols.................................................................................................2-4
2.3 Safety Symbols and Safety Notes.........................................................................2-5
2.3.1 Locations of safety symbols on the concrete batching plant..........................2-5
2.3.2 Safety Symbols and Safety Notes..................................................................2-6
2.4 Introduction..........................................................................................................2-10
2.4.1 Intended use.................................................................................................2-10
2.4.2 Scope of Responsibilities.............................................................................2-11
2.4.2.1 Responsibilities of users.....................................................................2-11
2.4.2.2 Responsibilities of the operators.........................................................2-11
2.5 Operation and Use...............................................................................................2-13
2.5.1 Operation and use as directed.....................................................................2-13
2.5.2 Operation and use not as directed...............................................................2-15
2.6 Requirement of the operator................................................................................2-16
2.6.1 Candidates and requirements......................................................................2-16
2.6.2 Operation responsibility................................................................................2-17
2.6.3 Protective equipment of workers..................................................................2-17
2.7 Special danger and handling of the batching plant..............................................2-20
2.8 Safety Requirements before, during and after operation..................................2-22
2.8.1 Safety requirements before operation..........................................................2-22
2.8.2 Safety requirements during operation..........................................................2-24
2.8.3 Safety requirements after operation.............................................................2-26
2.9 Safety Protection Devices....................................................................................2-27
2.9.1 Inspection switch..........................................................................................2-27

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Safety HZS60 Concrete Batching Plant

2.9.2 E-STOP button.............................................................................................2-28

2.10 Electrical Safety..................................................................................................2-30
2.11 Safety operation of the aggregate storage..........................................................2-31
2.12 Safety operation elevator....................................................................................2-32
2.13 Safety operation of mixer....................................................................................2-33
2.14 Conclusion..........................................................................................................2-34
2.14.1 Test on your knowledge..............................................................................2-34
2.14.2 Conclusion..................................................................................................2-34

WARNING
Always read the Safety section of this
manual before attempting to operate
this equipment. Failure to do this could
result in machine damage, personal
injury or death.

2-2 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Safety

2 Safety
2.1 Safety - General

Make sure you fully understand the

precautions described in this manual
and the safety labels on the machine
before operating or maintaining this
machine. Read and follow all safety
precautions. Failure to do so may result
in equipment damage, serious injury or
possibly death.

This section of your manual provides

detailed information on basic safety
precautions and preventative measures,
during operation and maintenance of this
machine.

Safety operation is very important. Prior

to operation and maintenance, you must
carefully read and understand all contents
in this section of this manual. Only after
completely understanding the contents in
this manual, can you safely and expertly
operate the machine. Following are some
of the benefits of doing this:

● ● Avoid personal injury or machine

damage caused by improper operation.
● ● Increase the reliability of the machine.
● ● Prolong the service life of the machine.
● ● Reduce repair cost and downtimes.

The safety information in this manual

provides a basic guide line on safety
operation for all authorized personnel.
SANY is unable to forecast all risks on
work sites, so workers, operators and
owners must consider if there are other
safety concerns that must be addressed
for specific job situation.

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Safety HZS60 Concrete Batching Plant

Local governments or authorities may have

stricter standards. If some stipulations in
this manual disagree with the local laws or
regulations, the stricter prevails.

2.2 Icons and Symbols

To help you operate the device safely,
safety items and marks fixed on the
machine are outlined. To avoid potential
accidents, instruction and precautions are
introduced.

Before operating and maintenance,

users and after sales personnel must
understand the safety icons and symbols.
Safety regulations and suggestions must
be obeyed strictly. To decrease death
injury and machine damage by incorrect
maintenance or danger, positive precaution
and solving measures must be taken.

This is the general warning sign. It is used to alert the user to potential
hazards. All safety messages that follow this sign shall be obeyed to
avoid possible harm.

Indicates an imminent hazard which, if not avoided, will result in serious

injury or death.

Indicates a potentially hazardous situation which, if not avoided, could

result in injury or possibly death.

Indicates a possible potential hazardous situation which, if not avoided,

could result in minor or major injury.

Indicates a situation which can cause damage to the machine, personal

property and/or the environment, or cause the equipment to operate
improperly.

This symbol indicates that the operation is not in conformity to the safety
regulations, is prohibited or may cause injuries or fatalities.

This symbol indicates that the operation is in conformity to the safety

regulations.

2-4 Safety, Operation & Maintenance Manual - October, 2014

 4
13 17 5
14
HZS60 Concrete Batching Plant

15 16 3

6
2
7 10
8 11
9
12
2.3 Safety Symbols and Safety Notes

Fig. 2-1 Locations of safety symbols on the concrete batching plant

1-No striding 2-Caution,falling objects 3-Caution,mechanical injurey 4-Caution,head collision 5-No drinking

Safety, Operation & Maintenance Manual - October ,2014

6-No entry 7-Caution,vehicle 8-Must wear safety helmet 9-Operating regulations 10-Caution roof fall
11-Caution,slip 12-Must fastened safety belt 13-Caution, danger 14-No switching on 15-No bruning
16-Authorized personnel only 17-Danger! electrical shock
2.3.1 Locations of safety symbols on the concrete batching plant
(Sketch of the standard CBP, detail drawings please refer to 8.2 )

2-5
Safety
Safety HZS60 Concrete Batching Plant

2.3.2 Safety Symbols and Safety Notes

Striding over locations below is forbidden:

● ● any pit in the aggregate storage;
1 ● ● two neighbouring powder silo roof platforms;
● ● two small neighbouring platforms of the
powder silo.

Be careful of falling objects in the following

circumstances:
● ● Walk below the throw belt.
● ● Walk below the storage bins of the aggregate
2 storage.
● ● Walk beside the storage bins of the aggregate
storage.
● ● Walk below the powder silo.
● ● Walk below the main tower.

Be careful of mechanical injuries in the following

circumstances:
● ● The mixer is running.
3
● ● The throw belt is running.
● ● The conveyor belt is running.
● ● The pneumatic cylinder is moving.

Watch for head collision in the following

circumstances:
● ● Enter the mixing floor along the staircase.
4 ● ● Enter the weighing floor from the mixing floor.
● ● Cross the screw conveyor on the weighing floor.
● ● Cross the motor support on the weighing floor.
● ● Walking under the powder silo support.

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HZS60 Concrete Batching Plant Safety

● ● It is prohibited to drink the mixing water.

● ● It is prohibited to drink the liquid admixture
for mixing.
5 ● ● It is prohibited to drink polluted water in the
batching yard.
● ● Human and animal is forbidden of drinking
the water referred above.

It is prohibited to enter into discharging zone

6 of the plant and feeding zone of the aggregate
storage.

Watch for truck mixers, transporting trucks,

7 loading and feeding trucks and other vehicles
inside the batching yard.

Visitors, operators and maintainers in the plant

8
must wear safety helmets.

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Safety HZS60 Concrete Batching Plant

● ● Strictly follow the procedures given on the mark

during feeding operation and maintenance. If
not, the equipment may not work normally or
be damaged. It may cause injuries and deaths
if a serious accident happens.
9 ● ● Pay close attention to the audible and visible
alarm. It is prohibited to fill remained powder
into the powder silo after the silo is fed up. If
not, the equipment may not work normally or
be damaged. It may cause injuries and deaths
if a serious accident happens.

It is prohibited to load and feed in an undisciplined

way. Regardless of alarms will lead to puffing of
10
powder from the powder silo. Be careful of roof
fall.

Be careful not to get slipped in the following

circumstances:
● ● Climb the staircase.
● ● Walk on the maintenance platform of the hoister.
11 ● ● Walk on the roof of the powder silo.
● ● Climb the ladder of powder silo.
● ● Walk on wet ground in the concrete batching
plant.
● ● Work on a wet maintenance platform.

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HZS60 Concrete Batching Plant Safety

Safety belts must be fastened in the following

circumstances:
● ● Maintain the powder silo high above the ground.
12 ● ● Maintain the main tower high above the ground.
● ● Maintain the aggregate storage high above the
ground.
● ● Maintain the throw belt high above the ground.

Pay attention to safety in the following

circumstances:
● ● Personnel work in concrete batching plant.
13
● ● Visitors walk in concrete batching plant.
● ● Drive vehicles in concrete batching plant.
● ● Park vehicles in concrete batching plant.

Forbid switching on in the following circumstances:

● ● Maintain the mixer.
14
● ● Maintain the throw belt.
● ● Maintain the conveyor belt.

● ● Burning inside the control room is forbidden.

15 ● ● Burning inside the main tower is forbidden.
● ● Burning at the oil depot in the yard is forbidden.

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Safety HZS60 Concrete Batching Plant

● ● Only authorized personnel can enter into the

control room.
● ● Only authorized personnel can enter into the
main tower when the concrete batching plant
16
is running.
● ● Only authorized personnel can enter into
the air compressor room when the concrete
batching plant is running.

Be careful of electrical shock in the following

circumstances:
● ● Operate a high voltage cabinet.
17
● ● Examine and repair electrical elements with
power on.
● ● Operate drive part with strong current.

2.4 Introduction
2.4.1 Intended use

The cement concrete batching plant (see

Fig. 2-2) is a set of equipment for mixing
concrete, and it is also known as concrete
factory. The plant features high levels
of mechanization and automation with
high productivity. It is often used in those
projects which require large amount of
concrete works, long construction periods
and concentrated construction, such as
highway pavement, bridge projects, large
and medium water conservancy projects,
power projects, buildings, concrete product
plants, and concrete factories.
Fig. 2-2 Cement concrete batching plant
(Sketch of the standard CBP,
detail drawings please refer to 8.2 )

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HZS60 Concrete Batching Plant Safety

2.4.2 Scope of Responsibilities

2.4.2.1 Responsibilities of users

1. Ensure that only those sufficiently

trained personnel who have read through
and understood the safety regulations can
operate and maintain the batching plant.

2. Confirm that all professional personnel

operating and maintaining the batching
plant are qualified to do their jobs and
perform their responsibilities.

3. Regularly inspect the safety awareness

of related personnel during working.

4. Immediately stop the batching plant

working in case of any fault impacting
safety.

5. Besides the inspections specified

by the manufacturer, plan responding
examinations for the batching plant,
according to local national laws and
regulations applicable.

6. Maintain and repair the batching plant

in time. Do not engage any nonprofessional
technicians to repair or disassemble the
batching plant.

2.4.2.2 Responsibilities of the

operators

1. Be responsible for operating and

controlling the concrete batching plant.

2. The operator should concentrate on

the machine operation, without listening to
radio with headphones.

3. Keep emotionally stable, clear-headed,

and quick in response.

4. The batching plant operator should

meet the following requirements:

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Safety HZS60 Concrete Batching Plant

● ● 18~55 years old, at a normal IQ level;

● ● Healthy;
● ● Vision (including the corrected vision)
above 0.8, not color-blind;
● ● Hearing should meet the requirements
of basic working conditions;
● ● Be familiar with fire-extinguishing
equipment on the batching plant and
have received related operation training;
● ● The operator should have received
specialized training and have been
proved to master the operating method.

The safety section provides some basic

information on possible circumstances
during the normal operation and
maintenance of the concrete batching
plant and proposes feasible methods
for safely handling such circumstances.

Other safety precautions may be

required according to the equipment
used, working situation, and service
areas situation. The manufacturer does
not directly control the application,
operation, inspection, lubrication and
maintenance of equipment. So, it is your
responsibility to take correct safety
operation regulations in such areas.

Local government may impose higher

standards for use of the concrete
batching plant. If local regulations have
conflicts to the safety rules described
herein, whichever the stricter applies.

If there is no Safety, Operation and

Maintenance Manual provided by SANY,
ask for one by SANY and keep this
Safety, Operation and Maintenance
Manual well.

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HZS60 Concrete Batching Plant Safety

2.5 Operation and Use

2.5.1 Operation and use as directed

Service life of the concrete batching

plant will be prolonged under the normal
using and maintenance circumstances,
while it will decrease when the operation
condition is bad. Service life of special
parts like conveying belts, liner plates,
pin shaft and so on, is shorter than the
whole machine. Therefore all operators
must strictly operate and use the concrete
batching equipment in accordance with
the operation instructions.

1. Check the machine/plant at least once

per shift for externally obvious damage
and defects. Report damages and defects
to the manager in time. If the circumstance
is serious, shut off the machine/plant
immediately and lock the main switch.

2. Adopt absolutely safe way to work

during operation.

3. Strictly comply with the test,

maintenance and repair items of the
mixer (including aged parts replacement)
referred in the operation and maintenance
sections. Operation must be carried out
safely.

4. Before maintenance job begin,

circumstances should be introduced to
all the personnel. A responsible person
should be chosen to supervise.

5. The temperature scope allowable for

the use of the batching plant is between
1°C ~ +40°C.

6. Make sure liquid is full and gas is

totally discharged, before start up the
additive pump.

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Safety HZS60 Concrete Batching Plant

7. Don’t face the discharge hole of the

additive pump, especially when the hot
water is used, to prevent scalds.

8. Make sure the air compressor and air

supplying system are running normally,
there are no abnormal noise and air leaking,
and pressure is kept in a prescribed scope.
(For detailed information, see “4.6.4
Operation of the air compressor “on
4-90)

9. Before operation, check around the

machine to ensure that there is no person
in danger during its startup.

Fig. 2-3

10. Immediately stop the machine and

lock the main switch if malfunction occurs,
then check and eliminate malfunction.

Fig. 2-4

11. When carry out check, maintenance

and repair work, shut off and lock the main
switch and maintenance switch to prevent
injuries by device start up suddenly.
Fig. 2-5

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HZS60 Concrete Batching Plant Safety

2.5.2 Operation and use not as directed

Any operation not as directed is contrary to

designated use. Besides the responsibility
of the manufacturer, the warranty will be
invalidated in any loss or injury caused by
contrary use, which should be assumed by
operator.

1. It is prohibited to operate and use the

mixer and relevant equipment improperly
or not in compliance with operation
instructions.

2. If the mixer and relevant equipment

are not maintained as required or not
maintained in any way, the operating
safety of the mixer and relevant equipment
will be lowered considerably.

3. Unauthorized operators are forbidden

to use the mixer and relevant equipment
without authorization.

Fig. 2-6
Special note:

The warranty card ensures that you can

get repairing service from our distributors
when the plant has any fault in warranty
period. Sometimes our distributors
may also provide site services even if
the warranty period expires, excluding
following circumstances:

a) Equipment has been abused,

disassembled or transformed without
approval.

Fig. 2-7

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Safety HZS60 Concrete Batching Plant

b) Direct or indirect personal injuries

or property losses cause by improper
operation or misoperation.

c) Irregular operation or functional change

make the plant beyond the regulation
of this manual as shown in “3 System
Functions “on 3-5, “4 Operation
“on 4-5, “5 Maintenance “on 5-5,
“6 Troubleshooting “on 6-3, and “7
Specifications “on 7-3.

d) Malfunction caused by earthquake,

fire, or other force majeure.

It is forbidden to start up mixer during

maintenance, or injuries may be caused.

2.6 Requirement of the operator

2.6.1 Candidates and requirements

All personnel using the mixer and relevant

equipment must be strongly responsible
and must reach the working age stipulated
in laws! Except the designated personnel,
any other people should not operate the
mixer and relevant equipment.

Operators must receive specialized

training or instructions; any one without
training should not be engage in relevant
jobs. Scope of responsibilities of different
personnel should be specified, e.g.
operation, installation, maintenance, and
repair, etc.

Employees, who need to receive field

training and instructions, may operate
and use mixer and relevant equipment
only under the supervision of professional
personnel.

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HZS60 Concrete Batching Plant Safety

Repair and maintenance for pneumatic,

mechanical and baric devices on mixer
and relevant equipment must be done by
technical experts, who master professional
knowledge and rich experiences, according
to related regulations and rules.

Fig. 2-8

2.6.2 Operation responsibility

Scope of responsibilities of the personnel

responsible for the mixer and relevant
equipment should be specified. If
necessary, the provisions of relevant
regulations should be used as reference.
The company authorizes such personnel
the veto power against any requirements
or suggestions, which are proposed by a
third party not in conformity with the safety
regulations.

2.6.3 Protective equipment of workers

1. Wear close-fitting clothes and suitable

safety equipment. You may need safety
equipments as below:

● ● Safety helmet

Fig. 2-9 Safety helmet

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Safety HZS60 Concrete Batching Plant

● ● Safety footwear

Fig. 2-10 Safety footwear

● ● Protective glasses

Fig. 2-11 Protective glasses

● ● Working gloves

Fig. 2-12 Working gloves

● ● Hearing protectors

Fig. 2-13 Hearing protectors

● ● Protective clothes

Fig. 2-14 Protective clothes

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HZS60 Concrete Batching Plant Safety

● ● Rain gear

Fig. 2-15 Rain gear

● ● Respirator or filtering mask

Fig. 2-16 Respirator or filtering mask

2. Wear necessary overalls and safety

equipment.

Fig. 2-17

3. Avoid wearing loose clothes, jewels,

or other things which may be hooked by
running components.

Fig. 2-18

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Safety HZS60 Concrete Batching Plant

4. Wear hearing protectors, such as

earplug, to avoid harmful or uncomfortable
strong noise.

Fig. 2-19

2.7 Special danger and handling

of the batching plant
1. Injuries that may be caused by a
moving component;

Measures: It is prohibited to touch the

rotating components or maintain the
machine when the batching plant is
working. Once accident occurs, shut off
the main power switch to stop the machine.

Fig. 2-20

2. Injuries that may caused by high

temperature gas;

Measures: Device running may bring high

temperature gas. To prevent personnel
from scalds, operate after it cools down
during maintenance and repair, please
treat scalds immediately.

Fig. 2-21

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HZS60 Concrete Batching Plant Safety

3. Danger of fire;

Measures: Please take measures to put

out fire, as separating air from fire source
or using fire extinguisher. Prevent fire
from spreading, or more property loss and
injuries may be resulted in.

Fig. 2-22

4. Danger of high voltage;

Measures: Don’t set the plant near high

voltage to avoid danger of high voltage.

Fig. 2-23

5. Danger of radio radiation at high

frequency;

Measures: Don’t build the plant in an area

where has a strong radiation, or else the
normal function of the device may be
affected.

Fig. 2-24

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Safety HZS60 Concrete Batching Plant

2.8 Safety Requirements before,

during and after operation
2.8.1 S a f e t y r e q u i r e m e n t s b e f o r e
operation

1. Inspect everyday to ensure all the

safety devices, such as safety covers and
warning marks, are at a good condition
before operation. If there is something
destroyed or lost, get a new one for
replacing at once.

2. Run the equipment without load before

production, to check its running. Make
sure the mixing system is normal, and then
start production.

3. A newly purchased mixer should work

with half load in the first 10 rounds. It is
forbidden to work with full load.

4. Check the connective positions of all

large components and ensure that all small
components are not installed insufficiently
or missed.

Fig. 2-25

5. All adapting pieces, such as pin shafts,

screws, etc., must be connected securely
without loosening.

.
Fig. 2-26

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HZS60 Concrete Batching Plant Safety

6. Water supply pipelines and air supply

pipelines must be sealed reliably, with no
water or air leakage.

Fig. 2-27

7. Before operation, ensure that there are

not any people in dangerous areas around
the batching plant.

Fig. 2-28

8. Check again that there are not any

people inside the mixer before its startup.

Fig. 2-29
9. The batching plant can be operated
only when all safety devices are installed
and function well.

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Safety HZS60 Concrete Batching Plant

2.8.2 S a f e t y r e q u i r e m e n t s d u r i n g
operation

1. Restart the machine after cleaning

up sandstone on the conveying belt if it
has been stopped working as required, to
avoid its startup with load.

2. When mixer is stopped for maintenance,

please cut off the power firstly, and pull
out the safety key of the power cabinet,
then put “No Switching in” sign at a visible
position besides the switch and have a
person supervised there.

3. Operator must operate on the control

console when the batching plant is
working. It is forbidden to leave the post
without authorization.

4. Other irrelevant personnel is prohibited

to enter control room of the batching plant
and dangerous areas around the plant.

5. Pay attention to warning indictor

light. When malfunction occurs, shut off
machine/device immediately and lock the
main switch to check and eliminate the
malfunction.

6. Push down the E-STOP button when

emergent shutdown is required owing to
fault.

7. It is prohibited to touch the rotating

components, especially the belt conveyor,
when the batching plant works; if an
overhaul is required, the plant must be
shut down while the power supply and
E-STOP switch are shut off.

Fig. 2-30

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HZS60 Concrete Batching Plant Safety

Main moving components of the

concrete batching plant include mixer,
levek belt conveyor, elevator and so on.
Keep away from them when they are
running, to prevent injuries.

8. It is forbidden to use the industrial

process computer for personal business
or entertainment.

9. It is prohibited to start up belt conveyor

with load.

Fig. 2-31

10. Diameter of the aggregate should

be controlled in 80 mm. Substandard
aggregate is prohibited.

11. Shut off the main power during a

thunder storm. Production is forbidden in
such weather.

Fig. 2-32

12. Don’t start up belt conveyor,elevator

and mixer during their maintenance.

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Safety HZS60 Concrete Batching Plant

2.8.3 S a f e t y r e q u i r e m e n t s a f t e r
operation

1. Carry out regular servicing and

maintenance to equipment.

2. The power supply must be shut off and

all operation buttons must be shifted to the
“OFF” or “LOCK” position.

Fig. 2-33

3. Doors of the control room must be

locked to prevent any unauthorized
personnel from using the batching plant.

Fig. 2-34

4. Ask manufacture for help, if related

situations or working conditions are not
referred in this manual.

5. To prevent injuries by machine/device

start suddenly, during check, maintenance
and repair work, measures as below should
be carried out:

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HZS60 Concrete Batching Plant Safety

● ● Shut off and lock the main switch and

inspection switch. Take the key with
you.

Fig. 2-35

● ● Put up a caution plate on the main

switch.

Fig. 2-36

2.9 Safety Protection Devices

2.9.1 Inspection switch

An inspection switch is beside overhaul

door of the mixer (see Fig. 2-37). The
maintenance cover is closed when mixer
is working. There is a limit pressure
plate pressing on the guard plate of the
inspection switch to make it closed (see
Fig. 2-38). The overhaul door is open when
mixer stops working for maintenance,
while the swing part of the inspection
switch bounces up to cut off power. This
switch used with E-STOP button together
will protect the maintenance personnel.

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Safety HZS60 Concrete Batching Plant

2 3

4
1 1
5
2

Fig. 2-38 Inspection switch

1-Overhaul door of mixer 2-Limit pressure plate
Fig. 2-37 Mixer 3-Guard plate 4-Limit switch
1-Overhaul door 2-Inspection switch 5-Switch mounting plate

2.9.2 E-STOP button

Concrete batching plant is equipped with

many E-STOP buttons: as shown in Fig.
2-39, button (1) is mounted on power
cabinet of the control room, two buttons
(2) are respectively on the upper and lower
ends of the elevator, button (3) is on the
column of the aggregate storage body, and
button (4) is on the mixer.

3
Fig. 2-39 Distribution of E-STOP buttons (Sketch of the standard CBP, detail drawings please refer to 8.2 )

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HZS60 Concrete Batching Plant Safety

1. E-STOP button on power cabinet of

the control room (see Fig. 2-40)

This button must be pressed immediately

in case of any accident or dangerous
circumstance. All facilities will stop.

Fig. 2-40

2. E-STOP buttons on the upper and

lower ends of the elevator (see Fig. 2-41)

E-STOP buttons are mounted on both

the upper and lower ends of the elevator.
E-STOP button must be pressed in case of
any accident or dangerous circumstance.

Fig. 2-41

3. E-STOP button on the aggregate

storage (see Fig. 2-42)

When any emergency or dangerous

situation occurs in the aggregate hopper,
press the E-STOP button to shut down
equipment.

Fig. 2-42

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Safety HZS60 Concrete Batching Plant

4. E-STOP button on the mixer (see Fig.

2-43)

One E-STOP button is mounted on

the mixer. In case of any accident or
dangerous circumstance, press the button
immediately to shut down the mixer.

Fig. 2-43

2.10 Electrical Safety

In order to avoid electrical danger, only

authorized person can open the power
cabinet and operation console for
maintenance!

Power cabinet and console both involve

high voltage. In order to prevent electric
shock and other accidents, all professionals
must strictly observe safety regulations
for operation during maintenance. Any
operation against such regulations should
be prohibited. In addition, any electrical
facilities with big power beyond the scope
of the system are prohibited to switch in.

Check if the electrical wires are creepage.

Replace the broken one. Supply power to
device according to regulations strictly to
keep the device running normally.

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HZS60 Concrete Batching Plant Safety

2.11 S a f e t y o p e r a t i o n o f t h e
aggregate storage
Keep away from the feeding area when
aggregate storage is running to prevent
injuries from the trucks. Pay special
attention to the following circumstances:

1. Don’t extend your hands inside the

discharge gate when it is in on-off motion,
so as to avoid injures.

Fig. 2-44

2. Keep away from the extending and

retracting area of the pneumatic cylinder
so as to avoid injuries.

Fig. 2-45

3. Prevent sandstone material above the

stock yard from falling and injuring eyes
and the respiratory system.

Fig. 2-46

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Safety HZS60 Concrete Batching Plant

4. Keep away from the transmission area

of the belt conveyor and elevator to prevent
being caught in and getting injured.

Fig. 2-47

5. Avoid extending your hands at the front

and back drums of the level belt conveyor,
so as to avoid getting injured.

Fig. 2-48

2.12 Safety operation elevator

Please don’t stay below the elevator during
its running to prevent injuries. You should
pay special attention to the following
circumstances:

1. Keep away from the elevator bucket

when the elevator is running, so as to
prevent sandstone material from falling
and injuring eyes and the respiratory
system.

2. Keep away from the elevator bucket

hoister, so as to prevent mechanical
Fig. 2-49
injuries.

3. Keep away from idlers during their

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HZS60 Concrete Batching Plant Safety

running, so as to prevent mechanical

injuries.

2.13 Safety operation of mixer

1. Avoid starting the mixer under any load
by all means.

2. It is prohibited to stand below the

discharge gate of the mixer.

Fig. 2-50

3. It is prohibited to extend your hands

or things into the rotating parts of any
equipment so as to prevent injuries and
faults.

Fig. 2-51

4. The mixer is suitable for processing

powdery and granular inert materials,
and the grain size should not be larger
than 80 mm. This mixer is not suitable
for processing adhesive media, such as
any sluggish material over 80 mm in size
and soil exceeding 12% in quantity and

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Safety HZS60 Concrete Batching Plant

approaching 15% in humidity. If semidry

concrete mixture is stuck to the mixing
shaft, diameter of the shaft will increase,
and this will finally reduce the mixing
efficiency of the mixing arm. So, keep the
mixing shaft clean.

Fig. 2-52

5. Check around the equipment before its

startup, to avoid injuries from the mixer.

2.14 Conclusion
2.14.1 Test on your knowledge

Now, you have read through the safety

manual. Do you understand:

● ● What contents are included in safety

regulations?
● ● How to check and operate the machine
correctly?
● ● Are there special potential dangers in
the working area?
Make sure that you can correctly anwser
all the questions above.

2.14.2 Conclusion

You have just read the safety section

of SANY concrete batching plant, but
this section may not cover all dangers.
Nonetheless, the safety protection
measures that you have learned and basic
safety rules that you should observe will
help you to make right judgment when you
are in danger. It is our aim to help you

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HZS60 Concrete Batching Plant Safety

to cultivate a good safety habit, so that

you may become a better operator of the
concrete batching plant.

Remember:

Safety is both your task and responsibility.

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Safety HZS60 Concrete Batching Plant

E
G
PA
K
N
LA
B

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HZS60 Concrete Batching Plant System Functions

System Functions
3 System Functions...............................................................................................3-5
3.1 General Overview..................................................................................................3-5
3.2 Aggregate storage.................................................................................................3-6
3.2.1 Basic structure of steel structure aggregate storage.....................................3-7
3.2.2 Function instruction.......................................................................................3-7
3.2.3 Aggregate weighing.......................................................................................3-8
3.3 Powder silo............................................................................................................3-9
3.3.1 Silo-top filter..................................................................................................3-9
3.3.2 Pressure safety valve..................................................................................3-11
3.3.3 Rotating resistance type material level indicator.........................................3-12
3.3.4 Silo body......................................................................................................3-13
3.3.5 Overhaul ladder...........................................................................................3-14
3.3.6 Powder delivery pipe...................................................................................3-14
3.3.7 Aeration pad................................................................................................3-14
3.3.8 Manual butterfly valve.................................................................................3-15
3.3.9 Leg..............................................................................................................3-15
3.4 Upper box componetn..........................................................................................3-15
3.4.1 Bag dusting.................................................................................................3-16
3.4.2 Powder weighing.........................................................................................3-16
3.4.2.1 Basic structure of the Powder weighing..............................................3-16
3.4.2.2 Function instruction of the Powder weighing......................................3-16
3.4.3 Water weighing............................................................................................3-17
3.4.3.1 Basic structure of the Water weighing.................................................3-17
3.4.3.2 Function instruction of the Water weighing.........................................3-17
3.4.4 Liquid additive weighing..............................................................................3-18

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System Functions HZS60 Concrete Batching Plant

3.4.4.1 Basic structure of the liquid additive weighing....................................3-18

3.4.4.2 Function instruction of the liquid additive weighing.............................3-18
3.5 Lower frame component.....................................................................................3-19
3.5.1 Air compressor............................................................................................3-19
3.5.2 Mixing system..............................................................................................3-20
3.5.2.1 Instruction of SANY mixer...................................................................3-20
3.5.2.2 Structure of the mixer..........................................................................3-21
3.5.2.3 Working principle of the mixer.............................................................3-21
3.5.2.4 Main parts of the mixer.......................................................................3-22
3.6 Discharge device.................................................................................................3-30
3.7 Conveying System...............................................................................................3-30
3.7.1 Belt weigher.................................................................................................3-30
3.7.1.1 Basic structure of the belt weigher......................................................3-30
3.7.1.2 Reducer of the belt weigher................................................................3-32
3.7.2 Elevator.......................................................................................................3-34
3.7.2.1 Basic structure of the elevator............................................................3-34
3.7.2.2 Reducer of the elevator.......................................................................3-34
3.7.3 Screw conveyor...........................................................................................3-36
3.7.4 Pneumatic delivery......................................................................................3-38
3.8 Liquid Supply System..........................................................................................3-38
3.9 Additive supply system........................................................................................3-39
3.9.1 Additive container........................................................................................3-39
3.9.1.1 Basic structure of the additive container.............................................3-39
3.9.1.2 Function instruction of the additive container......................................3-39
3.9.2 Additive pump..............................................................................................3-40
3.10 Pneumatic System.............................................................................................3-40
3.10.1 Basic structure of the pneumatic system...................................................3-40
3.10.2 Function instruction of the pneumatic system............................................3-41
3.10.3 Working principle of the pneumatic system...............................................3-41
3.10.4 Main parts of the pneumatic system..........................................................3-42
3.11 Control Room and Electric Control System........................................................3-42
3.11.1 Control room..............................................................................................3-42
3.11.2 Electrical control system............................................................................3-43
3.11.2.1 Control process of the concrete batching plant.................................3-43
3.11.2.2 Structure and principle of the control system ...................................3-45
3.11.2.3 Control of electronic measuring system............................................3-47

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HZS60 Concrete Batching Plant System Functions

3.11.2.4 Control of power driving system.......................................................3-48

3.11.2.5 Hardware of the control system........................................................3-49
3.11.2.6 Software of the control system..........................................................3-49
3.11.2.7 Control software system function instruction.....................................3-50

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System Functions HZS60 Concrete Batching Plant

WARNING
Always read the Safety section of this
manual before attempting to operate
this equipment. Failure to do this could
result in machine damage, personal
injury or death.

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HZS60 Concrete Batching Plant System Functions

3 System Functions
3.1 General Overview
The cement concrete batching plant is
a set of equipment for mixing concrete.
Compose cement and admixture, water,
sand, stone, additive etc. in a certain ratio;
then load, transport, store, measure, mix
and discharge the material; in this way, the
concrete is produced.

The concrete batching plant is mainly

consisted of aggregate storage, belt
weigher, elevator, liquid supply system,
pneumatic system, mixing system,
discharge device, control room,upper box
component, lower frame component, etc.
As shown in Fig. 3-1 on page 3-6, they
are all shown in the overall structure of
commercial concrete batching plant.

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System Functions HZS60 Concrete Batching Plant

13 12

14 11
10

Fig. 3-1
9

5 6 7 8

1 2 3 4
Overall structure of concrete batching plant
(Sketch of the standard CBP, detail drawings please refer to 8.2 )
1-Belt weigher 2-Aggregate storage 3-Liquid supply system 4-Aggregate elevator
5-Additive supply system 6-Pneumatic system 7-Discharge device 8-Control room
9-Main tower frame 10-Mixing system 11-Lower frame component
12-Upper box component 13-Powder silo 14-Screw conveyor

3.2 Aggregate storage

Aggregate storage bin is a storage for
aggregate when weighing aggregate,
and it is usually called as the aggregate
storage once integrated with the aggregate
weighing system.
Aggregate storage can be categorized
into underground aggregate storage and

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HZS60 Concrete Batching Plant System Functions

steel aggregate storage. HZS60F concrete

batching usually use the steel aggregate
storage as shown in Fig. 3-2.
3.2.1 Basic structure of steel structure
aggregate storage

Steel structure aggregate storage

has features of easy feeding, smooth
discharging, compact dimension, quick
installation and convenient transportation.
Its basic structure is shown in Fig. 3-2

1 2 3 4

6 7 8 9
Fig. 3-2 Steel structure storage
1- Front plate 2- Rear plate 3- Distance plate 4- Screen 5- Side plate
6-Weighing sensor 7- Aggregate belt weigher 8-Vibrator 9- Support frame

3.2.2 Function instruction

The front plate, rear plate, side plate

and distance plate at the upper part of
the steel structure aggregate storage
form an enclosed bin. Connected with
pin, the plates can be laid down along
with the hinge mechanism of the frame

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System Functions HZS60 Concrete Batching Plant

for transportation. Screen is arranged

at the lower part of the tank to avoid big
stones entering into the weighing hopper.
A weighing hopper is placed under each
tank with independent weigher to ensure
the weighing accuracy. This structure
features easy feeding, smooth discharging,
compact dimension, quick installation and
convenient transportation. The quantity
of bins in the aggregate storage depends
on aggregate types required for concrete
batching. 3-bins, 4-bins and 5-bins are
available, and normally 4-bins is enough
for the operation.

Operation of vibrator under no-load

condition shall be avoided to prevent
the crack of weld seam at vibrator base
and aggregate storage bin as well as
the consequential damage on the bin.

3.2.3 Aggregate weighing

Accumulative weighing device named

as belt weigher is adopted in the steel
structure aggregate storage as shown in
Fig. 3-2 on page 3-7.
When all the aggregate measurements
are completed, the belt conveyor started
to deliver the aggregate into the elevator
bucket. Belt conveyor is function as the
aggregate weighing hopper, therefore
it is called as belt weigher (for detailed
information, see: “3.7.1 Belt weigher”
on page 3-30). When the concrete
batching plant is producing continuously,
belt weigher is working intermittently.
It will save power consumption. The
discharge height of the level belt conveyor
is increased. This will reduce the height

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HZS60 Concrete Batching Plant System Functions

of the slope of the loading truck on the

aggregate storage or the depth of the base
pit of the aggregate storage.

3.3 Powder silo

As shown in Fig. 3-3 on page 3-9,
powder silo is composed of silo-top
filter, pressure safety valve, damper-type 1
6
material level indicator, silo body, overhaul
ladder, powder delivery pipe, aeration pad, 7
manual butterfly valve, leg, etc. This is a 2 8
silo for storage of powder material such
as, cement admixture (fly ash, mineral
powder, zeolite powder and silica fume)
and dry powder additives. According to the
capacity of the silo, it can be classified as
50t, 100t, 200t, 250t, and 300t.

3.3.1 Silo-top filter

1. Silo-top filter

As shown in Fig. 3-4 on page 3-10, silo- 3 9

top filter at the silo top is composed of 4
water-proof cover, vibrator, cable box and
filter core. 5

This device is mainly designed to protect

the environment by preventing the dust in
Fig. 3-3 Powder silo
compressed air from diffusing.
1- Silo-top filter 2- Silo body
3- Aeration pad 4- Manual butterfly valve
5- Leg 6- Pressure safety valve
The vibrator of silo-top filter must be 7- Damper-type material level indicator
started up before and after material 8- Overhaul ladder 9- Powder delivery pipe
conveyed into the powder silo, to shake
off the dust on filter core. It ensures
the airflow of powder silo smooth and
prevent danger from roof falling.

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System Functions HZS60 Concrete Batching Plant

Fig. 3-4 Silo-top filter

2. Parameters of silo-top filter

Table 3-1 Parameters of filter core

Filtering area Filter medium Quantity of filter core Length

24 ( m )
2
PP 14 900mm

Table 3-2 Parameters of vibrator

Degree of
Power Speed Voltage Frequency Current
protection
180W 3000rpm 230/400V 50HZ 0.85/0.46A IP65

Table 3-3 Spare parts

Filter core C013PP0V

Description Vibrator MVE200/3
SIOLV2V2 I type deduster
Material code 60069702 60055903

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HZS60 Concrete Batching Plant System Functions

3.3.2 Pressure safety valve

1. Pressure safety valve

Pressure safety valve (see Fig. 3-5) is

at the silo top as shown in Fig. 3-3 on
page 3-9. When bulked cement vehicle
pumps bulk-material into powder silo, if
the silo-top filter is jammed, pressure will
increase. Pressure safety valve is used to
protect the powder silo by releasing the
pressure when the pressure in the powder
silo reaches certain level.
Fig. 3-5 Pressure safety valve

2. Technical parameters of pressure

safety valve

Technical parameters of pressure safety

valve are shown as below:

Table 3-4 Technical parameters of pressure safety valve

Model Positive pressure Negative pressure kg

VCP273 B 280→1000mm H 2O• -20→120mm H 2O• 9.5

3. Caution items of using pressure

safety valve

Don’t fill viscous or corrosive materials into

the powder silo, which may corrode the
valve parts and impact the normal operation
of the VCP valve. The company takes no
responsibility for fault or damage of VCP
valve due to viscous or corrosive material
or other artificial factors.

If toxic products must be used, please do

take other measures to prevent emission
of toxic or hazardous material into the
environment.

It is forbidden to touch or stand near the

valve to prevent scalds when the device is
running.

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System Functions HZS60 Concrete Batching Plant

3.3.3 Rotating resistance type material

level indicator

1. Rotating resistance type material

level indicator

To detect the reserved material quantity in

the powder silo, a material level indicator
is usually installed in the silo body as
shown Fig. 3-3 on page 3-9. As shown
in Fig. 3-6, normal adopted material level
indicator is rotating resistance type. High
and low level indication is set there: High
level alarm means material in powder silo
will be full and you should stop feeding.
Low level alarm indicates that the material
in the powder silo will run out and new
material should be fed in time.

Fig. 3-6 Rotating resistance type material

level indicator

2. Technical parameters of the rotating

resistance type material level indicator

Technical parameters of material level

indicator are shown as follow.

Operating conditions:
Vessel pressure: 0.8 bar maximum

Internal temperature of vessel:-

20°C~+80°C

Ambient temperature of equipment:

-20°C~+70°C

Mechanical data:
Degree of protection: IP65

Installation connection: Thread G1 1/2”

and G2 1/2”

Connection part: Plastic

Blade and shaft: Stainless steel

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HZS60 Concrete Batching Plant System Functions

Friction sleeve: Protect the gear when

the blade is struck

Delay signal: About 1.3 second

Blade speed: 1 r.p.m

Electrical data:
Voltage: 24/48V 50/60Hz
or 115/230V 50/60Hz
or 24V DC (all the voltages
+10% -15%)

Power: 3VA (3W)

Lead-out wire: 1.5mm

Cable gland: 1×M20max×1.5 Plastic

Signal output: Float micro-switch

Max. AC: 250V 2A 500W, cosφ=1

Max. DC: 300V 2A 60W

Wiring diagram: see the printed circuit

for AC type; see the cover for DC type

Degree of protection: I

3.3.4 Silo body

Silo body (see Fig. 3-7) is a cavity container

with cylindrical upper part and conical lower
part. It must be sealed to protect powder
from rainfall, or the powder material inside
the silo body will agglomerate.

Fig. 3-7 Silo body

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System Functions HZS60 Concrete Batching Plant

3.3.5 Overhaul ladder

Overhaul ladder (see Fig. 3-8) is installed

beside the silo body as shown in Fig. 3-3
on page 3-9. It is mainly used to inspect
and maintain the relevant equipment on
the powder silo. For instance, clean the
core of silo-top filter, inspect and maintain
the material level indicator and pressure
safety valve.

Fig. 3-8 Overhaul ladder

Fasten the safety harness and wear
safety helmet before climbing the
overhaul ladder, and carry out the
operation in accordance with relevant
safety operation regulations, to avoid
danger from dropping down.

3.3.6 Powder delivery pipe

Powder delivery pipe fixed on the silo body

as shown in Fig. 3-3 on page 3-9 is a
delivery steel tube for material feeding.
Wearing measure is adopted in the bend
of the tube. There is quick connector
on the soft powder outlet of the bulked
cement vehicle. It is convenient to connect
the quick connector to the powder delivery
pipe on the silo body.

3.3.7 Aeration pad

To improve the discharge capacity of the

powder silo, an impact device is usually
installed on the lower cone of the silo body
as shown in Fig. 3-3 on page 3-9. The
impact device is used to break the arch
bridge of powder material and facilitate
discharging. SANY concrete batching
plant uses aeration pad as shown in Fig.
3-9, to break the arch.
Fig. 3-9 Aeration pad

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HZS60 Concrete Batching Plant System Functions

3.3.8 Manual butterfly valve

The upper part of manual butterfly valve

(see Fig. 3-10) is connected to discharge
outlet of the silo body as shown in Fig.
3-3 on page 3-9, while the lower part is
connected to the screw conveyor via the
transitional tube. The manual butterfly
valve is opened properly under normal
operation condition, to discharge powder
into the screw conveyor from the powder
silo. In case of fault from the screw
conveyor, the manual butterfly valve must
be closed before removing the screw
conveyor, to prevent powder material from
falling down.
Fig. 3-10 Manual butterfly valve

3.3.9 Leg

Legs shown in Fig. 3-3 on page 3-9 are

welded with steel tube and steel angle or
steel channel, used as the bearing piece
for powder silo.

3.4 Upper box componetn

As show in Fig. 3-11, box dusting device,
additive weighing device, water weighing
device and powder weighing device are
main parts of the upper box component. 1
2

4
3

Fig. 3-11 Upper box component

1- Bag dusting device
2- Additive weighing device
3- Water weighing device
4- Powder weighing device

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System Functions HZS60 Concrete Batching Plant

3.4.1 Bag dusting

Bag-type deduster is carried out by taking

advantage of scalability and tightness of
bag. The bag (see Fig. 3-12) is made of
low-cost canvas with simple structure,
which is effective to prevent dust from
escaping and eliminate the positive and
negative pressures. Bag-type deduster
is effective at beginning, but its effect is
degraded due to deposition of dust on the
bag wall with time, thus the deposited dust
must be removed regularly.
Fig. 3-12 Bag duster

3.4.2 Powder weighing

3.4.2.1 Basic structure of the Powder
weighing 1

As shown in Fig. 3-13, powder weighing

system is composed of ventilation tube, 2
powder weighing hopper, weighing sensor,
support, vibrator, pneumatic butterfly valve
(see Fig. 3-14) and pneumatic spherical 3
vibrator.
4
5
3.4.2.2 Function instruction of the
Powder weighing 6
Considering the cement and admixtures Fig. 3-13 Powder weighing sysem
are dusty, pollutive and water absorbing, 1-Ventilation tube 2-Powder weighing hopper
it is required that cement and admixtures 3-Weighing sensor 4-Support
should be weighed in a closed container. To 5-Vibrator 6-Pneumatic butterfly valve
ensure the weighing system is independent,
the connections between weighing hopper
and other parts should be flexible to ensure
the accuracy of measurement. When the
measurement begins, the screw conveyor
gets started after receiving the signal to
deliver powder material into the weighing
hopper, and part of the air and dust flow
Fig. 3-14 Pneumatic butterfuly valve
into the dust collector via the exhaust
pipe. When the powder material reaches

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HZS60 Concrete Batching Plant System Functions

the preset weight, the screw conveyor will

stop delivering and the measurement is
completed. The pneumatic butterfly valve
is actuated after receiving the discharge
indication to open the hopper door for
discharging. At the same time, the vibrator
starts to work to speed up the discharging.
When the weigher is empty, the operation
of the pneumatic butterfly valve is delayed
to close the discharge port and stop the
vibration.

3.4.3 Water weighing

3.4.3.1 Basic structure of the Water

weighing

As shown in Fig. 3-15, water weighing 1

system is composed of water inlet pipe, 2 6
sensor, liquid additive drain pipe, weighing
hopper, pneumatic butterfly valve and red
rubber pipe. 3

3.4.3.2 Function instruction of the

Water weighing

When the measurement begins, the water 4

pump is started after receiving the signal
5
to pump water from the water pool into the
weighing hopper. When the water reaches Fig. 3-15 Water weighing
the preset volume, the pump stops working 1- Weighing sensor 2- Liquid additive inlet
and the measurement is completed. The 3- Weighing hopper
pneumatic discharge butterfly valve is 4- Pneumatic discharge butterfly valve
actuated after receiving the discharge 5- Red rubber pipe 6- Water inlet
indication to open the hopper door and
discharge the water. When the weigher
is empty, the operation of the pneumatic
discharge butterfly valve is delayed to
close the discharge port.
During concrete production, realizing
designed ratio of water and powder is key
to ensure the concrete quantity. In order
to accurately control the water added into
the concrete, it is not enough to use high

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System Functions HZS60 Concrete Batching Plant

accuracy water weighing device. Because

the sand and stone in the water may enter
the mixer together, if there’s no considering
the existing of this part of water, the
designed ratio of water and powder will
not be realized accurately. Measure the
water content of the sand and stone and
then deduct the water to ensure the ratio
accuracy. For example, automatic modify of
the water and sand dosage can be realized
by sand water content measuring apparatus
measure the water content continuously.

3.4.4 Liquid additive weighing

3.4.4.1 Basic structure of the liquid

additive weighing

As shown in Fig. 3-16, liquid additive

weighing is composed of sensor, weighing 1
hopper, pneumatic discharge butterfly
valve, and liquid additive drain pipe. 2

3.4.4.2 Function instruction of the

liquid additive weighing
3
Considering the intensive corrosiveness 4
of the additive, the weighing hopper is
usually made of stainless steel. When the Fig. 3-16 Liquid additive weighing
measurement begins, the additive pump is 1- Weighing sensor 2- Weighing hopper
started after receiving the signal to pump 3- Pneumatic discharge butterfly valve
the additive from the additive storage tank 4- Liquid additive drain pipe
into the weighing hopper (2). When the
additive reaches the preset weight, the
pump stop working and the measurement
is completed. The pneumatic discharge
butterfly valve (3) is started after receiving
the discharge indication (after water
weighing completed) to open the hopper
door and discharge the additive into the
water weighing hopper. When the weigher
is empty, pneumatic discharge butterfly
valve will be delayed to close the discharge
gate.

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HZS60 Concrete Batching Plant System Functions

3.5 Lower frame component

As shown in Fig. 3-17, air storage tank, air
compressor and mixing system are main
parts of the lower frame component.

1
3
2

Fig. 3-17 Lower frame component

1-Air storgae tank 2-Air compressor
3-Mixing system

3.5.1 Air compressor

An air compressor, as shown in Fig. 3-18,

compresses the air via the upward and
downward movement of the piston in the
cylinder. During the downward stroke
of piston, the air is sucked via the inlet
valve and the exhaust valve is closed.
During the upward stroke of piston, the air
is compressed, the inlet valve is closed
and the exhaust valve is opened; and the
compressed air flows into the air tank via
one-way valve. The compressed air cannot
be utilized until the pressure in the air tank
raises to the required pressure.

Fig. 3-18 Piston-type air compressor

A location with low humidity, less dust,

less pollution, clean air, sufficient light
and good ventilation can prolong the
service life and improve the efficiency
of the air compressor.

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System Functions HZS60 Concrete Batching Plant

3.5.2 Mixing system

Mixer is the main part of mixing system.

Mixing system is designed to mix the
measured raw materials, such as aggregate,
cement, water, additive and so on, into
concrete with specified strength in the mixer.

3.5.2.1 Instruction of SANY mixer

With development of the concrete

producing technology, structure of the
mixer changes, various types of mixer is
developed. At present, SANY concrete
batching plant always use twin-shaft forced
horizontal mixer as shown in Fig. 3-19 on
page 3-21, which is the most popular type
be used.

Twin-shaft forced horizontal mixer mixes

the material by blades in a forced guiding
way. It has two synchronizing rotation
horizontal mixing shaft with reversing
rotating direction. Except blades mix the
raw material in the same rotating direction,
screw driving direction is reversing to
make the circumfluence of the material
in the mixing cylinder, and the mixing is
intensive. The volume of this structure has
high utilization, low line speed of blade,
light wearing. It can get best mixing quality
in lowest consumption. Because the mixer
mixes equably, and the aggregate can be
used in a wide range, this kind of mixer
is proper for mixing common concrete,
particular concrete and special concrete.
When big mixing power motor is equipped,
diameter of the aggregate can reach to 150
mm. For detailed information about the
mixer model, see: “7.2 Specifications of
Mixer” on page 7-5.

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HZS60 Concrete Batching Plant System Functions

3.5.2.2 Structure of the mixer

As shown in Fig. 3-19, SANY twin-

shaft concrete mixer is composed of
transmission device, cylinder body and
liner plate component, mixing device,
shaft end seal, upper cover and device for
pipe laying, discharge gate and lubrication
device.

5
4

3
6

1 7

Fig. 3-19 SANY twin-shaft horizontal mixer

1-Shaft end seal 2-Lubrication device 3-Mixing device 4-Cylinder body and liner plate
5-Upper cover and device for pipe laying 6-Transmission device
7-Discharge gate 8-Cable box

3.5.2.3 Working principle of the mixer

SANY mixer is developed by integrating

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System Functions HZS60 Concrete Batching Plant

domestic and overseas technology of the

mixer. It features small dimension, high
strength, high reliability, easy maintenance,
low consumption, high mixing efficiency.

This machine utilized technology of

hydrodynamics and tribology, realizes
correct and forced mixing by synchronous
rotation of two mixing shafts with mixing
arms and mixing blades. Material in the
mixing cylinder forced flows in horizontal
and vertical direction, and is mixed
adequately. Synchronous rotation of the
mixing shaft raises the material at times
and feeds back to the cylinder sometimes.
The circular motion ensure the most equal
concrete be produced in the shortest time.

This twin-shaft horizontal mixer is

a batch-type concrete mixer. Feed
aggregate, cement and water at specified
intervals. For detailed information, see:
“4.3.1 Time parameters definition and
setting” on page 4-17.
3 4 5
A
2 6
3.5.2.4 Main parts of the mixer

B 7
1. Shaft end seal

As shown in Fig. 3-20, shaft end seal is 1 8

composed of shaft sleeve, dust proof,
wearing ring, seal cushion, locating ring,
floating seal ring, floating ring, seal ring.
Main
Shaft
For the horizontal mixer, the main shaft
is immersed into aggregate and cement Fig. 3-20 Shaft end seal
whose friction is strong during the 1-Shaft sleeve 2-Dust proof 3-Wearing ring
operation. Thus the main shaft neck and 4-Seal cushion 5-Locating ring
bearing could be worn out soon if there is 6-Floating seal ring 7-Floating ring
no effective shaft end sealing measures. 8-Seal ring

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HZS60 Concrete Batching Plant System Functions

The sealing grease flows into the mixer

from port A via port B under the pressure
of motor pump. The sealing grease forms a
high pressure protection layer at the shaft
end to prevent slurry from entering into the
shaft end for protection.

The dust proof and wearing ring must

be replaced immediately if the clearance
between them reaches 6mm; otherwise,
there will be leakage at the shaft end seal.

Shaft end sea lubricant circuit is

composed of lubrication pump, oil nozzle
and connecting pipe. The lubricant circuit
functions as lubrication, radiation and
sealing device for bearing seat and mixing
shaft head, protecting the bearing seat
and mixing shaft from corrosion of slurry.

2. Lubrication device

Lubrication device (see Fig. 3-21) is

one of the key components of the mixer.
It provides lubricant to the mixer. It
affects the working efficiency and service
life of the mixer directly. For detailed
information, see: “5.7.2.1 Lubrication
of the mixer” on page 5-114 for more
detailed information.

Fig. 3-21 Lubrication device

3. Cylinder body and liner plate

assembly

As shown in Fig. 3-22 on page 3-24,

mixing cylinder of the mixer is a ω-shape
twin-drum made by wide and thick steel
plate. Special designed frame can bearing

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System Functions HZS60 Concrete Batching Plant

strong yield strength. The bearing part

makes the cylinder have enough rigidity
to ensure the parallelism of the twin
horizontal shafts and the concentricity of
one shaft.

An overhaul platform is installed on

each side of the cylinder. In order to
make operation and maintenance more
convenient, the platform can extend,
retract and support according to the
requirement. To prevent cylinder body from
wearing, liner plates are installed inside
Fig. 3-22 Liner plate assembly
and outside of the cylinder body. The liner
plates are fixed on the cylinder body by
countersunk bolts. Rhombic wearing liner
plates are adopted in the big wearing area
to ensure the interchange ability and wear
resistant.

4. Mixing device

As shown in Fig. 3-23, mixing device is

composed of main shaft, mixing arm, blade,
4
and scraping plate. The two parallel main
3
shafts of the mixing device are equipped
with several mixing arms and the two
adjacent arms on the same main shaft are
positioned at an angle of 60°. The relative
angles of mixing arms on the two main 2
shaft are fixed, and the fixed angles are 1
ensured by the coupler between the two
reducers. The mixing arm is designed with
hydromechanics to improve its strength as Fig. 3-23 Mixing device
well as reduce the mixing resistance and 1-Scraping plate 2-Main shaft
wearing. 3-Mixing arm 4-Blade

Do not disconnect the coupling arbitrarily

without professional service engineer.

1) Main shaft

The main shaft is made of high-quality alloy

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HZS60 Concrete Batching Plant System Functions

steel with several processes to ensure the

sufficient strength and rigidity.

2) Mixing arm

The mixing arm is made of wear-resistant

cast steel. The arm features screw shape,
high strength and wear resistance, low
operation resistance, long endurance and
low energy consumption.

3) Blade

The blade is made of high-chromium

wear-resistant cast iron. It features wear
resistance and long efficient operation time.

4) Scraping plate

The scraping plate is made of high-

chromium wear-resistant cast iron. During
the operation, direct contact of mixing arm
and cylinder body should be avoided so as
to protect the mixing arm and prolong its
service life.

Mixing device of this machine is similar

to double-screw structure. It is mainly
composed of mixing unit, main mixing unit,
side mixing unit, thin caulking ring, etc.
Arrangement of mixing arms as shown in
Fig. 3-24 is applicable to JS1000 mixer.

Shaft A Shaft B

Shaft A

Shaft B

Fig. 3-24 Mixing device with 6 arms on the main shaft

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System Functions HZS60 Concrete Batching Plant

5. Upper cover and device for water pipe

laying

Upper cover of the mixer is equipped to

prevent dust from flowing out, and ensure
3
the safety of personnel. As shown in Fig. 1
3-25, water pipe laying supplies water to 4
mixer. Proper laying of pipes can make 2
water power equably distributes in the
cylinder. Injected water can mix powder
and prevent dust from flowing to protect
Fig. 3-25 Upper cover and water pipe laying
environment.
1-Materia inlet 2-Observation door
3-Overhaul door 4-Water pipe

6. Transmission system

As shown in Fig. 3-26, transmission system

of the mixer is composed of motor, motor
belt pulley, V-belt, reducer belt pulley,
synchronous transmission shaft, planetary
reducer, spline shaft, spline shaft sleeve
and belt cover, etc.
1 2 3 4 5

9 8

7
6

Fig. 3-26 Transmission system

1- Transmission shaft 2- Reducer belt pulley 3- Planetary reducer 4- Spline shaft
5- Spline shaft sleeve 6- Motor 7- Motor belt pulley 8- V-belt 9-Belt protective cover

Motor reduces speed from high to low via

V-belt and planetary reducer, and then
drives the main mixing shaft via spline

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HZS60 Concrete Batching Plant System Functions

and spline shaft sleeve. At the same

time, synchronous transmission shaft
connects the two reducers, to ensure the
synchronous movement of the two shafts.
The advantage of this system is: steady
transmission, big transmission torque and
good cost performance.

1) Motor

Special motor of high quality is selected. The

motor adopts high-temperature protective
equipment. It is high-grade protection and
insulation. The specifications of the motor
are shown in Table 3-5.

Table 3-5 Main performance parameters of motor

Rated Rated
Rated Rated rotation Frequency Weight
Motor type power voltage
current (A) speed (r/min) (Hz) (kg)
(kW) (V)
Motor Y2-180M-4 18.5 380 36.5 1470 50 183
Motor Y2-200L-4 30 380 57.6 1470 50 270
Motor Y2-225S-4 37 380 69.9 1480 50 285
Motor Y2-250M-4 55 380 103 1480 50 427
Motor Y2-280S-4 75 380 140 1480 50 560

2) Reducer

SANY special planetary reducer is adopted.

This reducer features compact structure,
high reliability and easy maintenance.

3) Belt pulley

Belt pulley is made of cast iron, it has

taken the balance verify, to ensure the
pulley balance at a best condition during
its running. Shaft end of the motor belt
pulley is pressed tightly by the clamping
plate. The reducer belt pulley is connected
to the reducer flange with high-strength
screw to prevent mechanical wearing due
to displacement of the belt pulley.

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System Functions HZS60 Concrete Batching Plant

4) Synchronous transmission shaft

A special universal synchronous

transmission shaft for mixer is adopted to
ensure the synchronous movement of the
two main mixing shafts.

5) Spline shaft and spline shaft sleeve

Both parts are made of high strength alloy

steel and processed with special heat
treatment to improve the durability. These
two parts are used together to transmit
drive between the reducer and the mixing
main shaft.

6) Belt protective cover

Protective cover is designed with reasonable

structure and thus it provides effective
protection and convenience for disassembly
and maintenance; the condition of belt
can be checked via the sight glass on the
protective cover conveniently.

7. Discharge gate

Discharge gate located at the bottom of

the mixer as shown in Fig. 3-19 on page
3-21. As shown in Fig. 3-37on page3-30,
discharge gate is composed of discharge
gate body, cylinder and proximity switch.
The discharge gate can be set to full-open,
full-close and half-open during automatic
operation.

1) Discharge gate body

The body is composed of discharge gate

and bearing. The clearance between the
arch of mixing tank and the discharge
gate shall be controlled within 0.5~1.5mm.
To prevent the travel of discharge gate
from interference due to accumulation
of concrete, the deposition around the
discharge gate shall be cleaned regularly.

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HZS60 Concrete Batching Plant System Functions

2) Limit proximity switch

NPN proximity switch is installed on the

support to control the movement status
and position of the discharge gate, and
provide position signal indication at the
same time. Discharge gate has 3 working
states: full-open, full-close and half-open.
These 3 position states are controlled by
3 independent proximity switches and
inductive plate together (make sure the
distance of the inductive plate and the
inductive head of the proximity switch not
more than 10 mm). When inductive plate
and inductive head of the proximity switch
coincide, a signal will be transmitted to the
control cabinet via line cable box (shown
in Fig. 3-19 on page 3-21). At the same
time, 24V power is supplied to the proximity
switch by power distribution cabinet to
control the states of the discharge gate.

8. Electric control system

Electric control system of the mixer

is composed of mixing motor control,
discharge gate control and cable box.
For detailed information about the
mixing motor control circuit, see: “8.1
Schematic Electric Diagram of the
Mixer” on page 8-3.

1) Mixing motor control

Startup of the motor shown in Fig. 3-19

on page 3-21 drives the mixing cylinder
rotating, and then drives the running of
mixer.

2) Discharge gate control

This electric control circuit is provided

by user. The company only provides the
control circuit for reference. For detailed
information, see: “Fig. 8-3 Proximity
switch of the discharge gate control

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System Functions HZS60 Concrete Batching Plant

circuit” on page 8-11.

3) Cable box

Cable box shown in Fig. 3-19 on page

3-21 is mainly used to connect the
discharge gate control and limit proximity
switch control of the discharge gate.
Terminals and wiring diagram are provided
in the cable box.

3.6 Discharge device

As shown in Fig. 3-27, discharge device
is mainly composed of discharge hopper
body, plate, clamp, rubber pipe.

This is a transition hopper for storing

1
concrete after it is discharged from the
mixer and before falling into the truck 2
mixer. It is used for storing the finished
product temporarily, as a buffer for truck
mixer and it enables the finished product
can be discharged quickly from the 3
mixer. Throttle device can be added on
the discharge gate to reduce the feeding 4
speed of the finished product to the truck
mixer. Grip, plug-in board valve, etc. can
be used to control the open/close of the Fig. 3-27 Discharge device
discharge gate.
1- Discharge hopper body 2- Plate
3- Clamp - Rubber pipe

3.7 Conveying System

The conveying system located as shown
in Fig. 3-1 on page 3-6 in the concrete
batching plant mainly comprises aggregate
conveying and cement and admixture
conveying. This system adopts belt
weigher and aggregate elevator to carry
out belt delivery of sand and stone.

3.7.1 Belt weigher

3.7.1.1 Basic structure of the belt weigher

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HZS60 Concrete Batching Plant System Functions

Belt weigher located as shown in Fig. 3-1

on page 3-6 is composed of bin body,
weighing sensor, turnabout drum, screw
rod, trough idler, level lower idler, automatic
checking device, nylon conveying belt,
scraper, driving drum and reducer. The
basic structure is shown in Fig. 3-28.

1 2 3 4

5 6 7 8 9
Fig. 3-28 Belt weigher
1-Turnabout drum 2-Trough idler 3-Weighing hopper 4-Reducer 5-Level lower idler
6-Bin body 7-Nylon conveying belt 8-Scraper 9-Driving drum

1. Turnabout drum

It is used to change the running direction

of the delivery belt or add cornerite angle
between delivery belt and turnabout drum.

2. Adjusting screw rod

It is adopted to tension the delivery belt

and adjust the running state of delivery
belt. It ensures the delivery to run in the
normal position.

3. Idler
It is adopted to support material loaded
on the delivery belt and ensure steady
running of the device.

4. Scraper
It is used to clear the material adhered on

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System Functions HZS60 Concrete Batching Plant

the delivery belt

3.7.1.2 Reducer of the belt weigher

Reducer as shown in Fig. 3-28 is the main

driving part of the belt weigher. It adopts
helical-bevel gear reducer structure
which features great reduction ratio, high
efficiency, compact volume, less trouble,
long service life, great bearing capacity,
convenient assembly and disassembly,
and easy maintenance. Its structure is
shown in Fig. 3-29.

1 2 3

9
8
7
6
5
4

11
10
Fig. 3-29 Helical-bevel gear reducer
1-Small gear 2-Gear 3-Driving gear 4-Gear 5-Driving gear shaft 6-Gear
7-Output shaft 8-Key 9-Shaft sealing ring 11-Rolling bearing 12-Clamp ring

Installation and operation notes of helical-

bevel gear reducer:

a) Install the gearmotor with bolts of 8.8

precision level.

b) Do not tighten the housing legs and

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HZS60 Concrete Batching Plant System Functions

mounting flanges against each other and

ensure the permitted lateral and axial
tension during installation.

c) Adopt the lubrication method which is

suitable for the installation (see instruction
on the namemark). Add enough lubricant
the reducer as required.

d) Assembly is easier if you apply

lubricant to the output element or heat it
for awhile (to 80~100°C) before.

e) There may be slight deviation at the oil

level indicator as a result of the different
installation methods, which are permitted
within the permitted tolerances.

f) Never install the belt pulleys, couplings,

small gears, etc. to the shaft end by hitting
them with a hammer, this may damage the
bearings, housing and the shaft.

g) During installing the belt, ensure

correct tension of the belt.

h) Installed driven elements should be

balanced after fitting and must not give
rise to any impermissible radial or axial
forces.

i) Pull switch circling the belt weigher is

adopted as a safety protective device for
the running of belt weigher. It can stop the
running of belt if fault and accident occurs.

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System Functions HZS60 Concrete Batching Plant

3.7.2 Elevator

Elevator is often adopted in narrow work

site to convey aggregate to the storage 7 8
device. Engineering concrete batching 9
plant use bucket skip elevator for feeding.
It features small area occupied, but big
lifted power, frequency conversion timing,
smooth and reliable running, many working
mode for choice: such as slowly startup -
quickly lifting, quickly falling - slowly perch. 6

3.7.2.1 Basic structure of the elevator

Aggregate elevator located as shown in 5

Fig. 3-1 on page 3-6 is composed of
lower guiding rail, middle guiding rail, 4
aggregate hopper, pull rod assembly, top 3
crash protective device and motor. Its
basic structure is shown in Fig. 3-30.

2 1
Fig. 3-30 Elevator
1-Aggregate hopper 2-Lower guiding rail
3-Pull rod 4-Middle guiding rail 5-Steel wire
rope 6-Upper guiding rail 7-Reducer 8-Reel
9-Top crash protective device

3.7.2.2 Reducer of the elevator

Reducer as shown in Fig. 3-30 on

page 3-34 is the main driving device
of the elevator. The reducers features
interchangeable spare parts, compact
dimension, light weight, high accuracy,
great bearing capacity, high efficiency,
long service life, high reliability, stable
transmission, low noise, etc. As is shown
in Fig. 3-31.

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HZS60 Concrete Batching Plant System Functions

8 9 10

7
6
4 5
1 2 3
11

Fig. 3-31 Bevel gear reducer (elevator)

1-Key 2-Output shaft 3-Key 4-Oil sealing 5-Washer 6-Bearing
7-Shaft sleeve 8-Bearing 9-Clamp ring 10-Clamp ring 11-Washer

Installation and operation notes of bevel

gear reducer:

Before installation and operation of the

reducer, please ensure the following items.

a) Keep power accordant with the

namemark.

b) Driving device is not damaged by

delivery or storage.

c) It is forbidden to install driving device

in the following circumstances:

● ● Explosive circumstances
● ● Oil
● ● Acid and corrosive circumstances
● ● Gas
● ● Water vapour
● ● Radiative

d) Install the gearmotor with bolts of 8.8

precision level.

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System Functions HZS60 Concrete Batching Plant

e) Do not tighten the housing legs and

mounting flanges against each other and
ensure the permitted lateral and axial
tension during installation.

f) Adopt the lubrication method which is

suitable for the installation (see instruction
on the namemark). Add enough lubricant
the reducer as required.

g) Assembly is easier if you apply

lubricant to the output element or heat it
for awhile (to 80~100°C) before.

h) There may be slight deviation at the oil

level indicator as a result of the different
installation methods, which are permitted
within the permitted tolerances.

i) Installed driven elements should be

balanced after fitting and must not give
rise to any impermissible radial or axial
forces.

3.7.3 Screw conveyor

Screw conveyor uses rotary screw blade

or rotary channel with inner screw surface
to deliver material. The powder material
used in concrete batching plant (tower)
is delivered by screw conveyor. Feeding
of powder material is controlled via the
rotation and stop of the screw blade. The
delivery must be carried out in a totally
sealed cavity to prevent environment
pollution and agglomeration caused by
moisture. The pipe-type screw conveyor
is usually adopted to deliver cement and
admixtures. Generally, the delivery screw
can operate at certain inclination about 45°
or even 60°. Screw conveyor with different
length can be obtained by adjusting
the standard sections. Longer delivery
distance can be realized by connecting the
screw.

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HZS60 Concrete Batching Plant System Functions

Pipe-type screw conveyor, as shown in

Fig. 3-32, can deliver material horizontally,
vertically and aslant. The delivery
productivity of the powder material has
relationship with the screw pitch and
8 7
rotation speed. And it is also connected 6
with the volume and full-fill status of the
5
material. In order to improve the delivery
capacity, varying screw pitch blade is
adopted. In lower feeding section screw
pitch is small than it in conveying section. 4
Feeding amount is big and it will be reduced 3
2
with the increasing of the screw pitch. This
1
measure can prevent reversing movement
of the high flowing powder material during 9
10
delivery.
11
12
Diameter of the screw used to convey
Fig. 3-32 Screw conveyor
cement and admixture range from φ168mm
to φ406mm. The productivity is 20t/h ~ 1- Motor MT 2- Gear reducer M1
150t/h. The rotation speed is 90r/min ~ 3- Gear reducer shaft seal XUK
300r/min. The feeding status of the screw 4-Inlet end bearing XTB 5-Hook point Xkg
conveyor during working is connected 6- Intermediate bearing XLR 7- Screw blade
with the material falling and status of the 8- Outlet end bearing XTA 9-Serial number
10- Viewing port XKA 11- Enclosure
material. The full-fill coefficient is about
12- Material inlet XBC
30% ~ 50%.

Wearing condition of the screw conveyor

is related with the material delivered. If the
screw is worn out, the clearance between
the top surface of screw and the screw
pipe will increase (normally the clearance
between blade and pipe wall is about
10mm) and the delivery efficiency will be
degraded. Besides, the screw blade may
be stuck, jammed or blocked, and the
motor could be burned.

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System Functions HZS60 Concrete Batching Plant

In areas with high humidity, material in

the screw conveyer shall be discharged
thoroughly, if the screw conveyor will be
left unused for a long period. Close the
manual butterfly valve at the inlet of the
screw conveyor, start the screw conveyor
motor and run for several minutes; then
stop the device to finish the operation.

3.7.4 Pneumatic delivery

Pneumatic delivery is mainly used in
powder silo as shown in Fig. 3-3 on page
3-9 to transport powder material. Cement
and admixtures are normally transported
by bulk cement truck. By using the delivery
system on the bulk cement truck, the
powder material is blown into suspension
status by the compressed air. The mixed
air flows into the silo via pipe, and the silo-
top filter collects the dust escaped from
the silo. A set of suction device is required
for pneumatic delivery of cement in bags.

3.8 Liquid Supply System

As shown in Fig. 3-33 on page 3-38,
Liquid supply system is composed of water
supply pipes and water pump, Water used
in the concrete batching plant is normally
clean water, but industrial water recycled
1
from the washing device could also be
used partly. After weighing, water only
flows into the mixer by gravitation, also
a pump can be arranged below the water 2
weighing hopper to deliver pressurized
water into the mixer to accelerate water
supply and flush the mixing device.
Fig. 3-33 Liquid supply system
1- Water supply pipes 2-Water pump

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HZS60 Concrete Batching Plant System Functions

3.9 Additive supply system

Additive suppply sysem supplys additive
for the concrete batching station, its main
component is addtive container.

3.9.1 Additive container

3.9.1.1 Basic structure of the additive

container

Additive container is part of the liquid

additive supply system. As shown in Fig. 1
3-34, additive container is composed 2
of material inlet, tank body, liquid level
indicator, ladder, return pipe, additive 3
pump, and discharge pipe. 4

3.9.1.2 Function instruction of the

additive container 5
6
Additive container is used for storing the 7
liquid additive. Additive is widely used
in concrete batching plant. The tank is Fig. 3-34 Additive storage tank
cylindrical. The liquid level indicator is 1- Tank body 2- Return pipe
used to indicate the level of additive 3- Ladder 4- Liquid level indicator
inside the tank, prevent the additive from 5- Additive pump 6- Discharge pipe
overflow during filling and remind user 7- Material inlet
to add additive when the level is low. A
discharge valve is arranged at the bottom
of tank to drain the waste deposited at the
bottom considering the deposition feature
of additive. A return pipe is arranged on
the tank to maintain the uniformity of liquid
additive and prevent deposition during its
running. Once the additive pump is started,
part of the additive will be delivered to the
additive weighing hopper for weighing,
while the other part returns to the tank. The
impact in the tank caused by the pumped
additive with certain pressure makes the
additive flow, thus prevents deposition
and maintains the uniformity, contributing
to improve the stability of the concrete

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System Functions HZS60 Concrete Batching Plant

quality. For some special additive, mixing

device can be used. The mixing device
can prevent additive from depositing by
working periodically during producing.

3.9.2 Additive pump

10
1 11
As shown in Fig. 3-34 on page 3-39,
12
additive pump is composed of motor, pump 13
head, guidance blade, impeller, pressure 2 14
proof tube, water in & out section, pump 3 15
shaft, mechanical sealing, etc. It has 4 16
17
features of high efficiency, low noise, 5 18
light-erosion proof, compact structure, 19
nice shape, small volume, light weight, 6
7 20
convenient use and maintenance, reliable
21
sealing, etc. 8
9

Fig. 3-35 Additive pump

1-Motor 2-Mechanical sealing 3-Shaft coupler
4-Pump head 5-Pull rod 6-Wire spring 7-Water
outlet guidance blade 8-Pump shaft 9-Water
in & out section 10-Snap ring sleeve 11-Seal
distance piece 12-Impeller distance piece
13-Guidance blade 14-Impeller short distance
piece 15-Wearing shaft sleeve 16-Supporting
guidance blade 17-Impeller 18-Chopped-off
head impeller pressure cover 19-Flow guider
20-Pressure proof tube 21-Seal ring

3.10 Pneumatic System

3.10.1 Basic structure of the pneumatic
system

Pneumatic system is composed of

integrated valve, filter relief valve, aeration
pad, pneumatic butterfly valve, pneumatic
spherical vibrator, air compressor,
pneumatic triplet, air reservoir, pneumatic
cylinder, connector, air pipe, etc.

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HZS60 Concrete Batching Plant System Functions

3.10.2 Function instruction of the

pneumatic system

Most mechanisms in the concrete batching

plant are pneumatic driven. Pneumatic
driving features the advantages of low
cost and no pollution. The basic principle
diagram is shown in Fig. 3-36.

1 2 3 4 5 6 7 8

Agregate
storage

Powder silo Main tower

Fig. 3-36 Basic principle diagram of the pneumatic system
1-Air compressor 2-Filter relief valve 3-Air reservoir 4-Aeration pad
5- Air pipe 6- Pneumatic triplet 7- Pneumatic butterfly valve 8- Pneumatic cylinder

3.10.3 W o r k i n g p r i n c i p l e o f t h e
pneumatic system

The high pressure air from the air

compressor flows into the solenoid valve
via the pneumatic triplet. The solenoid
valve connects through relevant circuits
after receiving the control signal, to supply
compressed air into the driving elements
(pneumatic cylinder, vibrator, and aeration
pad) to carry out relevant actions (open/
close of hopper door, start/stop of
vibration, start/stop of arch breaking). The
operating pressure shall be greater than
0.4MPa when the pneumatic elements
work individually or together.

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System Functions HZS60 Concrete Batching Plant

3.10.4 Main parts of the pneumatic

system

As shown in Fig. 3-37, pneumatic

triplet features the functions of filtering,
depressurizing and oil spraying. Filtering
is to separate the impurities, such as
condensation water and oil dirt, from the
compressed air to purify the compressed
air. The depressurizing function regulates
the pressure at outlet by using the
pneumatic triplet; oil spraying function
provides oil mist to lubricate the air valve.
Fig. 3-37 Pneumatic triplet

3.11 Control Room and Electric

Control System
3.11.1 Control room

The control room is provided for operator

to operate and manage the concrete
batching plant. It is usually located on the
ground as in engineering batching station.
Control room assembly with electric
control system is the nervus system of the 1
concrete batching plant which determines 2
movement of every part. It is composed of
computer, air conditioner, table and chair,
printer, control system (such as operation 3
console, etc.) (see Fig. 3-38),

Fig. 3-38 Control room

The control room is enclosed with sandwich 1-Computer 2-Control room 3-Power cabinet
panels, equipped with plastic-steel doors
and windows, and decorated inside. It is
thermal-insulated, soundproof and fire-
resistant. It provides a quiet, comfortable,
spacious and bright work environment. The
operation complies with the ergonomics
with beautiful appearance. In order to
protect the control room from vibration
caused by mixer and other equipment and
to ensure the normal operation of electrical

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HZS60 Concrete Batching Plant System Functions

elements, the control room is normally

located 50mm away from the main tower
frame.

3.11.2 Electrical control system

3.11.2.1 Control process of the concrete

batching plant

Concrete batching plant control system

controls every executive part to complete
the production of concrete according to
the requirement of producing process. It is
located in the control room as shown in
Fig. 3-38 on page 3-42. The brief process
diagram is shown in Fig. 3-39. The brief
description of the control process is shown
as below.
or
at
ev
el

Fig. 3-39 Process diagram of the concrete batching plant

Before production, control system start
up air compressor to supply pressure

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System Functions HZS60 Concrete Batching Plant

air to cylinders of the whole system and

pneumatic executive unit as aeration pad
(for detailed information, see: “4.6.4
Operation of the air compressor” on
page 4-90). Then level belt conveyor
and inclined belt conveyor are started,
preparing for the aggregate elevation. Start
mixer to prepare for concrete mixing (for
detailed information, see: “4.6.1 Other
Operation” on page 4-75). Set product
parameters of the system and transform
data as formulation of concrete via
industrial process computer (for detailed
information, see: “4.3.5 Debugging” on
page 4-27). Start material batching after
all these preparations finished.

Basic devices of the concrete batching

plant contain aggregate weigher, powder
weigher and liquid material weigher with
different feeding methods (for detailed
information, see: “3.4 Upper box
componetn” on page 3-15). Aggregate
weigher measures free falling aggregate
via discharge gate which is driven by
cylinder. Powder weigher measures
cement and powder additive by delivery of
screw conveyor. Liquid material weigher
measures water and liquid additive by
delivery of the pipes. When the weight
meets the requirement of the formulation,
close batching door, and stop screw
conveyor and pipe pump. Then the
measurement is completed.

Weighed aggregate (sand and stone)

is discharged on the level belt conveyor
and elevated to the waiting hopper above
the mixer by inclined belt conveyor. At
the same time powder and liquid material
measurement are completed by the
relevant measure system. After elevation
of all the aggregate and other material,
control system discharges them to the

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HZS60 Concrete Batching Plant System Functions

mixer according to the technics order.

After mixing in a set time, system opens
the discharge gate of the mixer to feed the
concrete to truck mixer which will transport
the concrete to work site.

3.11.2.2 Structure and principle of the

control system

1. Structure of the control system

Electric control system of SANY concrete
batching plant is composed of electronic
measuring system (weighing terminal and
sensor), programmable logic controller
(PLC), signal input system (such as
sensor data collection), power driving
system (power cabinet, motor, solenoid
valve, etc.), dynamic simulating monitor
and data management (industrial process
computer). The structure of the control
system is shown in Fig. 3-40.

SYMC

Fig. 3-40 Structure of the control system

2. Principle instruction
Electronic measure system mainly collects
and transforms data by CAN bus net which
is composed of SANY data collection
module and display control module.

Working principle of the measuring system:

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System Functions HZS60 Concrete Batching Plant

transformed weight signal is transmitted

to CAN net via high accuracy sensor and
signal converter, and then PLC can collect
data from CAN net. Industrial process
computer communicates bidirectional
with PLC via net twine, and transmits
formulation and falling parameters. The
computer reads real-time weight from PLC
and displays them on the monitor interface.

Programmable logic controller (PLC)

is called lower-computer as shown in
Fig. 3-42 on page 3-49. M340 series of
Schneider PLC are adopted. In order to
complete production, PLC collects various
local signals and sends commands to
the upper computer to control various
movements of executive units as motor,
solenoid valve.

Power driving system is composed of

executive units of motor and solenoid
valve, and driving of these units.

Industrial process computer is called upper

computer in the control structure. It has two
tasks. One is to monitor and control the
whole product process. Monitor function
is to display the local state and collected
measuring data in cartoon simulation and
other visual methods by communication
with PLC and weighing terminals. Control
function is to send control parameters
and commands to PLC, in order to control
the production process. The other task
is to record information as material data,
production data and customer data. Then
produce several of production tables and
print them.

For detailed information about the

electrical diagrams, see: “8.1 Schematic
Electric Diagram of the Mixer” on page
8-3.

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HZS60 Concrete Batching Plant System Functions

The system adopts 380V, 50Hz 3-phase

4-wire system power supply. The total
installed power and section area of inlet
cable are shown in Table 3-6.

Considering the effect of capacity of

the transformer and inlet cable distance
decreasing voltage, the dimension of the
cable should be changed accordingly.

Table 3-6 Total installed power and inlet cable reference section of the system

Inlet cable (copper cable)

Model Total installed power (kW)
reference section (mm 2)
HZS60F 100 ≥3×70+1×25

3.11.2.3 Control of electronic measuring

system

Electronic measuring system is composed

of weighing sensor, weighing terminal and
sensor cable box.

Sensor collects weight signal to the

weighing terminal. The signal is amplified,
transformed, and displayed by the weighing
terminal, which also finishes batching and
discharging of the material. Industrial
process computer communicates with
weighing terminal and transmits parameters
to the weighing terminal as shown in Fig.
3-40 on page 3-45. It displays real-time
data read during weighing on the monitor
interface as shown in Fig. 4-4 on page
4-13.

1. Weighing sensor
Weighing sensor is called weighing
transmitter. Its function is to convert tensile
or pressure force signal to electrical signal.

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System Functions HZS60 Concrete Batching Plant

2. Sensor cable box

Sensor cable box shown in Fig. 3-19
on page 3-21 is a kind of connector. Its
function is to connect several sensors in a
special way.

3. Weighing terminal
Weighing terminal is batching controller,
which is a single chip system. Its functions
include A/D transition, display, input/
output, etc. Batching and discharging
process of the material can be completed
according to the input formulation.

3.11.2.4 Control of power driving system

Powder driving system is the strong current 1 2 3

part of the control system. Main units of the
system are installed in the power cabinet
as shown in Fig. 3-41, which includs main
power switch, breaker, contactor, current 4
transformer, control transformer, fuse, DC
switching mode power supply, etc.

Breaker is called air switch whose function 5

is to protect shortcut and overload of
the motor. Contactor is driven by output
6
contactor of the PLC which is used to
connect and cut off the motor. Breaker and
contactor compose the main circuit of the 7
motor control. RC suppressor module is
in parallel with the coil of the contactor.
It is used to release power produced by
reversing electromotive force during
the on/off of the contactor coil. It also
protects the output contactor of the PLC
and reduces interference in the system by
electromagnetism noise. Fig. 3-41 Units in the power cabinet
1- Main power switch 2- Current transformer
3- Contactor 4 -Frequency transformer
5- DC switching mode power supply
6- Control transformer 7-Breaker

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HZS60 Concrete Batching Plant System Functions

3.11.2.5 Hardware of the control system

Hard ware of the control system is SYMC,

The commercial machine and frequency
transformer used in the engineering
batching plant.

1. SYMC

SYMC is called lower-

computer in the control structure. It collects
local signal and control local device to
carry out logical task.
SYMC reads states of local devices into
the internal memorizer by the input units
connected with the input devices. Then
CPU analyses and calculates the states
of devices according to the pre-stored
working process code, and then writes the
output states to the units connected to the
driving units. Driving units drives executive
units to complete the required movement.

2. The commercial machine

IPC is called upper computer in the control

structure. It is used to manage data in the
control procedure and monitor the control
procedure via a visual method.

3.11.2.6 Software of the control system

Software adopted in the system contains
PLC software, monitor software, manage
software and database software.

1. SYMC software

PLC software can be compiled by 3

standard languages of the engineering
control software (structured text, ladder
diagram and FBD). The three languages
can be shifted from one to others. Ladder
diagram is frequently used. PLC software
is to complete the logical control task of
the batching plant working procedure.

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System Functions HZS60 Concrete Batching Plant

2. Monitor software

The main functions of the monitor

software include operator login and rights
management, simulation and monitoring
of various running states and movement,
setting and modifying of system
parameters, setting high priority manual
operation button on the interface, etc.

3. Management software

Its main functions are data processing

and advanced functions management,
which include task management, recipe
management, report management,
maintenance of the basic data of system,
etc. In addition, extending interface function
with other software, such as lab software,
financial software, etc. which composes
the administration of networks system via
networks can be supplied according to the
requirement of customers.

4. Database software

Database software is used to organise and

store data in the system. When the system
is running, database software is running.

For detailed information of functions

and operation of the software, see: “4
Operation” on page 4-5.

3.11.2.7 Control software system

function instruction

1. System configuration

Basic requirements:
Processor of P4, 2GHZ or above;
RAM of 128MB or above;
VGA, SVAG, LCD, resolution above
800×600;
Windows XP1.

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 HZS60 Concrete Batching Plant System Functions

management, report management,

maintenance of the basic data of system,
etc. In addition, extending interface function
with other software, such as lab software,
financial software, etc. which composes
the administration of networks system via
networks can be supplied according to the
requirement of customers.

2. Functional description
The software specially designed for SANY
concrete batching plant is the core for
controlling concrete batching plant. The
software can be applied for monitoring and
management.

1) Monitoring (For detailed information,

see: “4.3 Operation and Application of
Monitoring System” on page 4-19)

Automatic controlling of the whole

process as batching, unloading, mixing
and discharging, real-time display of set
value, weighing value, weighing error and
batching data, etc.
Pause the batching, feeding and
discharging automatically, and warn if an
unusual condition arises.

Automatic correction of preact, automatic

weight deduction, supplementation and
zero point following-up.

2) Management (For detailed

information, see: “4.4 Operation and
Application of Management System” on
page 4-42)

Real-time troubleshooting to assist

nonprofessional operator solve problems
easily during production.

Complete recipe management, including

maintenance such as recipe adding and

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System Functions HZS60 Concrete Batching Plant

modifying; detailed record of historical

recipe establishment, modify and deletion.
Complete report function.
Printing of various delivery orders; “block
building” function is available; the user
may adjust the format of delivery in order
to meet different demands.
Continuous production in sequence; when
a number of orders (with truck as the unit)
are given by the user, the control system
will carry out production according to
the orders in sequence, in order to fulfill
advanced batching upon shifting of tasks
and improve the productivity.
Online adjustment of sand and water
according to production demand; automatic
increase of sand and reduction of water
based on the water content of aggregates.

Manual/automatic shifting of functions and

combination of functions.

Strict password authorization, setup, clear

responsibilities and rights are defined
to improve the management level of the
batching plant.

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HZS60 Concrete Batching Plant Operation

Operation
4 Operation
4.1 Preparation and Precautions before Operation.......................................................4-5
4.1.1 Inspection before operation............................................................................4-5
4.1.1.1 Parts inspection of the concrete batching plant....................................4-5
4.1.1.2 Inspection of electrical units of the concrete batching plant..................4-7
4.1.1.3 Inspection of the software system.........................................................4-8
4.1.2 Selection and qualification of operators.........................................................4-9
4.1.3 Precautions during operation.......................................................................4-10
4.1.3.1 Basic requirement...............................................................................4-10
4.1.3.2 Precautions.........................................................................................4-11
4.2 Quick Start Operation Guide of the Concrete Batching Plant Control System......4-13
4.3 Operation and Application of Monitoring System...................................................4-17
4.3.1 Time parameters definition and setting........................................................4-17
4.3.1.1 Time parameters definition..................................................................4-17
4.3.1.2 Time parameters setting.....................................................................4-18
4.3.1.3 Automatically disable the material (Yes/No)........................................4-19
4.3.2 Sandstone batching interface and button functions.....................................4-20
4.3.2.1 Information instruction.........................................................................4-20
4.3.2.2 Button function....................................................................................4-21
4.3.3 Water, cement feeding interface and button function...................................4-22
4.3.3.1 Cement weighing system....................................................................4-22
4.3.3.2 Water weighing system.......................................................................4-23
4.3.3.3 Additive weighing system....................................................................4-23
4.3.4 Production process control and prompt function..........................................4-25
4.3.4.1 Production process control buttons.....................................................4-25

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Operation HZS60 Concrete Batching Plant

4.3.4.2 Production task queue display window...............................................4-26

4.3.4.3 Other information................................................................................4-26
4.3.5 Debugging....................................................................................................4-27
4.3.5.1 Instrument parameter..........................................................................4-27
4.3.5.2 Aggregate feeding setting...................................................................4-30
4.3.5.3 Striper set............................................................................................4-31
4.3.5.4 Other setting.......................................................................................4-31
4.4 Operation and Application of Management System..............................................4-32
4.4.1 Guidelines to functions of the management system.....................................4-32
4.4.2 Guidelines for the operation of system management menu.........................4-34
4.4.2.1 Data backup........................................................................................4-34
4.4.2.2 Data restore........................................................................................4-35
4.4.2.3 Database management function.........................................................4-35
4.4.2.4 System setup......................................................................................4-36
4.4.2.5 User management, login and cancellation..........................................4-38
4.4.3 Guidelines for recipe menu operation..........................................................4-39
4.4.3.1 Recipe manage...................................................................................4-39
4.4.3.2 Recipe view.........................................................................................4-41
4.4.3.3 Steps for deleting the login information of operator............................4-42
4.4.4 Guidelines for task menu operation..............................................................4-42
4.4.4.1 Steps for increasing production tasks.................................................4-42
4.4.4.2 Steps for viewing production tasks.....................................................4-43
4.4.4.3 Steps for modifying production tasks..................................................4-43
4.4.4.4 Steps for deleting production tasks.....................................................4-44
4.4.5 Guidelines for the operation of delivery manage menu................................4-44
4.4.5.1 Delivery order information...................................................................4-44
4.4.5.2 Modify of delivery order.......................................................................4-45
4.4.5.3 Delivery order printing.........................................................................4-45
4.4.6 Guidelines for inventory management menu operation................................4-46
4.4.6.1 Inventory management.......................................................................4-46
4.4.6.2 Material storage information (maintenance).......................................4-47
4.4.7 Guidelines for truck mixer management menu operation.............................4-47
4.4.7.1 Input, modify and deletion of truck mixer information.........................4-47
4.4.7.2 View and printing of truck information.................................................4-49
4.4.7.3 Shift of drivers.....................................................................................4-50
4.4.8 Guidelines for report management menu operation.....................................4-52

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HZS60 Concrete Batching Plant Operation

4.4.8.1 Manufacture dates report....................................................................4-52

4.4.8.2 Consumption report............................................................................4-53
4.4.8.3 Statistical report..................................................................................4-55
4.4.9 Guidelines for data management menu operation......................................4-57
4.4.9.1 Customer data management..............................................................4-57
4.4.9.2 Employee data management..............................................................4-59
4.4.9.3 Silo management................................................................................4-61
4.4.9.4 Batching plant data management.......................................................4-62
4.4.9.5 Construction part management...........................................................4-64
4.4.9.6 Pouring method maintenance.............................................................4-65
4.5 Production Operation and Other Setting...............................................................4-67
4.5.1 Production operation....................................................................................4-67
4.5.1.1 Automatic operation............................................................................4-67
4.5.1.2 Manual production operation..............................................................4-68
4.5.2 Washing operation.......................................................................................4-69
4.5.3 Shutdown Procedures..................................................................................4-70
4.5.4 Invoking method of the software..................................................................4-70
4.5.5 Setting of printer...........................................................................................4-71
4.5.6 Operation of system restore.........................................................................4-73
4.6 Other Operation.....................................................................................................4-75
4.6.1 Other Operation............................................................................................4-75
4.6.2 Operation of winch (elevator).......................................................................4-75
4.6.2.1 Opreation of the elevator steel wire rop..............................................4-75
4.6.2.2 Proximity switch of the elevator..........................................................4-82
4.6.2.3 Other precautions of the elevator........................................................4-86
4.6.2.4 Special statement...............................................................................4-87
4.6.3 Operation of mixer........................................................................................4-87
4.6.3.1 Delivery of the mixer...........................................................................4-87
4.6.3.2 Transport of the mixer.........................................................................4-87
4.6.3.3 Installation of the mixer.......................................................................4-88
4.6.3.4 Drive of the mixer................................................................................4-89
4.6.4 Operation of the air compressor...................................................................4-90
4.6.4.1 Preparation and installation of the air compressor..............................4-90
4.6.4.2 Operation of the air compressor.........................................................4-91
4.6.5 Operation of additive pump..........................................................................4-93
4.6.5.1 Startup of additive pump.....................................................................4-93

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Operation HZS60 Concrete Batching Plant

4.6.5.2 Disassembly and assembly of additive pump.....................................4-95

WARNING
Always read the Safety section of this
manual before attempting to operate
this equipment. Failure to do this could
result in machine damage, personal
injury or death.

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HZS60 Concrete Batching Plant Operation

4 Operation
Read and understand this chapter carefully
before operation to use the plant in a better
way, improve its reliability and reduce
repair expense and down time. Strictly
operate according to safety requirements
in Chapter 2 “2 Safety” on page 2-3.
Consult SANY technical department when
you have questions to ensure correct
operation. SANY shall not be liable for any
consequences resulting from operation
not in compliance with the requirements
of this manual. Damage caused by natural
disaster like lightning stroke is not included
in the free maintenance.

4.1 Preparation and Precautions

before Operation
4.1.1 Inspection before operation

4.1.1.1 Parts inspection of the concrete

batching plant

1. Check the sealing of every conveying

system

Check whether the connections (such as

the inlet of the screw conveyor and inlet of
the mixer shown in Fig. 3-1 on page 3-6)
are reliable and have no powder leakage.

2. Check and test the belt weigher

a) Check the center straightness and two

side levelness of the belt weigher frame;
rotation flexibility of each idler and drum;
whether the scraper contacts evenly with
the belt and can rotate freely; whether
tightness of the belt is proper; and whether
the axes of drums are level and parallel
with each other.

b) Test belt weigher: Ensure the right

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Operation HZS60 Concrete Batching Plant

rotating direction of the belt. Ensure the

E-STOP button as shown in Fig. 2-41 on
page 2-29 is fixed well and reliably. Press
E-STOP button during belt running without
load to observe if the belt stops.

c) Check the wear and tear of belt weigher.

Check whether there are problems like
breakage and damage. If the problems are
serious, change the belt in time.

3. Check powder silos

a) Ensure the connections of powder

silos are firm as shown in Fig. 3-3 on
page 3-9. Perpendicular error of the axis
of the powder silo and ground should be
not more than 2‰.
b) Check whether the manual butterfly
valve of the powder silo as shown in Fig.
3-3 on page 3-9 is open.

4. Check the connection and sealing of

pipelines

Check whether the pipelines for air supply,

water supply and additive supply (see
Fig. 3-15 on page 3-17) are expedite or
leaked. Ensure there is no water or air
leakage.

5. Check whether the connections are

firm

Check fasteners (as bolts and nuts) for

looseness. Ensure there is no looseness.
Anti-loosing measures should be taken on
the bolts. The tightening torque of the bolt
should be suitable. Drop-proof measures
should be taken on axis pins.

6. Check whether the lubricant supply

is enough

a) Check every lubrication position, and

add proper grease and lubricant oil (For

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HZS60 Concrete Batching Plant Operation

detailed information about lubrication

position, see: “5.7.1 Lubrication part of
the batching plant” on page 5-113).

b) Check whether the grease in the

centralized lubrication oil cylinder is
sufficient.

c) Check whether the lubricant in the

other rotation parts is sufficient.

7. Check whether the materials are

sufficient

Check whether there are enough

aggregates, powder, water and additives.

8. Check if there is residue in the mixer.

Check whether there is residue in the

mixer and clean it (see Fig. 4-1).

4.1.1.2 Inspection of electrical units

of the concrete batching plant
Fig. 4-1 Check the mixer
1. Check whether the electrical line is
normal

Check whether the electrical line is correct;

the connection is firm. Ensure truck mixer
and feeding machine will not damage the
device during working. Ensure insulation
of the electrical line. Resistance of the
batching plant to the ground is not more
than 4Ω.

2. Check whether all switches can be

operated normally

a) Open the overhaul door to check

whether the inspection switch as shown
in Fig. 5-70 on page 5-47 is operated
normally.

b) Operate the discharge gate manually

to check whether the proximity switch
as shown in Fig. 5-68 on page 5-45 is

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Operation HZS60 Concrete Batching Plant

moving normally.

3. Check whether the switches are on

the correct position

a) Check whether all the switches are at

normal positions.

b) Before operate the batching plant,

ensure all the switches in the power
cabinet as shown in Fig. 3-41 on page
3-48 are switched on. Turn on the main
power switch and breakers as required,
and then close the cabinet door. Turn the
voltage universal conversion switch on the
power cabinet to observe whether every
phase of voltage is normal.

c) Turn the voltage universal conversion

switch on the power cabinet as shown
in Fig. 3-41 on page 3-48 to observe
whether the 3-phase voltage is normal. If
VAB=VBC=VCA=380V±38V and V0=0V,
the 3-phase voltage is normal. Otherwise
please check inlet voltage.

d) Ensure the normal of the 3-phase

voltage, turn the power switch on the
power cabinet door as shown in Fig. 3-41
on page 3-48.

e) Press the startup button of the air

compressor on the power cabinet door.

4.1.1.3 Inspection of the software system

Start up the computer and enter the

system interface. Double click icon “sany.
exe” (to run the monitor program) on
the desktop as shown in Fig. 4-2. Singly
click management system to operate the
management program. Observe whether
there is alarm information on the alarm
window. Remove the faults according to
the alarm information. Ensure there is
no alarm information, and then produce Fig. 4-2 “sanycan.exe” on the desktop

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concrete according to the requirement. Pay

attention to the indicator lights and working
procedures, and deal with the problems in
time. For detailed information, see: “4.3
Operation and Application of Monitoring
System” on page 4-17.

4.1.2 Selection and qualification of

operators

1. Operators

a) Working responsibilities: operate and

control the concrete batching plant.

b) Personal conditions: 18~55 years old,

and healthy, at a normal IQ level.

c) Only those technically trained

personnel who are proved to have the
operating ability may operate the batching
plant.

For detailed information, see: “2.6

Requirement of the operator” on page
2-16.

2. Welder and electrician

a) Welder: welders must be personnel

with valid certificate, and they mainly
handle cracks on the welded structural
parts of the batching plant (such as
welding between outrigger installation
plate and embedded part of foundation,
welding of staircase platform, and other
important parts).

b) Electrician: electricians must be

personnel with valid electrician certificate,
and they mainly handle electric lines of the
batching plant, connection, modification,
and upgrading of electric elements, and
other operations.

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Operation HZS60 Concrete Batching Plant

Contact us when any structural part of

the batching plant cracks or the electric
system fails. It is prohibited to do repair
welding or make modification without
authorization, and SANY shall not be
liable for any consequence hence caused.

3. After-sales engineer

a) Job responsibilities: after-sales

engineers are mainly responsible for the
maintenance of the batching plant, including
troubleshooting, daily maintenance
direction, replacing of accessories, and
system upgrading, etc.

b) Personal skills: SANY after-sales

engineers designated everywhere should
all have been trained by SANY. They
may cope with various faults of the
batching plant and provide each user
with one-to-one service independently. If
you have any question on the function,
operation, maintenance and servicing of
the equipment, you may call the service
hotline 0086-40088788318, and contact
with the service scheduling center. We will
try our best to help you.

4.1.3 Precautions during operation

4.1.3.1 Basic requirement

1. Power

The system adopts 380V, 50Hz, and

3-phases 4-wires (TN-S) power supply.

2. Operator

Operators are responsible for operating

and controlling the concrete batching
plant. Operators must be skilled workers

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HZS60 Concrete Batching Plant Operation

who have received training. They should

keep emotion normal, clear-headed, and
quick reaction.

For detailed information, see: “2.6

Requirement of the operator” on page
2-16.

4.1.3.2 Precautions

1. Forbid to touch the transmission

parts

It is strictly forbidden to touch the

transmission parts during the operation
of the batching plant, especially the belt
weigher as shown in Fig. 3-28 on page
3-31. If maintenance is needed, you must
stop machine and cut off the main power
switch.

2. Deal with the malfunction

Press the E-STOP button, when emergency

malfunction occurs. For detailed
information about the E-STOP button, see
“2.9.2 E-STOP button” on page 2-28.

3. Startup of the mixer and conveying belt

Mixer and conveying belt can’t be started

up with load, or the performance of the
device will be decreased and the service
life will be shortened.

4. Deal with the network problems of IPC

Network interface of the IPC is closed when

it leaves factory. If customer needs to use
the network interface, please contact with
our technical department to take measures
of lightning protection.

5. Operation of the software

a) If you shift into manual operation mode,

before automatic weighing of next cycle,

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Operation HZS60 Concrete Batching Plant

obverse the waiting hopper to ensure

there is no aggregate, and then you can
weighing again.

b) If there are problems in automatic

operation, please check the record cycles
in the computer. You can produce the left
cycles manually, and check the problems
(it is suggested that use the manual mode).

For detailed information of the software,

see: “4.3 Operation and Application
of Monitoring System” on page 4-17,
and “4.4 Operation and Application of
Management System” on page 4-32.

6. Precautions during operating the

hydraulic and air line

a) Fluid supply system includes additive

supply system and water supply system.
Water for mixing is always clean water. But
clean industrial water recycled from the
flushing device is adopted too.

b) The inlet of the air filter must be

kept clean to prevent decreasing of the
air supply caused by jam. For detailed
information, see: “4. Maintenance of air
compressor” on page 5-99.

c) Open the exhaust valve of the air

compressor as shown in Fig. 5-133 on
page 5-94 to discharge the air before the
machine is started and after it is shut off.

d) Prevent scrap iron, dust and fragments

of sealing material from entering into the
pipes during maintenance. Blow and clean
the pipeline with compressed air.

e) During maintenance, pay attention to

not leave the sundries and fragments like
adhesive tape in the tube.

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4.2 Quick Start Operation Guide

of the Concrete Batching Plant
Control System
This section will introduce you the quick
start operation guide of the concrete
batching plant with the control system.

Step 1: Click the shortcut “sany.exe” on

the desktop as shown in Fig. 4-2 on page
4-8 to start the software (see Fig. 4-3).

Fig. 4-3 L o g i n w i n d o w o f t h e c o n c r e t e
batching panlt control system
Step 2: Input “Operator“ name and
“Password”, click “Confirm” button shown
in Fig. 4-3 to enter SANY concrete batching
plant control system interface as shown in
Fig. 4-4.

Fig. 4-4 SANY concrete batching plant control system interface

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Operation HZS60 Concrete Batching Plant

Step 3: Click “MANAGE” button shown in

Fig. 4-4 to pop up a window (see Fig. 4-5).

Fig. 4-5 L o g i n w i n d o w o f t h e m a n a g e
system

Step 4: Input “User” name and “Password”,

click “Login” button in Fig. 4-5 to enter the
management system (see Fig. 4-6).

Fig. 4-6 Manage system of concrete batching plant

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HZS60 Concrete Batching Plant Operation

Step 5: Determine concrete recipe. Click

“Recipe Manage” on “Recipe” pop menu
shown in Fig. 4-6 on page 4-14 or click
on the right of the “Recipe Number”
shown in Fig. 4-4 on page 4-13 to pop up
manage window of recipe (see Fig. 4-7).
Click “Add”, “Modify”, “Delete” to perform
the establishment and modify operation
etc. as demanded. Click “Save” to finish
setup of the recipe database after those
operation, or click “Cancel” to cancel the
setting. Click “Close” to quit the recipe
edit window. For detailed information
about recipe management, see: “4.4.3
Guidelines for recipe menu operation”
on page 4-39.

Fig. 4-7 Manage recipe window

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Operation HZS60 Concrete Batching Plant

Step 6: Establish a production task. Click

on the right of the “Task Name”
shown in Fig. 4-4 on page 4-13 to pop
up manage task window (see Fig. 4-8).
Click “Add” button to input information
about production task. (“Task ID” can
be created automatically or modified
manually. “Task-name” is necessary. It is
suggested selecting “Recipe Name” and
inputting “Plan Quantity”. Other items are
not essential.) After inputting production
task information click “Save” button to
establish production task. Click “Close”
to exit edit task widow and carry out next
step. For detailed information of task
management, see “4.4.4 Guidelines for
task menu operation” on page 4-42.

Fig. 4-8 Manage task window

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HZS60 Concrete Batching Plant Operation

Step 7: Start production. Click “Run”

button on the right lower of control system
interface shown in Fig. 4-4 on page 4-13
to initiate the system for production.

4.3 Operation and Application

of Monitoring System
This chapter mainly introduces the
interface and functions of the monitoring
system of concrete batching planting.

The layout on the main monitoring interface

(see Fig. 4-9) simulates the production
interface and status. Buttons controlled by
mouse in corresponding positions of the
process can be applied to interfere with
the production.

Fig. 4-9 M o n i t o r i n g s y s t e m o f c o n c r e t e
batching plant

4.3.1 Ti m e p a r a m e t e r s d e f i n i t i o n
and setting

4.3.1.1 Time parameters definition

This section will introduce meanings of

parameters. Click “SET→Time setting” on
the right upper position of the monitoring
system shown in Fig. 4-9 to pop up the
time setting window as shown in Fig. 4-10.

Fig. 4-10 Key time setting of the interface

1. Half open time
It refers to the period discharge gate kept
half-open during the mixer discharging
automatically

2. Full open time

It refers to the period discharge gate kept

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Operation HZS60 Concrete Batching Plant

full-open during the mixer discharging

automatically.

In order to discharge concrete product

safely and quickly into truck mixer, the
opening position is classified into two
grades, which is respectively named as
“half-open” and “full-open”. The “half-
open” can be adjusted manually to
control the discharge speed. The “full-
open” position is fixed and it cannot be
adjusted.

3. Enhance the fight rising time

After all the aggregate discharged from

the aggregate weigher hopper, time of all
the aggregate discharged to the waiting
hopper refers to the “AGG Up”. During
the process of automatic production, the
aggregate waiting hopper will display
“occupied” if the time is up. Otherwise, it
will display red “not occupied”.

4. Enhance the fight durationtime

It refers to the period of aggregate

discharging from the waiting hopper to
mixer. That is the period of waiting hopper
discharging gate staying open.

5. Mixing time

After all the material fed into the mixer,

the required mixing time in the mixer for
specified quality refers to the “Mix Time”.

4.3.1.2 Time parameters setting

Usually, the above parameters should be

optimized by the operator of batching plant
to achieve the best efficiency. The general
principle of setting is to shorten the time
of each procedure while guaranteeing

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HZS60 Concrete Batching Plant Operation

the stability and smooth production. For

example, in the circumstance without
material leakage (truck mixer receiving
material normally), reducing the “Half
Open Time” as much as possible and
properly increasing the “Full Open Time”
shorten the total discharging time while
completing discharging.

4.3.1.3 Automatically disable the

material (Yes/No)

There’s a “Yes/No” button on left top

position of the monitoring system as shown
in Fig. 4-9 on page 4-17, which provide
options to confirm whether the automatic
discharging is forbidden for the first cycle
production for each delivery order. Select
“Yes” is to forbid automatic discharging in
the first cycle of each delivery order. Select
“No” to discharge automatically every
cycle. This option is to remind operator to
confirm the material receiving position of
truck mixer. After confirmation the mixer
can be discharge.

The automatic forbidding of discharge is

an auxiliary function, which can prevent
the advanced open of discharge gate
and thus to ensure the proper discharge.
In general, it can be set as “Yes” during
working at night. After operator confirming
the truck mixer under the receiving
location, click “Pause Discharge” under Fig. 4-11 "Discharge" button
the right interface shown in Fig. 4-9 on
page 4-17 (zoomed as shown in Fig.
4-11) to realize automatic discharging
after production. If the operator doesn’t
confirm, even if the first cycle of mixing is
completed (counting down of mixing time
is completed and finished product of this
cycle is completed), automatic discharging
will not be carried out.

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Operation HZS60 Concrete Batching Plant

4.3.2 Sandstone batching interface

and button functions

This section introduces sandstone

batching system interface as shown in
Fig. 4-12 from the top to bottom, including
explanations to information displayed in
the interface and button functions.

4.3.2.1 Information instruction 1

1. Water content for AGG 2
3
The top number shown in Fig. 4-12
indicates the percentage of moisture in
the aggregate. User can adjust the recipe 4
according to this data.

2. Aggregate bins information (AGG1,

AGG2, AGG3, AGG4) Fig. 4-12 S a n d s t o n e b a t c h i n g i n t e r f a c e
and button functions
The interface shown in Fig. 4-12 indicates
1-Water content 2-Material name
aggregate bins from left to right, distributed
3-Batching bins 4-Weigher hoppers
from the end far from the inclined belt
to the end near the inclined belt in the
installation site.

If the recipe value is zero, and then the

color of words representing corresponding
bin becomes red from green.

3. Batching bin

The three grade I silos shown in Fig.

4-12 are batching bins. A vibration motor
is installed on the sand batching bin to
increase the weighing speed.

4. Weigher hopper

The four grade II hoppers at the bottom of

Fig. 4-12 are called as weighing hoppers,
each of which is provided with a discharge
gate at the bottom. A vibration motor used
for speeding up the discharge of sand is
also installed to the sand weighing hopper.
For detailed information, see: “1. Manual

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HZS60 Concrete Batching Plant Operation

discharge and discharge vibration” on

page 4-21.

4.3.2.2 Button function

In this section, buttons of the batching plant

shown in Fig. 4-12 on page 4-20 will be
introduced, such as manual and automatic
weight deduction, manual coarse, precise
weighing and batching, manual discharge,
sand batching vibration and discharge
vibration, run and stop operation for the
batching station. User should read this
section carefully to understand manual
operation of the batching plant.

1. Manual discharge and discharge

vibration

Weigher hopper is introduced in the last

section. As shown in Fig. 4-13, a dark green
rectangle button called as “discharge”
button is arranged under the four grade
1
II weigher hoppers. The left side of the 2
sand weigher hopper is provided with a
small dark green button, called “discharge
vibration”. When the cursor is moved to
a button, words will appear to introduce
functions of such button. Fig. 4-13 “Discharge” button
1-Discharge vibration 2-Discharge
When manual control is applied, click
corresponding button to discharge or
vibrate for accelerating the discharge.

2. run and stop button

As shown in Fig. 4-14, there are two

buttons under the belt weigher. The left
green one is “run” button for restart the
batching station and belt weigher if they 1
are pause stopped. The right red one is 2
“stop” button for stop the batching station 3
and belt weigher if there’s something Fig. 4-14 "Run" and "stop" button
emergent. 1-Belt weigher 2-”Run”button 3-”Stop” button

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Operation HZS60 Concrete Batching Plant

4.3.3 Water, cement feeding interface

and button function

This section introduces water, cement

feeding interface, including explanation
to information of the interface and button
function.

4.3.3.1 Cement weighing system 1

1. Cement silo 2

Words in the top row describe material

name (see Fig. 4-15). 3
4
Manual discharge button shown in Fig.
4-15 is applied for manual discharging
of silo (during the manual weighing, the
materials of corresponding powder will be
weighed when click such button).

The flashing green line shown in Fig. 4-15

at the bottom of the powder silo indicates
Fig. 4-15 Coment silo
the sufficient of materials (it is green when
1-Material name 2-Cement silo
materials are shortage). 3-Green line 4-Manual discharge button

2. Cement weigher hopper

a) Manual feeding button: the dark green

button on the cement weigher hopper as
shown in Fig. 4-16 is used to feed the
cement powder into the weigher hopper.

b) Manual discharge button and vibration

button: There are vibration button and
manual discharge button effective during
the normal working of mixer.

1
2
3

Fig. 4-16 Cement weigher hopper

1-Cement weigher hopper 2-Vibration button
3-Manual discharge button

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HZS60 Concrete Batching Plant Operation

4.3.3.2 Water weighing system

According to Fig. 4-17, the water weighing

system includes: water pool, water feed
pipeline, batching value and dynamic
actual value display window, water weigher
hopper and manual discharge button.

1. Water pool

The information of water pool covers

material name. In addition, one manual
feed button shown in Fig. 4-17 is arranged
on the water pool to initiate the pump for
feeding.

2. Water weigher hopper:

Water weigher hopper, weighing error

state display button and manual discharge
button on the lower left side are arranged
1
at the end of water feed pipeline as shown
in Fig. 4-17. 2

a) Weighing error state: The square box

3
at the cone of multi-purpose weigher
hopper shown in Fig. 4-17 is a weighing
error state window, with functions same
4
as those of cement weigher hopper.
For detailed information, see: “4.3.3.1
Cement weighing system” on page 4-22. 5
b) Manual discharge button: A dark green
button called as manual discharge button
shown in Fig. 4-17 is arranged on the
Fig. 4-17 Water weighing system
left side of water weigher hopper cone. 1-Water pool 2-Water feeding button
(Effective during the normal working of 3-Manual feeding pipeline
mixer) 4-Water weigher hopper
5-Manual discharge button

4.3.3.3 Additive weighing system

According to Fig. 4-18 on page 4-24, the

additive weighing system includes: two

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Operation HZS60 Concrete Batching Plant

additive tanks, two additive feed pipelines,

batching information box, actual value
display window, a weigher hopper and
corresponding discharge button.

1. Additive tank

Each additive tank includes a tank, and

a tank selection button as shown in Fig.
4-18.
1
Words on the tank describe material 2
name and model (material name cannot
be modified; however, the model may be 3
modified; see “4.4.9.4 Batching plant
data management” on page 4-62 for
detailed information.
4
Manual feeding button shown in Fig.
4-18 means: during the manual weighing,
the materials of corresponding additive 5
tank will be weighed when clicking such
button; during the automatic production,
the system will select tank automatically
according to recipe). Fig. 4-18 Additive weighing system
1-Additive tank 2-Additive feeding button
2. Additive weigher hopper 3-Manual feeding pipeline
4-Additive weigher hopper
Manual feed buttonas shown in Fig. 4-18 5-Manual discharge button
is arranged on additive weigher hopper .
When clicking such button manually, the
materials inside corresponding tank will be
weighed.

3. Manual discharge button

Manual discharge button as shown in Fig.

4-18 is arranged at the bottom of additive
batching value and actual batching
information display window. During the
normal production and when manual
control mode is applied, the user may
click such button to discharge additive into
water weigher hopper for dilution.

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4.3.4 P r o d u c t i o n p r o c e s s c o n t r o l
and prompt function
4.3.4.1 Production process control
buttons

Besides dark green buttons used for

manual control of materials, SANY
concrete batching plant monitoring
interface involves manual interference
control buttons during the production of
concrete, which are shown in Fig. 4-19.
Detailed explanations to each button are
listed below.
Fig. 4-19 Production process control button
1. Initiate production

After the task is exported, saved for

production and if the recipe is downloaded
successfully, the user may click “Run”
button shown in Fig. 4-19 to initiate the
production.

2. Cancel production

In the process of production, the user may

click “Stop” button shown in Fig. 4-19 to
stop the production task undergoing and all
tasks in the queue. Apart from the moving
mixer and belt, other equipment will stop
and return to the initial condition.

It is strongly recommended that the

user dispose materials inside the mixer
and weigher hopper manually after the
production is cancelled.

3. Manual and automatic shift button

Apart from the display of current production

state (manual, automatic), such button can
also serve for the manual and automatic
shifting of production state.

When “Manual” button shown in Fig.

4-19 is clicked during the production, all

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Operation HZS60 Concrete Batching Plant

the equipment except mixer and belt will

stop and return to initial condition. The
mixing time will be counted continuously.
In addition, the “Manual” button will
become the “Auto” button. After the
manual operation is finished, the user may
click “Auto” button to return to automatic
production and continue the unfinished
production.

4. Discharge

“Pause Discharge” button shown in

Fig. 4-19 on page 4-25 is applied to
forbid the discharge of the mixer, even
when the mixing time is up; and stop the
discharge instantly, when the materials
are undergoing the discharge.

This button can only be used under an

emergency. The materials cannot be left
inside the mixer for a long time.

4.3.4.2 Production task queue display

window
The task under production and that to
be carried out are displayed on the left
lower corner of the control interface. Due
to limited space, only the top three tasks
are displayed in Fig. 4-20. The first row
indicates the task undergoing will be
shown as green. The upper part of such
window also displays detailed information
of the task undergoing. Fig. 4-20 Production task queue display window

4.3.4.3 Other information

Apart from above information, the control

interface shown in Fig. 4-9 on page 4-17
also shows maintenance information of the
mixer, emergency stop information, cycle
information and related alarm information
etc.

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HZS60 Concrete Batching Plant Operation

The mixer menu will show corresponding

notice when it is under maintenance or the
emergency-off button is pressed down.

“Count” under the mixer shown in Fig. 4-9

on page 4-17 is applied to record finished
cycles of delivery order for current task.
When the detection signal cannot meet
the demand for normal operation, the
system will pop alarm window under the
maintenance information of the mixer, thus
to remind the user to dispose the abnormal
situation.

4.3.5 Debugging

Click “Debug” button on the control

interface shown in Fig. 4-4 on page 4-13
to enter debugging data setting window as
shown in Fig. 4-21 and set data including
instrument parameter, aggregate weighing
setting, discharge setting and others.

4.3.5.1 Instrument parameter

The instrument parameter setting interface

is shown in Fig. 4-21. Seeing from such
figure, this interface can be applied to set
all the weighing instruments of the batching
plant, including “Target”, “Fine”, “Preact”,
“Alarm” and “Compensate”. “Fact”is used to
display the state of weighing instruments.
The meaning of each setting and display is
respectively introduced below. Fig. 4-21 I n s t r u m e n t p a r a m e t e r s e t t i n g
interface

1. Target
Such value refers to the target weighing
value of corresponding material. Being
different from that of the value in “Manage
recipe” interface shown in Fig. 4-7 on page
4-15, clicking the finger-shape cursor on
“Target” box shown in Fig. 4-21 will pop
the target weighing value modify window

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Operation HZS60 Concrete Batching Plant

as shown in Fig. 4-22. Input the target

value and click “OK”; the modification is
successful when the modification value is
displayed in the box.

Fig. 4-22 Modify target interface

2. Fine

The value refers to the precise weight

(for two-speed weighing system) of
corresponding material. Clicking the finger
shaped cursor on “detailed setting” box
will pop the detailed setting modify window
as shown in Fig. 4-23. Input the target
value and click “OK”; the modification is
successful when the modification value Fig. 4-23 Modify fine interface
is displayed in the box. This setting can
cooperate with “4.3.5.2 Aggregate
weighing setting” on page 4-30 to
improve the aggregate weighing speed
and precision to the utmost.

3. Disparities

Such value refers to the fall (also called

as advance quantity, which is applied to
compensate the feeding) of corresponding
material. Move the cursor to “preact” box
of corresponding material; click the box
when the cursor becomes a finger, then, a
fall modify window as shown in Fig. 4-24
will appear; input value and click “OK”;
the modification is successful when the
Fig. 4-24 Modify disparities interface
modification value is displayed in the box.

4. Actual

The value refers to the actual consumption

of corresponding material. The difference
between this value and the “Target” is the
absolute weighing error. This value cannot
be modified here, because it is uploaded
from the weighing system.

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5. Alarm

The value is the error limit for corresponding

material (when the weighing error reaches
or exceeds such value, the control system
will stop operation temporarily and pop
weighing error alarm window and button
on the control interface; then, the system
can only continue the production after
measures are applied and the button is
clicked for confirmation). Move the cursor
to “error on alarm” box of corresponding
material; click the box when the cursor
becomes a finger, then, an alarm error
modify window as shown in Fig. 4-25 Fig. 4-25 Alarm error change interface
will appear; input value and click “OK”;
the modification is successful when the
modification value is displayed in the box.

6. Compensate

With such function, the system can

automatically calculate weighing error of
corresponding material in the production
of this cycle and make compensation
in the next cycle. That is, the system
automatically modifies the target weighing
value to compensate the error of last cycle.
Theoretically speaking, such function
can reduce the weighing error to 1/3 and
even lower in comparison with the original
one. The user may tick the small box in
front of the “Auto” shown in Fig. 4-21 on
page 4-27 item to initiate the automatic
compensation. Such function is cancelled
when the small box is empty.

Usually, the fine of aggregate ranges

from 250 ~ 400, the preact (advance
quantity) of aggregate ranges from 0 ~
10; powder, water and additive are fed in
single speed and only preact (advance
quantity) is supposed to be set; power

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Operation HZS60 Concrete Batching Plant

preact (advance quantity) related to the

size of spiral tube ranges from 0 ~ 30;
the preact (advance quantity) of water
and additive is related to pipeline and
water pump power; generally speaking,
the preact (advance quantity) of water
ranges from 0~ 45 and that of additive
ranges from 0 ~ 1.5.

4.3.5.2 Aggregate weighing setting

Click “Debug” button on the control

interface shown in Fig. 4-4 on page 4-13
to enter system parameter setup window
as shown in Fig. 4-21 on page 4-27.
The user may set instrument parameter,
aggregate weighing setting, discharge
setting and others on this window. Clicking
the header of “Agregate weighing set”, the
interface will shift to aggregate weighing
setting window as shown in Fig. 4-26.
Such interface is used to set the open
time of precise aggregate weighing gate
impulse and confirm whether the coarse
weighing is applied
.
Fig. 4-26 Aggregate weighing setup
1. AGG fine feeding gate pulsation
open time

SANY batching plant conducts coarse

weighing of aggregate with two gates
and precise weighing of aggregate with
one gate. In general, the impulse period
is 2s (adjustable as demanded). In Fig.
4-26, “Aggregate fine, sand door pulsating
opening time” is the time when precise
weighing gate is open and it is generally
set as 5 (0.5s) before delivery (the set
range is 1~10). The user may modify the
time according to the actual situation.

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2. Normal completion time

“Sand batching scales normal completion
time” is the time when the shortage of
grit is overtime, then the vibration of the
weighing bin will be automatically shut
down, and it is generally set as 10~15s.
The user may modify the time according to
the actual situation.

4.3.5.3 Stripper set

Click “Debug” button on the control

interface shown in Fig. 4-4 on page 4-13
to enter system parameter setup window
as shown in Fig. 4-21 on page 4-27.
The user may set instrument parameter,
aggregate weighing setting, discharge
setting and others on this window. Clicking
the header of “Stripper set”, the interface
will shift to discharge setting window as
shown in Fig. 4-27. Such interface is used
to set the discharging delay time, after
material in the waiting hopper discharged
to the mixe. It can reduce the concussion
of mixer caused by material discharging
together. It is set to 0 for water or additive,
6 for powder, and delay time of powder
must not be less than water.
Fig. 4-27 Stripper set interface

4.3.5.4 Other setting

As shown in Fig. 4-28, this part is for

setting window displayed on the main
monitoring interface shown in Fig. 4-9
on page 4-17, such as “Automatic Alarm
window”, “Show automatic bell”, “Display
the remaining”, “Show withholding water”,
“Error compensation target”. The user may
select the “√” before corresponding choice
the according to the actual demand.
Fig. 4-28 Other setting interface

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Operation HZS60 Concrete Batching Plant

4.4 Operation and Application

of Management System
This chapter mainly introduces the
functions and operation steps of the
concrete batching plant management
system shown in Fig. 4-6 on page 4-14.
It includes functions as: data backup,
data maintenance, delivery order print
setup and system setup, user authority
management, production task manage, log
view, delivery order view, storage manage,
truck manage, report manage, etc.. They
will be separately introduced as below.

4.4.1 Guidelines to functions of the

management system

● ● Data backup, data restore and database

management can be realized through
“System Manage” menu. See “4.4.2
Guidelines for the operation of
system management menu” on page
4-33 for detailed operation method.
● ● Batching plant information setup and
view functions can be realized through
“Data Maintenance → Construction site
data maintenance” menu. See “4.4.2.4
System setup” on page 4-36 “4.4.9.5
Construction part management” on
page 4-64 for detailed operation
method. Fig. 4-29 Management system of concrete
● ● Delivery order print setup and system
setup can be fulfilled through “System
Manage →System Setup” menu. See
“4.4.2.4 System setup” on page 4-36
for detailed operation method.
● ● User (operation) authority management,
login and cancel functions can be
fulfilled through “System Manage”
menu. See “4.4.2.5 User management,

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login and cancellation” on page 4-38

for detailed operation method.
● ● Recipe data management can be
fulfilled through “Recipe” menu. The
addition, modify and view of recipe are
referred to “4.4.3.1 Recipe manage”
on page 4-39.
● ● The establishment, modify and deletion
of concrete production task can be
fulfilled through “Task Manage” menu.
See “4.4.4 Guidelines for task menu
operation” on page 4-42 for detailed
operation method.
● ● View of the current status of delivery
order, setup of delivery order and
listing function is illustrated in “4.4.5
Guidelines for the operation of
delivery manage menu” on page 4-44
for detailed operation method.
● ● Storage manage is illustrated in “4.4.6
Guidelines for inventory management
menu operation” on page 4-46.
● ● Truck manage, including input, modify,
deletion of vehicle information,
information view and printing, view of
the shifting of drivers are illustrated
in “4.4.7 Guidelines for truck mixer
management menu operation” on
page 4-47.
● ● Report manage, including production
details, is illustrated in “4.4.8
Guidelines for report management
menu operation” on page 4-52.

4.4.2 Guidelines for the operation

of system management menu
4.4.2.1 Data backup

This function is used to back up the data

saved in database and ensure data safety.

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Operation HZS60 Concrete Batching Plant

If the data is required to be imported into

Excel table for filing or as the statistical
evidence, the report can be applied to
import data. See “4.4.8 Guidelines for
report management menu operation” on
page 4-52 for exact ways of operation.

Steps for fulfilling the function:

Enter the management system as shown

in Fig. 4-29 on page 4-32; click “System
Manage → Database Backup” to pop data
backup window as shown in Fig. 4-30.

Set according to the data noted on the

figure. The default setup is “Server Name: Fig. 4-30 Backup database window
sany9; Database: jxc”. Click “…” sign
behind “Select a location for the backup
file” to pop “save as…” list box. Find the
target path, and input file name of backup
data at “file name” box (The current time
is recommended for naming the file. Make
sure the name is different from that of
existing backup files), then click “Backup”
to return data backup window. Click “Test
Connection” to check the inspection setup;
click “Close” to exit data backup window
without backup; click “Backup” to create
backup document at appointed position
and indicate “Backup succeeded” as
shown in Fig. 4-31. Now, the data backup
is successful. Fig. 4-31 Notice of successful operation

4.4.2.2 Data restore

This function is mainly applied to recover

the files created in “4.4.2.1 Data backup”
on page 4-33. Data restore will cover all
existing data in the database. Back up
existing data prior to restore, in order to
ensure the data can be recovered.

Steps for fulfilling the function:

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Enter the management system as shown

in Fig. 4-29 on page 4-32, click “System
Manage→Data Restore” to pop data
restore window as shown in Fig. 4-32.

Set according to the data noted on the

figure. The default setup is Server Name:
sany9; Database: jxc”. Click “…” sign
Fig. 4-32 Data restore window
behind “select backup file” to pop “Open”
list box. Find and click the file to be
recovered, and then click “Open” to return
to data restore window. Click “Close” to
exit data restore window without restore;
click “Restore” to recover data. “Backup
succeeded” shown in Fig. 4-33 will appear
Fig. 4-33 Notice of successful recovery
provided the restore is successful. Then,
click “OK” to exit data restore window.
Login the management system again after
data restore.

4.4.2.3 Database management function

This function is applied to manage the
data of database. The user may delete
production details and delivery orders
data of a given period, information about
all the customers, suppliers, checkers,
cement, construction places and vehicles
etc., recipe and tasks data (caution: the
deleted data cannot be recovered). When
it is required to delete some information,
refer to “4.4.9 Guidelines for data
management menu operation” on page
4-57.

Steps for fulfilling the function:

Enter the management system as

shown in Fig. 4-29 on page 4-32, click
“Manage→Database Maintenance” to pop
database maintenance window as shown
in Fig. 4-34. If it is required to delete
production details, delivery orders data
and manual data, select such item, set the
period and then click “Delete” button; if

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Operation HZS60 Concrete Batching Plant

it is required to delete the data about all

customers, suppliers and checkers, select
the data in middle field and then click
“Delete” button at the bottom.

Fig. 4-34 Database maintenance window

4.4.2.4 System setup

This function is applied to set the login

menu, software type, print and contents of
delivery order.

Enter the management system as shown in

Fig. 4-29 on page 4-32, and click “System
Manage→System Setup” to pop system
setup window as shown in Fig. 4-35.

Click the small box in front of the “Show log

window on startup” as shown in Fig. 4-35.
Fig. 4-35 System setup window
The login interface will pop automatically
upon logging on.

Click “Delivery Setup” button to open it as

shown in Fig. 4-36 and Fig. 4-37 on page
4-37.

In the window, the user may set the items

to be printed on the delivery order and
their positions as demanded. The unit
of the figure is centimetre. The default
setup is standard SANY delivery order
(38cm×14cm). If the user wants to apply
customized delivery orders, then following
steps should be followed.

Firstly click “Modify” button as shown in

Fig. 4-36 on page 4-37, and then select
the small box in front of each item, because
the front “Tab.” is corresponding to the
item name behind.

Double click the space between “Tab.”

and corresponding item name, the table

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size and content setup window will pop

up, where the user may set up the size
of characters, position of table, size of
table and display of name (i.e. table title).
The user may also modify the title if it is
required to display.

As to the printing position of item, the

user may refer to mesh coordinate, drag it
with mouse to the position corresponding
to delivery order and click “Preview” as
shown in Fig. 4-36 to view the setup style.
The position can also be adjusted based
on the printing result. After adjustment,
click the “Save” button as shown in Fig.
4-36 to save the customized delivery
order. The modification will be cancelled if
the “Cancel” button as shown in Fig. 4-36
is clicked before saving.

Click “Default” as shown in Fig. 4-36 to set

Fig. 4-36 Delivery order setup window
delivery order to standard format of SANY,
and click “Default (Tab)” as shown in Fig.
4-36 to set delivery order to standard
printing format of SANY with table; “Tab”
button as shown in Fig. 4-36 will print
items selected by the user with table in
unification; “Show” button as shown in Fig.
4-36 will print items selected by the user
with name in unification.

“Instruction” and “standby application”

options are also available in setup, which
enable the user to use options excluded
in the management system; find out
“instruction or standby” from “PrintSet.ini”
in “sanycan” file, and input contents to be
displayed in “ShowLab” as shown in Fig.
4-37.
Fig. 4-37 “PrintSet.ini” window

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Operation HZS60 Concrete Batching Plant

The new printing format of delivery

order becomes effective instantly after
modify, and the user may print it without
existing management program; it is
required to exit management program
provided “instruction” or “standby
application” modifies.

4.4.2.5 User management, login and

cancellation

This function is applied to the login and

cancellation of operator or administrator,
as well as for the administrator to manage
the operator’s data and authority.

User login: click “Manage→User Login” as

shown in Fig. 4-29 on page 4-32 to enter
login interface shown in Fig. 4-5 on page
4-14.

User management: click “System Manage

→User Manage” as shown in Fig. 4-29 on
page 4-32 to enter user manage window
as shown in Fig. 4-38. The operator may
set up and modify his own password via
such window.
Fig. 4-38 User manage window

User cancellation: click “System Manage

→User Logout” as shown in Fig. 4-29
on page 4-32 to pop up the window for
confirming the cancellation; click “Yes”
to cancel all operation authority, and
click “No” or “Cancel” to return to normal
operation.

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4.4.3 G u i d e l i n e s f o r r e c i p e m e n u
operation
4.4.3.1 Recipe manage

This function is applied for the management

of concrete recipe including edit, input,
deletion, modify and view.

Steps for the edit and input (increase of

recipe) of recipe:

Click “Recipe→Recipe Manage” on menu

bar or directly click “Recipe Manage” on
shortcut bars shown in Fig. 4-29 on page
4-32 or enter recipe manage window
as shown in Fig. 4-39 with shortcut key
Ctrl+G. Firstly, Click “Add” button at the
bottom of the window, then edit and input
corresponding recipe parameter, finally,
and click “Save” button to finish the
increase of recipe data.

1. Steps for viewing recipe:

Click “Recipe→Recipe Manage” on menu

bar or directly click “Recipe Manage” on
shortcut bars shown in Fig. 4-29 on page
4-32 or enter recipe manage window as
shown in Fig. 4-39 with shortcut key Ctrl+G.
Input mixing ratio number to textbox on the
right of “Select Recipe”, click button
on the right of text box to export recipe Fig. 4-39 Recipe manage window
data of corresponding number; toolbar
as
shown in Fig. 4-39 can also be applied to
find out required mixing ratio number and
recipe data.

2. Steps for modifying recipe:

Click “Recipe→Recipe Manage” on menu

bar or directly click “Recipe Manage” on
shortcut bar as shown in Fig. 4-29 on page
4-32 or enter recipe manage window as
shown in Fig. 4-39 with shortcut key Ctrl+G.

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Operation HZS60 Concrete Batching Plant

According to Fig. 4-39 on page 4-39,

firstly, find out the recipe to be modified
and display it on the page, secondly
click “Modify” button at the bottom of the
window, then edit and input corresponding
recipe parameter, and finally, click “Save”
button to finish the modification of recipe
data.

1. When “Add” and “Modify” the recipe:

a) “Recipe ID” as shown in Fig. 4-39
must be inputted and it cannot be the
same with others;
b) Cement and water data must be
included in recipe;
c) Only one type of cement can be
selected (for single-purpose weigher);
d) Only one type of admixture can be
selected provided there is only one
admixture weigher available;
e) Input gravel into recipe as required;
f) Unit weight refers to the weight of
1m 3 concrete;
g) Concrete features related to recipe
can be inputted if required.
2. Recipe refers to the proportion of
various materials measured in kg in 1m 3
concrete after mixing and ramming.

3. Steps for deleting the recipe:

Click “Recipe→Recipe Manage” on the

menu bar or directly click “Recipe Manage”
on shortcut bar shown in Fig. 4-29 on
page 4-32 or enter recipe manage window
shown in Fig. 4-39 on page 4-39 with
shortcut key Ctrl+G. According to Fig. 4-39
on page 4-39, firstly, find out the recipe to
be deleted and display it on the page, then
click “Delete” button at the bottom of the

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window, and finally, click “Close” button to

exit recipe manage window.

The deleted recipe cannot be recovered.

You have to input it again if required.
Think twice before deletion.

4.4.3.2 Recipe view

This function is provided to operators or

related staffs, personnel with authority
for modifying the recipe, and for the
modification of recipe.

Methods for viewing the modification

recipe:

Click “Recipe→Recipe view” on the

command bar as shown in Fig. 4-29
on page 4-32 to enter “Modification
Information of Recipe” window as shown
in Fig. 4-40.

The user may view the modification recipe

with three methods according to the
notices:

1. View the modification of recipe

according to “time of modify”: firstly, click
the small box in front of “Date/Time” as
shown in Fig. 4-40, then set the start time Fig. 4-40 Modification information of recipe
and end time of such period, and finally,
click “Find” button to check the modification
recipe of the above period.

2. View the modification of recipe

according to “User Name”: firstly, click the
small box in front of “User Name” as shown
in Fig. 4-40, then select a user name on
the pop menu, and finally, click “Find”
button to check the modification made by
the user to recipe.

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Operation HZS60 Concrete Batching Plant

3. View the modification of recipe

according to “Scheme ID”: firstly, click the
small box in front of “Scheme ID” as shown
in Fig. 4-40 on page 4-41, then select
a mixing ratio number on the pop menu,
and finally, click “Find” button to check the
modification recipe.

4.4.3.3 Steps for deleting the login

information of operator

Click “Manufacture→Log view” on menu

bar as shown in Fig. 4-29 on page 4-32
to enter task manage window. Firstly, find
out the journal to be deleted with aforesaid
steps, then click “Delete” button at the
bottom of the window to delete all the
information on login and exit (cancellation),
and finally, click “Close” button to leave
journal browse window.

4.4.4 G u i d e l i n e s f o r t a s k m e n u
operation
Click on the right of the “Task Name”
in the “SANY CONCRETE CONTROL
SYSTEM” interface as shown in Fig.
4-4 on page 4-13. Enter into “Edit Task
Window” as shown in Fig. 4-8 on page
4-16 to perform the task mange setting.

4.4.4.1 Steps for increasing production

tasks

Click “ADD” button at the bottom of the

task edit window as shown in Fig. 4-41.
Input task data into the box after each
notice; or select corresponding contents
according to list box and clicking .
Then click “SAVE” button.

Fig. 4-41 Button in the task edit window

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When creating a new production task:

“Task ID” can only be figures produced
automatically; These figures are
different and can be modified manually;
“Task Name” must be inputted without
repetition; Other input boxes are optional.
Fill in complete information to ensure the
completeness of production record.

4.4.4.2 Steps for viewing production

tasks

Input task title to the text box on the right

of “Select Task ID” and click button
on the right of text box as shown in Fig.
4-41; then the task of given title can be
displayed by the page.

4.4.4.3 Steps for modifying production

tasks

Find out the task to be modified and display

it on the page, and then click “MODIFY”
button at the bottom of the window as shown
in Fig. 4-42. Edit and input corresponding
task data. Finally, click “SAVE” button to
finish the modification of task data. Fig. 4-42 Option in the task edit window

a) “Task ID” can only be figures without

repetition;
b) “Task Name” is unique (not repeated)
and it must be inputted;
c) Fill in complete information to ensure
the completeness of task information and
facilitate the pouring of delivery order for
initiating the production;
d) “Total Quantity” is effective data
produced automatically and they are only
used for viewing and understanding. In
addition, they can be amended.

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Operation HZS60 Concrete Batching Plant

4.4.4.4 Steps for deleting production

tasks

Find out the task to be deleted and display

it on the page. Click “DELETE” button
at the bottom of the window as shown in
Fig. 4-42. Click “QUIT” button to exit task
manage window.

The deleted task cannot be recovered.

Think twice before deletion.

4.4.5 Guidelines for the operation

of delivery manage menu

This function is applied for viewing

delivery order. The items can be managed
including delivery order inquiring, modify
and printing. The delivery order will
automatically record delivery information.

4.4.5.1 Delivery order information

Click “Ship Management→Ship order

view” on menu bar enter “Delivery Order
Information” window as shown in Fig. 4-43.

Display field setup: “Select Columns”

field is available on the left upper corner Fig. 4-43 Delivery order information
of delivery order view window as shown
in Fig. 4-43. The user may select the
contents to be viewed and displaced from
the list under such field. The contents
not selected will not be displayed. For
instance, when a “Recipe No.” as shown in
Fig. 4-43 is selected, the “Recipe No.” will
be displayed in the list.

View conditions setup: The user should

firstly set time period in “Date/Time” field
as shown in Fig. 4-43 and then input view
conditions according to the words notice in
front of each field. All the delivery records

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of such time period will be found out

provided no other condition is set.

After the setting of time period and other

conditions, click “Find” button as shown
in Fig. 4-43 on page 4-44 to display
delivery records meeting conditions on the
underlying display field.

4.4.5.2 Modify of delivery order

Before the modification of delivery order,

the user should, according to “4.4.5.1
Delivery order information” on page
4-44, find out the delivery order record to
be modified, and double click such delivery
order to pop delivery order window as
shown in Fig. 4-44.

When modifying the delivery order as

shown in Fig. 4-44, the user should
click “Modify” button at the bottom of the
window, then modify related information,
click “Save” button to put the modification
in force and save the modification. The
modification can be cancelled through
direct clicking of “Cancel”. After modifying Fig. 4-44 Change of delivery order
operation is finished, click “Close” button
to leave the window.

4.4.5.3 Delivery order printing

Before printing the delivery order, the user

should, according to “4.4.5.1 Delivery
order information” on page 4-44, find
out the delivery order record to be printed,
and double click such delivery order to pop
delivery order window as shown in Fig.
4-44.

Directly click “Print” button as shown in

Fig. 4-44 for printing such delivery order
(exact content should be set up at “4.4.5.2
Modify of delivery order” on page 4-45).
The user may also click “Preview” button

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Operation HZS60 Concrete Batching Plant

to check the printing content and format.

Refer to “4.4.5.2 Modify of delivery
order” on page 4-45 when the printing
content and format are supposed to be
modified.

After the printing task is sent, the user may

click “Close” button as shown in Fig. 4-44
on page 4-45 to leave the window.

4.4.6 G u i d e l i n e s f o r i n v e n t o r y
management menu operation

This function is mainly applied to the

management of materials inventory,
including inventory management and bin
view (maintenance), of which the former
will concern purchase ID, bin number, date
stock, material type, material type and
quantity, and the latter will enable the user
to view and maintain the inventory of each
powder silo and additive warehouse.

4.4.6.1 Inventory management

Click “Inventory Management → Single
storage management” on menu bar or
click “Single storage management” under
the title bar as shown in Fig. 4-29 on page
4-32 to enter “Inventory Management”
window as shown in Fig. 4-45. When
increasing the inventory for the batching
plant, click the “Add” button, the bin
number will add 1 automatically, and then
the system will automatically display the
stock date. Select material type from the
dialogue box. Click the selected item, then
click “OK” button to close the dialogue box.
Then, fill the quantity (default quantity is 1, Fig. 4-45 Inventory management window
with the unit of ton) inventory management
window, and click “Save” button to finish
the increase of a new warehouse warrant.

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4.4.6.2 Material storage information

(maintenance)
Click “Inventory Management → Silo
inquiry” on menu bar or click “Silo inquiry”
under the title bar as shown in Fig. 4-29
on page 4-32 to enter material storage
information window as shown in Fig. 4-46.
Such window enables the user to view
the inventory of each powder material
silo, manage the data, and assists the
user in deciding warehousing time, type
and quantity. When maintaining the data, Fig. 4-46 Material storage inforamtion
click the “Modify” button beside the data
to be modified to pop an inventory modify
dialogue box as shown in Fig. 4-47, and
input a new value, click “OK” button as
shown in Fig. 4-47. After all the data of
each silo is modified and confirmed, click
“OK” button as shown in Fig. 4-46 to finish
the modification of silo data.

Fig. 4-47 Inventory change dialogue box

Fig. 4-46 displays the existing inventory of

each silo. This software may automatically
deduct the consumption of each kind
of material and follow up the existing
inventory in real time. However, update
and maintain data timely to truly bring into
force the functions of silo maintenance.
Correctly and timely update data before
the warehousing of materials; correctly
and timely update data when clearing
the silo; the inventory should be checked
regularly (once a month is recommended)
and updated correctly and timely.

4.4.7 G u i d e l i n e s f o r t r u c k m i x e r
management menu operation
4.4.7.1 Input, modify and deletion of
truck mixer information

This function is applied for the management

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Operation HZS60 Concrete Batching Plant

of concrete truck mixer related information,

including truck mixer number, selection of
driver on duty, name of driver and carrying
capacity of truck mixer.

1. Steps for inputting truck mixer

information

Click “Vehicle Management→ Vehicle

Information Maintenance” on the menu bar
as shown in Fig. 4-29 on page 4-32, as
shown in Fig. 4-48.

Firstly, click “Add” button at the bottom of

the window to pop truck information edit
window.
Input related information in the edit box Fig. 4-48 Truck information maintenance
under information notice, and click “OK”
button to finish the increase of truck mixer
data; after inputting, click “Save” button
to put the truck mixer data in force; click
“Cancel” to cancel the input operation; and
finally, click “Close” button to leave truck
mixer data management window.
Do not input empty information. Otherwise,
the newly increased records cannot be
saved.

2. Steps for modifying and deleting

truck mixer information

Before modifying and deleting truck mixer

data, the user must enter truck information
maintenance window as shown in Fig.
4-48 with the aforesaid method, find out
and click the information to be modified
and deleted.

According to Fig. 4-48, when modifying

the information, click “Modify” button to
modify the information at edit box, click
“OK” button to return to truck information
maintenance window, and then click “Save”
button to put the modification in force.

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Repeat above steps for modifying the

information of different truck mixers.

According to Fig. 4-48 on page 4-48, click

“Delete” button to delete the information.
Finally, click “Close” button to leave truck
mixer management window.

4.4.7.2 View and printing of truck

information

This function is applied to view the

transport information of concrete truck
mixer, task name, truck number, driver
name, transport stere, haul distance and
time. The quantity of concrete measured
in cubic meter can be accumulated in the
result of view.

This window can be applied to view the

status of truck mixers based on “Date/
Time”, “Task Name”, “Driver/truck Option”,
or in a combined way.

1. Steps for truck mixer information

view

Click menu bar “Vehicle Management →

Vehicle Information” as shown in Fig. 4-29
on page 4-32 to enter “Truck Information”
window as shown in Fig. 4-49.

According to Fig. 4-49, view condition

setting:

a) When viewing based on time period,

job order, driver name or truck mixer
Fig. 4-49 Truck information
license number, tick the small box of
corresponding notice, input view condition
in list or edit box behind, and then click
“Preview” button to got all the information
of truck mixers meeting conditions.

b) The user may also set two or more

time periods, job orders, driver names
or truck mixer license numbers to further

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Operation HZS60 Concrete Batching Plant

narrow down the scope of view. For

instance, setting the time period as 8
a.m. to 10 a.m. and the driver as Mr. Li,
click “Preview”, all the information will
be displayed, including service time,
truck license number, number of cubic
meter of concrete per truck mixer, travel
distance and total number of cubic meter
of concrete. With such method, the user
may view required information easily.

2. Steps for printing truck mixer

information

Before printing transport information of

truck mixers, the user must enter truck
mixer information view window as shown
in Fig. 4-49 on page 4-49, find out related
information based on steps mentioned
before, and then click “Print” to print all
the viewed results, number of cubic meter
and travel distance. The user may also
click “Preview” button to enter truck mixer
information preview window to browse the
content.

4.4.7.3 Shift of drivers

According to “4.4.7.1 Input, modify and

deletion of truck mixer information” on
page 4-47, one concrete truck mixer can
be arranged with two drivers for shifting.
This function is applied for converting
(shifting) drivers on duty in batch. The
shift of driver for an individual truck mixer
will be operated in other window and
introduced additionally.

1. Shift of drivers in batch for all truck

mixers

Click menu bar “Vehicle Management →

driver shifting” as shown in Fig. 4-29 on
page 4-32 to enter the information window
of current drivers on duty as shown in Fig.

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4-50. In the window, the user may view the

current drivers on duty (driver 1 or driver
2), and click “Shift 1” or “Shift 2” button
at the right lower corner to current drivers
of all truck mixers to driver 1 or driver 2
(the conversion is finished completely in
one time).

Fig. 4-50 I n f o r m a t i o n w i n d o w o f c u r r e n t
drivers

2. Shift of driver for one individual

truck mixer

Method 1: Click menu bar “Vehicle

Management → Vehicle Information
Maintenance” as shown in Fig. 4-29
on page 4-32 to enter truck mixer data
management window as shown in Fig.
4-50. Click the truck mixer number (license
number), then click “Modify” button to
pop truck mixer information edit window,
and input 1 or 2 (1 or 2 indicates that
the current driver on duty is modified to
driver 1 or driver 2; the name of driver
can be modified here) to the box under
“driver selection (1/2)”; click “OK” to exit
the window and then click “Close” button
in Fig. 4-50 to finish the modification of
current driver on duty for one individual
truck mixer.

Method 2: As shown in Fig. 4-51, when

giving the order for production, the
selection of truck mixer license number and
corresponding driver in “Truck Information”
bar may realize the automatic conversion
(the default driver is driver 1 provided
driver 1 is selected; the default driver
is driver 2 provided driver 2 is selected)
of drivers. The automatic conversion is
realized when selecting for the first time. Fig. 4-51 Conversion of truck mixer driver via
No repeated selection is required in future. giving production order

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Operation HZS60 Concrete Batching Plant

4.4.8 Guidelines for report management

menu operation

This menu is applied for the management

of detail production report, materials
consumption and delivery information
of the batching plant, including view,
preview, printing and data export of
detail production report and materials
consumption reports, and summarized
view of delivery information.

4.4.8.1 Manufacture dates report

This function is applied to the management

of detail production report of concrete,
including view, preview, printing and data
export of production information.

Click “Report Manger→Report query” on

menu bar or directly click “Report query”
button on shortcut bar as shown in Fig.
4-29 on page 4-32 or enter “Manufacture
Reports” window as shown in Fig. 4-52
with shortcut key Ctrl+D.

1. View of detail production report:

Detailed production report can be divided

into cycle-based statistics, truck mixer-
based statistics, delivery order ID statistics Fig. 4-52 View window of manufacture reports
and delivery order title statistics as shown
in Fig. 4-52.

Steps of view: Before viewing the report,

the user must set the time of data,
report type, batching plant number and
modify report title (the user may apply
the default title without modify) and then
click “Preview” button to pop report data
meeting the given requirements as shown
in Fig. 4-53 and Fig. 4-54 (view results
of cycle-based statistics and project title-
based statistics). The user may apply the
left shortcut key and the right shortcut key

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to turn the page of browsed contents.

2. Steps for printing detail production

report:

Before printing, the user must view the

report to be printed with aforesaid steps,
and then click to print the view results.
The current window can be closed by
clicking “OFF” button at the top.

The user may click “Print” button after

Fig. 4-53 View results of report (cycle-based
setting view conditions in Fig. 4-52 on
statistics)
page 4-52 to print directly without entering
the preview window (such operation is not
recommended, in order to guarantee the
accuracy of data).

3. Steps for exporting detail production

report:

Before exporting, the user must view the Fig. 4-54 View results of report (project title-
report to be exported in line with the above based statistics)
steps and confirm the exported data.

Exact steps of exporting: Firstly, set view

conditions in Fig. 4-52 on page 4-52
and click “Export” button to pop data
export window; confirm the data and then
click “Export (.txt)” button and “Export
(.xls)” button to pop text document and
excel table, which record the data to be
memorized; and directly save such table
into hard disc or other mobile memories.
Then, close windows in sequence to return
to the main interface of management
system; if the data is wrong, cancel directly
and reset view condition; then repeat the
aforesaid operation to finish data export.

4.4.8.2 Consumption report

This function is applied for the management

of raw materials consumption, including
view, preview, printing and data export of
raw materials consumption.

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Operation HZS60 Concrete Batching Plant

Click “Report Manger→Scan Report” on

menu bar or directly click “Scan Report”
button on shortcut bar as shown in Fig.
4-29 on page 4-32 or enter “Manufacture
Reports ” window as shown in Fig. 4-52
on page 4-52 with shortcut key Ctrl+D.
Click “ Consumption Report ” title on the
right upper part of the window to shift
to consumption report view interface as
shown in Fig. 4-55.
Fig. 4-55 View window of consumption reports
1. View of consumption report:

The consumption report can be

divided into normal consumption report
(material consumption report created
automatically), manual consumption report
(material consumption report created
manually) and total consumption report.
The normal consumption report can be
further classified into project title-based
consumption report, customer name-
based consumption report, construction
part-based consumption report and total
consumption report (total consumption of
materials) as shown in Fig. 4-55.

Steps of view: Before the view of report, the

user must set the time of data, report type,
batching plant number and modify report
title (the user may apply the default title
without modify) and then click “Preview”
button as shown in Fig. 4-55 to pop report
data meeting given requirements as shown
in Fig. 4-56.

2. Steps for printing consumption

report:

Before printing, the user must view the

report to be printed with aforesaid steps,
and then click to print the view results.
The current window can be closed by
clicking “Close” button at the top shown in Fig. 4-56 Co n s u mp t io n Re p o rt -Co u n t by
Fig. 4-56. Contruct Part

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HZS60 Concrete Batching Plant Operation

According to Fig. 4-55 on page 4-54,

the user may click “Print” button after
setting view conditions to print directly
without entering the preview window (such
operation is not recommended, in order
to guarantee the accuracy of data). After
printing, click “Cancel” button to leave
report view window.

3. Steps for exporting consumption

report:

Before exporting, the user must view the

report to be exported according to above
steps and confirm the exported data.

Exact steps of exporting: Firstly, set view

conditions in Fig. 4-55 on page 4-54, click
“Export” button; the following operations
are the same with that for exporting detail
production data.

4.4.8.3 Statistical report

This function is applied for viewing the

delivery information of concrete, including
view, preview, printing and data export
of accumulated delivery order quantity
(number of dispatched truck mixers) and
delivered quantity measured in cubic
meter.

Click “Report Manger→Scan Report” on

menu bar or directly click “Scan Report”
button on shortcut bar as shown in Fig.
4-29 on page 4-32 or enter “Manufacture
Reports” window as shown in Fig. 4-52 on
page 4-52 with shortcut key Ctrl+D. Click
“Stat. Report” title on the right upper part
of the window to shift to statistical report
view interface as shown in Fig. 4-57.

1. View of statistical report: Fig. 4-57 Aggregate view of delivery order

The aggregate delivery report can be

divided into five types such as recipe

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Operation HZS60 Concrete Batching Plant

report, project title statistical report,

project title and recipe statistical report,
aggregate report I and aggregate report
II. The aggregate report I presents total
delivery quantity and delivery times based
on “project name”, “project company”,
“construct part”, “intensity”, “recipe name”
and “work method”. The aggregate report II
includes all the content of aggregate report
I and exact recipe of each aggregation.

The user may define time period for the

view of each report types shown in Fig.
4-57 on page 4-55.

Steps of view: Before the view of report, the

user must set the time of data, report type,
batching plant number and modify report
Fig. 4-58 Aggregate report I
title (the user may apply the default title
without modify) and then click “Preview”
button in Fig. 4-57 on page 4-55 to pop
report data meeting given requirements as
shown in Fig. 4-58, Fig. 4-59 (view results
of aggregate report I and aggregate report
II). The user may apply the left shortcut
key and the right shortcut key to turn the
page of browsed contents.
Fig. 4-59 Aggregate report II
2. Steps for printing detail production
report:

Before printing, the user must view the

report to be printed with aforesaid steps,
and then click to print the view results.
The current window can be closed by
clicking “Close” button at the top shown in
Fig. 4-58 and Fig. 4-59.

3. Steps for exporting aggregate

delivery report data:

Before exporting, the user must view the

report to be exported according to above
steps and confirm the exported data.

Exact steps of exporting: Firstly, set view

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conditions in Fig. 4-57 on page 4-55,

and click “Export” button; the following
operations are the same with that for
exporting detail production data.

4.4.9 Guidelines for data management

menu operation

4.4.9.1 Customer data management

Customer data management is applied to

record information about the customer of
batching plant, including customer name,
address, way of contact etc. and it involves
the establishment, modify and deletion of
customer data. The exact operations are
shown below:

Click “Data Maintenance → Customer

Maintenance” shown in Fig. 4-29 on page
4-32 or enter “Customer Maintenance”
window as shown in Fig. 4-60 with shortcut
key Ctrl+L.
Fig. 4-60 Customer Maintenance window
1. New establishment of customer data:

Such function can be operated by all the

users authorized to open and increase
“Customer Data” (for detailed information,
see “4.4.2.5 User management, login
and cancellation” on page 4-38).

Firstly, enter “Customer Maintenance”

window as shown in Fig. 4-60, and then
click “Add” button at the bottom of the
window to pop customer data edit window.

The user may input customer information

in the edit box of corresponding title and
then click “OK” button to finish the editing.
Such operation can be repeated to add
data of other customers.

Note: Click “Save” button after editing the

information. Other operations can only
be performed after saving. Click “Close”

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Operation HZS60 Concrete Batching Plant

button to leave “Customer Maintenance”

window.

2. Modify of customer data:

The function can be operated by all the users

authorized to open and modify “Customer
Data” (for detailed information, see
“4.4.2.5 User management, login and
cancellation” on page 4-38).

Firstly, enter “Customer Maintenance”

window as shown in Fig. 4-60 on page
4-57 based on aforesaid method, click
“Customer Number” to be modified, and
then click “Modify” button at the bottom
of the window to pop customer data edit
window.

The user may Modify customer information

in the edit box of corresponding title and
then click “OK” button to finish the editing.
If the data of a number of customers is
required to be modified, the user may
double click corresponding “Customer
Number” to pop customer data modify
window. Then, modify customer data with
above method.

Note: Click “Save” button shown in Fig.

4-60 on page 4-57 after editing the
information. Other operations can only
be performed after saving. Click “Close”
button to leave “Customer Maintenance”
window.

3. Deletion of customer data:

The function can be operated by all the users

authorized to open and delete “Customer
Data” (for detailed information, see
“4.4.2.5 User management, login and
cancellation” on page 4-38).

Firstly, enter “Customer Maintenance”

window as shown in Fig. 4-60 on page

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4-57 based on the aforesaid method, click

“Customer Number” to be deleted, and then
click “Delete” button at the bottom of the
window to pop deletion warning window as
shown in Fig. 4-61. Click “OK” or “Cancel”
to delete or not to delete customer data.
After finishing the operation, click “Close” Fig. 4-61 Deletion warning window
to leave “Customer Maintenance” window.

4.4.9.2 Employee data management

Employee data management is applied

to record information about the concrete
inspector of batching plant, including
employee name, address, way of contact
etc. The exact operations are shown as
below:

Click “Data Maintenance → Staff data

maintenance” shown in Fig. 4-29 on page
4-32 or enter “Staff data maintenance”
window as shown in Fig. 4-62 with shortcut
key Ctrl+E.

1. New establishment of employee

data:

Such function can be operated by all the

users authorized to open and increase
“Employee Data” (for detailed information,
see “4.4.2.5 User management, login
and cancellation” on page 4-38).

Firstly, enter employee data management

window based on the aforesaid method,
and then click “Add” button at the bottom
of the window as shown in Fig. 4-62 to pop
employee data edit window.
Fig. 4-62 Staff data maintenance window
The user may input employee information
in the edit box of corresponding title and
then click “OK” button as shown in Fig.
4-62 to finish the editing. Such operation
can be repeated to add data of other
employees.

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Operation HZS60 Concrete Batching Plant

Note: Click “Save” button as shown in

Fig. 4-62 on page 4-59 after editing the
information. Other operations can only
be performed after saving. Click “Close”
button as shown in Fig. 4-62 on page
4-59 to leave employee data management
window.

2. Modify of employee data:

Such function can be operated by all

the users authorized to open and modify
“Employee Data” (for detailed information,
see “4.4.2.5 User management, login
and cancellation” on page 4-38).

Firstly, enter employee data management

window as shown in Fig. 4-62 on page
4-59 based on the aforesaid method,
click “Number” to be modified, and then
click “Modify” button at the bottom of the
window to pop employee data edit window.

The user may modify employee information

in the edit box of corresponding title and
then click “OK” button to finish the editing.
If the data of a number of employees
should be modified, the user may double
click corresponding “Number” as shown
in Fig. 4-62 on page 4-59. Then, modify
employee data with the above method.

Note: Click “Save” button as shown in

Fig. 4-62 on page 4-59 after editing the
information. Other operations can only
be performed after saving. Click “Close”
button as shown in Fig. 4-62 on page
4-59 to leave employee data management
window.

3. Deletion of employee data:

Such function can be operated by all

the users authorized to open and delete
“employee data” (for detailed information,
see “4.4.2.5 User management, login

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and cancellation” on page 4-38).

Firstly, enter employee data management

window as shown in Fig. 4-62 on page
4-59 based on the aforesaid method, click
“employee number” to be deleted, then
click “Delete” button at the bottom of the
window to pop deletion warning window as
shown in Fig. 4-63. Click “OK” or “Cancel”
to delete or not to delete employee data. Fig. 4-63 Deletion warning window
After finishing the operation, click “Close”
to leave employee data management
window.

4.4.9.3 Silo management

Storage bin management is applied

to record material information of each
raw material silo of the batching plant,
including material name and specification.
The exact operations for the modification
of silo category data are shown below:

Click “Data Maintenance→Silo class data

Management” shown in Fig. 4-29 on page
4-32 on menu bar or enter “Storage Bin
Management” window as shown in Fig.
4-64 with shortcut key Ctrl+J.

Modify of silo data:

Firstly, enter silo data management
window as shown in Fig. 4-64 based on the
aforesaid method, click the content to be Fig. 4-64 Silo management window
modified, and then click “Modify” button on
the right of the window; select a batching
station, input corresponding information in
material name box and specification box,
and click “Save” to finish the modification,
or click “Cancel” to give up the modification
before clicking “Save” button.

The user may modify material information

of other silos based on aforesaid method.
After modifying, click “Close” button to
leave silo data management window.

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4.4.9.4 Batching plant data

management

Batching plant data management is applied

to set and manage batching station number,
name, model, establishment date, capacity
(number of cubic meter per cycle) and
owner information. The user may delete,
increase and modify batching station data
as demanded. The exact operations are
shown below:

Click “Data Maintenance → Mixing station

data management” shown in Fig. 4-29 on
page 4-32 on menu bar to enter “Edit
Station” window as shown in Fig. 4-65.

1. Modify of batching plant data:

The function can be operated by all the

users authorized to open and modify
“Station Data” (for detailed information,
see “4.4.2.5 User management, login
and cancellation” on page 4-49).

During initialization, one data record about

the batching plant is available for batching
plant management window. The “Type” and Fig. 4-65 Edit station window
“Quantity/Pot” are set based on technical
requirements of the contract. So, the
user is only required to modify “Number”,
“Station ID”, “Creation Note” and “Owner”.

Steps of modify:

Firstly, enter the “Station Management”

window as shown in Fig. 4-65 based on
the aforesaid method, click “Number” to be
modified; then click “Modify” button on the
right of the window, input corresponding
information in the edit box behind the title
in the upper part of the window, and click
“Save” to finish the modification, or click
“Cancel” to give up the modification before
clicking “Save” button.

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2. Increase of new batching plant data:

The function can be operated by all the

users authorized to open and increase
“Station Data” (for detailed information,
see “4.4.2.5 User management, login
and cancellation” on page 4-49).

In general, one batching plant only has a

piece of batching plant information. When
the user possesses different batching
plants, different numbers can be set in
different batching plant management
systems.

A record can only be increased when there

is no batching plant data record available.
Otherwise, the increase is invalid. That is
to say, the user has to delete the existing
record to increase a new one.

Steps of increase:

Firstly, enter the “Station Management”

window as shown in Fig. 4-65 on page
4-62 based on the aforesaid method, click
“Add” button on the right of the window;
input corresponding information in edit box
behind the title in upper part of the window,
and click “Save” to finish the modification,
or click “Cancel” to give up the increase
before clicking “Save” button.

3. Deletion of batching plant data:

Such function can be operated by all

the users authorized to open and delete
“Station Data” (for detailed information,
see “4.4.2.5 User management, login
and cancellation” on page 4-49).

Firstly, enter the “Station Management”

window as shown in Fig. 4-65 on page
4-62 based on aforesaid method, click
“Number” to be deleted, and then click
“Delete” button on the right of the window

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Operation HZS60 Concrete Batching Plant

to pop deletion warning window as shown

in Fig. 4-66. Click “OK” or “Cancel” to
delete or not to delete batching plant data.
After finishing the operation, click “Close”
to leave batching plant data management
window.

Fig. 4-66 Deletion warning window

4.4.9.5 Construction part management

The construction part data management

includes increase, modify and deletion
of construction part data. The exact
operations are shown as below:

Click “Data Maintenance→Construction

site data maintenance” shown in Fig. 4-29
on page 4-32 to enter “Construction Part
Maintenance” window as shown in Fig.
4-67.

1. New increase of construction part

data: Fig. 4-67 Construction site maintenance
window
Firstly, enter construction part management
window as shown in Fig. 4-67 based on the
aforesaid method, click “Add” button on the
right of the window to automatically create
a number in the upper part of the window,
input “Project Part”, and click “Save”
button on the right to finish the increase.
Repeat the aforesaid operation to increase
other construction parts. Click “Cancel”
to give up the increase before clicking
“Save” button. Click “Close” to leave the
management window of construction part
data.

2. Modify of construction part data:

Firstly, enter construction part management

window as shown in Fig. 4-67 based on
the aforesaid method, click “Construction
Part” to be modified, and then click

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“Modify” button on the right of the window

to modify construction part name in the
upper part of the window. After modifying,
click “Save” button on the right to finish the
modification. Repeat aforesaid operation
to modify other construction parts. Click
“Cancel” to give up the modification before
clicking “Save” button. Click “Close” to
leave construction part data management
window.

3. Deletion of construction part data:

Firstly, enter construction part management

window as shown in Fig. 4-67 on page
4-64 based on aforesaid method, click
“Construction Part” to be deleted, and then
click “Delete” button on the right of the
window to pop deletion warning window as
shown in Fig. 4-68. Click “OK” or “Cancel”
to delete or not to delete construction part
data. After finishing the operation, click
“Close” to leave construction part data Fig. 4-68 Deletion warning window
management window.

4.4.9.6 Pouring method maintenance

The pouring method data management

includes the increase, modify and deletion
of pouring method data. The exact
operations are shown below:

Click “Data Maintenance→Pouring

Method Maintenance” shown in Fig. 4-29
on page 4-32 to enter “Pouring Method
Maintenance” window as shown in Fig.
4-69.

1. New increase of pouring method

data:

Firstly, enter pouring method maintenance

window as shown in Fig. 4-69 based on
Fig. 4-69 P o u r i n g w a y m a i n t e n a n c e
the aforesaid method, click “Add” button
window

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Operation HZS60 Concrete Batching Plant

on the right of the window to automatically

create a number in the upper part of the
window, input “work method”, and click
“Save” button on the right to finish the
increase. Repeat aforesaid operation to
increase other pouring methods. Click
“Cancel” to give up the increase before
clicking “Save” button. Click “Close” to
leave pouring method data management
window.

2. Modify of pouring method data:

Firstly, enter pouring method maintenance

window as shown in Fig. 4-69 on page
4-65 based on aforesaid method, click
“Pouring Method” to be modified, then click
“Modify” button on the right of the window
to modify pouring method name in the
upper part of the window, after modifying,
click “Save” button on the right to finish
the modification. Repeat the aforesaid
operation to modify other pouring methods.
Click “Cancel” to give up the modification
before clicking “Save” button. Click “Close”
to leave pouring method data management
window.

3. Deletion of pouring method data:

Firstly, enter pouring method maintenance

window as shown in Fig. 4-69 on page
4-65 based on aforesaid method, click
“Pouring Method” to be deleted, then click
“Delete” button on the right of the window
to pop deletion warning window as shown
in Fig. 4-70. As shown in Fig. 4-69 on page
4-65, click “OK” or “Cancel” to delete or
Fig. 4-70 Deletion warning window
not to delete pouring method data. After
finishing the operation, click “Close” to
leave pouring method data management
window.

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4.5 Production Operation and

Other Setting
4.5.1 Production operation

4.5.1.1 Automatic operation

Automatic operation steps are as below:

Recipe manage: in the recipe manage

window of the management software,
operations, such as new recipe,
modification, and deletion, can be realized.

Task manage: in the recipe manage window

of the management software, operations,
such as new task, modification, and
deletion, can be realized.

The process of automatic operation carried

out by the software follows the procedures
below.

Step 1: Maintain the recipe and task

according to the dispatching information.

Step 2: Send tasks according to the truck

and dispatching information.

Step 3: Begin production by pressing the

“Run” button on the computer monitor
menu (see Fig. 4-71). Then the system will
start production automatically.

In the process of operation, the monitor

menu will display the equipment operation
status, mixing time, truck cycle number,
etc. in dynamic way.

During automatic operation, manufacturing

Fig. 4-71 "Run" and "Stop" button
process may be controlled according to
actual requirements, such as suspending
mixing, suspending adding material,
and prohibiting discharging with the
manufacture process; and the working
parameters can also be modified. For
detailed information, see: “4.3 Operation

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Operation HZS60 Concrete Batching Plant

and Application of Monitoring System”

on page 4-17.

During automatic operation, the operators

need to observe carefully to discover and
handle abnormal situations in time. The
procedures will be operated according to
the process of mixing, baiting, lowering,
dispatching, and discharging repeatedly.

When the automatic operation is to

be stopped, click the “Stop” button on
the upper computer (see Fig. 4-71 on
page 4-67) monitor menu, and then
the automatic operation will stop. If the
automatic operation stops, the process
unfinished need to be done manually. After
that, the next automatic circle can start.

If any abnormal situation is found

during production, the process can be
modified form auto to manual. Then, the
manufacturing process will be stopped
for a short time. After the fault has been
remedied manually, reset the operation
mode back to the auto. Hence, the circle
can finish automatically.

4.5.1.2 Manual production operation

Manual operation includes: operating the

upper computer and the skip elevator.

1. Manual operation of the upper

computer

The upper computer monitor menu includes

all operation buttons of equipment (see
Fig. 4-72), and no matter under whichever
state, manual operation or automatic
operation, all the buttons can be pressed
through the mouse to start or stop the
machine, etc.

Fig. 4-72 "MANUAL" button

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2. Lifting system manual operating

procedures

Lifting system of the engineering batching

plant is controlled by buttons (see Fig.
4-73). During the elevator bucket moving
up and down at a setting speed, up and
down speed decreasing buttons are
invalid, while the “up and down stop
position buttons” and limit position switch
are still valid.

Set control system to the “MANUAL” mode.

Observe in the batching station: when
discharge beginning, the elevator bucket
should stop at the bottom limit position.
Then start the belt weighing. After all the
materials are discharged into the elevator
bucket, press the moving up button (the
green button shown in Fig. 4-73 ) to move
the bucket to the top limit position,then
press the red button shown in Fig. 4-26.
Stop for about 10s to ensure all the
materials discharged into the waiting-for-
feed hopper. Then press the moving down
button of the elevator bucket .
Fig. 4-73 Belt weigher button

4.5.2 Washing operation

After finishing production or continuous

production for a long period, the mixer
should be washed. The process is called
washing.
Steps of mixer washing:
Ensure the production is completed.

Ensure there is a truck mixer under the

discharge gate of the mixer to receive the
water and material residue flushed out.

Press wash button of the mixer on the

upper computer software as shown in Fig.
4-74. Observe the material flowing out Fig. 4-74 Mixer wash button

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Operation HZS60 Concrete Batching Plant

from the discharge gate of the mixer via

monitor to judge whether the washing is
completed. If there is only water without
material residue flowing out from the
discharge gate, the washing operation of
the mixer is completed.

When the washing operation of the mixer

is completed, press the wash button again,
the mixer washing is completely finished.

4.5.3 Shutdown Procedures

After production, carry out shutdown
procedures. The steps are shown below:

1. Firstly, Click the red button under

belt weigher in right corner of the upper
computer monitor interface as shown in
Fig. 4-73 on page 4-69, to stop the belt
weigher running, and then the elevator
will stop running automatically 3 senconds
later;

2. Then you need to wash the mixer.

For detailed information, see: “4.5.2
Washing operation” on page 4-69;

3. Shut off the air compressor by press

the stop button on the power cabinet as
shown in Fig. 3-41 on page 3-48;

4. Shut down computer;

5. Shut down power.

4.5.4 I n v o k i n g m e t h o d o f t h e
software

The invoking method of the upper computer

monitor and management system is shown
as below:
The upper computer program includes
two parts: monitor software (sany.exe/
sanycan.exe) and management software
(file name is “cncrt.exe”). When replacing

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of monitor software or management

software is needed, copy the needed files
“sany. exe/sanycan.exe” or “cncrt.exe” to
path “D:\sanycan”.
If there isn’t a shortcut of the monitor
system on the Windows operation system
interface. You can find the program of
monitor software——“sany.exe/sanycan.
exe”, and click right mouse button to
select “sent shortcut to the desktop”. You
can change the name of program icon on
the desktop if you need (see Fig. 4-75).
If there isn’t default engineering file in the
monitor program, “can’t find the default
engineering file” will pop up when you
Fig. 4-75 “sanycan.exe” and “cncrt.exe”
open the monitor program from shortcut
. You can create a new desktop shortcut
again or designate the link you need by
path in the prompt box.

4.5.5 Setting of printer

After ensuring there isn’t any malfunction
in the printer, please set printer as follow:

1. Servers attribute setting

a) Press “start” menu in the left bottom

of the desktop. Then press “printers and
faxes” in order. As shown in Fig. 4-76, enter
the “printers and faxes” setting window.

Fig. 4-76 Printer setting

b) Singly click right button of the mouse
at the blank of the printer setting window.
“Server Properties” menu pops up as Fig.
4-77. Singly click server properties to pop
up servers properties setting dialog box as
Fig. 4-78.

Fig. 4-77 Printer setting menu

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Operation HZS60 Concrete Batching Plant

c) Find SANY printing format by scroll bar

or by pressing key S. Set the dimensions
of paper as shown in Fig. 4-78. Set the
width to 24.00cm and height according to
the paper. If the dimension is wrong during
automatic printing, measure the paper
height and modify by method above. Save
the format and press enter to confirm.

Fig. 4-78 Print server properties setting

dialog box

2. Select default printer

According to the printer mode, select

default printer match SANY concrete
batching plant. Default printer is which
has a tick on the icon. If there isn’t a tick
on the using printer, please right click the
icon. Setting menu is shown as Fig. 4-79,
singly click “Set as Default Printer”. The tick
appears on the printer icon, as indicates
the printer setting completed. Fig. 4-79 Printer setting menu

3. Attribute setting

a) Right click the printer icon to pop up

printer setting menu as shown in Fig. 4-80,
and select attribute. Printer properties
setting dialog box is shown as Fig. 4-80.
Singly click device settings button, and set
manual paper feed, tailed tug paper feed,
bottom tug paper feed and printer to SANY.

Fig. 4-80 Printer properties setting dialog box

b) Enter to the advanced printer selection

dialog box. Click “Advanced” button on the
print properties setting dialog box to enter

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HZS60 Concrete Batching Plant Operation

advanced options dialog box as shown in

Fig. 4-81. Or select print preferences in the
printer setting menu to enter the preference
dialog box as Fig. 4-82 and then click
“Advanced” button. In the advanced dialog
box, set the paper dimension to SANY.

Fig. 4-81 Printer advanced dialog box

Fig. 4-82 Print preference dialog box

c) Set port according to the connected

port between printer and industrial process
computer. In the print properties setting
dialog box, singly click “ports” button to
select the using connected port, and click
“OK” (see Fig. 4-83).

Fig. 4-83 Port setting dialog box

4.5.6 Operation of system restore

During starting, if the system can’t be

found or system is too abnormal to go
on working. Please use GHOST one key
recover operation. This operation is to
restore C disk to initial state, and it will
format the C disk. Therefore, if there are
important files except system, please
remove or backup them.

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Operation HZS60 Concrete Batching Plant

Steps of GHOST one key recover operation:

1. Restart computer, and intermittently

press key F8 (don’t keep immobility after
press key F8) until the item below appears
(see Fig. 4-84,):

Start Windows Normally

Restart
Return to OS Choices Menu

Fig. 4-84 Selected items

2. Please use the direction key board to

select the third item [Return to OS Choices
Menu] shown in Fig. 4-84 and press enter.
System shows [Please select the operating
system to start] items (see Fig. 4-85):

Microsoft Windows XP Professional

1 Key System Back (Please backup the

important data in system disk before using)

Fig. 4-85 Select the operation system

3. Select the second item [1 Key System

Back] shown in Fig. 4-85, and then press
enter. GHOST interface will appear, and
menu below will pop up (see Fig. 4-86):

Proceed with partition restore?

Destination partition will be permanently

overwritten.
Yes No
Select [Yes], and then press enter.
Fig. 4-86 Question

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4. Waiting for the system to carry out

recover. Please don’t cancel or interrupt
(see Fig. 4-87).

After the recover completed, restart the

system.
Fig. 4-87 Restore interface

4.6 Other Operation

4.6.1 Other Operation

4.6.2 Operation of winch (elevator)

Elevator bucket with winch for steel wire

rope and braking motor is controlled
automatically or manually. See “Braking
motor operation manual” and “Electrical
device operation manual” from the
production provider for detailed operation.

4.6.2.1 Opreation of the elevator steel

wire rop

Steel wire rope is used in the elevator

bucket of the concrete batching plant, the
cover plates of the series-wound aggregate
storages opening, calibration device and
cover plate of the mixer opening.

1. Different model of the steel wire rope

Different elevator of concrete batching

plant uses different models of steel wire
rope (see Table 4-1).
Table 4-1 Model of common steel wire rope

Model of steel wire rope

Batching
Code Designation/Model Remark
plant type
Outsourcing part 22 m per
HZS60F 13109282 Steel wire rope 16-35×7-1960-UGB8918
rope

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Operation HZS60 Concrete Batching Plant

Skip elevator should only install

corresponding steel wire rope. In special
state, other type of steel wire rope with
same length, diameter, structure and
break tension.

2. Storage of the steel wire rope

It is not allowed that there is erosion,

mar or dirt. It is better to put the rope on
a suitable wood bracket. The position for
storage should be dry, clean and cool.

When the transmission of rope starts

up accidently, prevent being caught in.
Shut off the main switch before
installation and maintenance. Prevent
the main switch of the device from
being switch on accidentally.

3. Installation of steel wire rope

Improper installation of the steel wire rope

increases abrasion and reduces service
life. It is danger for operator and machine
both. Please carefully install the steel wire
rope according to the introduction below.

(1) Check before installation:

Check whether the rope is suitable for the

rope groove, and install steel wire rope
according to the models upward.

Check the flexible of the steel wire rope

pulley.

Check whether there is any problem in the

steel wire rope anti-loosing device on the
top of the elevator and its installation seat.

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Clean the grease on the pulley (if

necessary).

(2) Precaution during installation:

When the steel wire rope extends from the

reel or the rope coil, or when the elevator
tenses the steel wire rope installed in
the pulley, measures should be taken to
prevent steel wire rope from interleaving
as ring or twisting together. If the tight steel
wire rope is twisted together, strength of
the rope will be decreased.

Please don’t put the rope on the ground.

Because the dust and the dirty will adhere
to the grease on the rope, and damage the
rope or increase the abrasion.

The end of the steel wire rope should be

enlaced or sintered to prevent steel wire
rope from loosening (see Fig. 4-88).
Fig. 4-88 Wire rope be enlaced

(3) Installation steps :

Fix one end of the steel wire rope to the

ring (rope hanging ring) under the anti-
loosing device, and fasten the rope clip.
In HZS60F batching the rope is fixed by
aluminium alloy pressing connectors as
shown in Fig. 4-89. The connectors will be
delivered after preassemble.

Fig. 4-89 Aluminium alloy pressing connector

in HZS60F batching plant

a) Keep the elevator bucket in the bottom

of the pit and put the steel wire rope on

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Operation HZS60 Concrete Batching Plant

the elevator. Install the flexible end of the 1

steel wire rope on the moving pulley of
the pulling rod frame from the inside main
tower frame. (see Fig. 4-90)

b) Pull the flexible end of the steel wire

2
rope up to the top of the elevator, and
install it on the fixed pulley of the upper
guide rail outside the main tower frame.

c) Pull the flexible end of the steel wire

rope down to the reel, and coil from middle
drum to the two ends. Pay attention to 4
the direction where the rope comes out. 3
Coil the rope on the reel for 2~3 rounds in
advance, and then coil another 2 rounds to
fix. Install 2~4 rope pressing plates on the
drum to fix the rope.

d) Check the length : pull up the steel Fig. 4-90 Installation steps of the steel
wire rope until it is tense, and then inching wire rope
put the elevator bucket down. The inching 1-fixed pulley 2-anti-loosing device
distance should be as small as possible. 3-moving pulley 4-reel
Furthermore, knock the two tense rope and
judge the length of them are consistent
according to the tense degree.

e) After adjustment, install all the rope

pressing plates and fix them.

(4) Operation after installation:

Check whether the rope is installed in the

pulley and real groove as regulation.

Check whether steel wire rope of the

elevator slips in the reel.

Check whether exist inclined traction which

may cause abrasion of the rope and reel.
Steel wire rope must coil in monolayer.
It is forbidden of overstepping the range of
reel groove.
Pay attention to the distance of the rope
coiled on the reel and the fixing state of

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HZS60 Concrete Batching Plant Operation

the rope end.

After installation the two ropes should
have equal length and pulled straight.

Check whether all the function of devices

which are relevant to the rotation of the
steel wire rope (pulley, reel, proximity
switch, limit switch and rope loosening
switch) run well.

In order to adjust the steel wire rope and

its accessories to the proper state for
practical use, please carry out several up
and down moving on the elevator in a no-
load state.

Carry out loading test after ensuring all

the situations are going well. Never start
to produce until the test is errorless.

4. Installation situation of the steel

wire rope
(1) Coiled rounds in advance
On the two ends of the reel, besides the
fixed 2 rounds, other required rounds
should be coiled near the fixed rounds.

(2) Direction of the rounds

The reel groove is spiral, and the direction if the reel left turning groove
where rope comes out must be the same is on the left, rope comes pre-round number
out above the reel no skip round
as the reel groove. Right turning steel wire
rope is proper for the left turning reel, and
the right-hand judgement is suitable. As
is reverse for left turning steel wire rope.
Face the elevator, if the reel left turning
groove is on the left, direction where the
rope comes out is above the reel. If the
right turning groove is on the left, rope will
come out from the bottom of the reel (see
Fig. 4-91). Fig. 4-91 Correct installation of steel wire
rope

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Operation HZS60 Concrete Batching Plant

(3) Skip round

The 2~3 pre-rounds of the steel wire rope
skip round during pre coiling
should be no skip round (it is to say the
steel wire rope skips groove and coils to
the next one or two rounds, as is shown
in Fig. 4-92). Skip round is made after
the elevator bucket rushing to the bottom.
Therefore check the situation of rope round
is very important after elevator bucket
rushing to the bottom.

Fig. 4-92 Skip round during pre coiling

If there are situations as insufficient

pre-rounds, wrong coming out direction
of rope, skip round and so on, please
install the steel wire rope in a correct
way. If skip round still exist, please
check whether the rail is level and
straight, the elevator bucket is out of
shape, length of the two steel wire rope
are same, or other reasons.

5. Adjust length of steel wire rope

a) During installation, length of the two
Normal position: bottom screw
steel wire ropes should be as same as rod is parallel and level with the
possible. After installation, adjust by the inner end face of the cross-shape
connecting rod
cross-shape connecting rod of the anti-
loosing protective device. Adjustment
diagrams are shown in Fig. 4-93 and Fig.
4-94.
b) After installation, deviation of the
two rope length should not exceed 5mm.
Checking measures: put elevator bucket
down by inching, and the step should as
small as possible. Springs on the two anti-
Fig. 4-93 Adjustment of the rope length 1
loosing devices of steel wire rope should

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HZS60 Concrete Batching Plant Operation

jack the anti-loosing switches at the same Adjust cross-shape connecting rod
time. Besides, knock the two tense steel downward, 50 mm at most
wire rope to judge the length of two ropes
are equal according to the tension grade.

Fig. 4-94 Adjustment of the rope length 2

6. Fixing method of the steel wire rope clip:

Fix the steel wire rope clip as shown in

ring
Fig. 4-95. Never place the clip alternately (rope hanging ring) Rope clip
on the steel wire rope. It is to say that the
direction of the clips should be the same.

(1) Number of the rope clip:

CK batching plant need 4 clips every steel
wire rope. The distance A between clips is
about 120 mm.

(2) Strength on the clip fixed position:

If dispose and fix according to the method Fig. 4-95 Fixing method of the rope clip
above correctly, strength on the fixed
position should be 80% of the steel wire
rope strength at least.

(3) Precautions:
Force of every clip should be considered
during fixing it. Never first fix the clip furthest
leaving the rope hanging ring individually.

The clip nearest the rope hanging ring

(first clip) should close to the ring as much
as possible, but you should ensure the
clip be screwed down correctly and never
damage the outer steel wire of the rope

Ensure the clips are still firm after

several steres (about 100 steres). Fix it if
necessary.

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7. Steel wire rope limit assembly

To prevent the steel wire rope running out

of the pulley groove, limit assembly should Bolt
be installed. Limit assembly of HZS60F
batching plant shown in Fig. 4-96 limits
steel wire rope via bolts.

Fig. 4-96 L i m i t a s s e m b l y f o r s t e e l w i r e
rope in HZS60F batching plant

8. Anti-loosing switch of the steel wire

rope test

The anti-loosing switch should be effective.

Test method: moving the elevator bucket
down to the pit bottom until reaching the
position set the anti-loosing switch. At the
same time, the anti-loosing switch should
be alarm by jacking. Test whether the two
switches are effective.

4.6.2.2 Proximity switch of the elevator

There are 3 kinds of proximity switch on

the elevator. One kind is green inductive
switch , whose name is proximity switch
NBN40-U1-Z2 (see Fig. 4-97). It is installed
on the trail to reduce the speed and stop,
when the elevator is near the upper and
lower limit position.

Fig. 4-97 Proximity switch

Another kind of switch called position

limit switch WLCA32-41 (see Fig. 4-98)

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HZS60 Concrete Batching Plant Operation

is installed on the rail to function, when

the stop proximity switch of the upper and
lower limit position has malfunction. It cut
off the power of transducer and elevator
reducer to protect them.

Fig. 4-98 Proximity switch

The last kind of switch called position limit

switch WLCA12 (see Fig. 4-99) is installed
on top of the elevator. When the spring
of steel wire rope doesn’t have enough
pressure, this switch function to stop the
winch from extending the rope.

Fig. 4-99 Position limit switch

1. Number of the proximity switches

Number of the proximity switches used

in different model of elevator is shown in
Table 4-2 on page 4-83.

Table 4-2 Number of the proximity switches

Batching Switch
Number Part Requirements
plant model model

Two switches on each end of the rail, induce

A 4 On the rail
the elevator bucket and reduce the speed.

One switch on the upper part of rail, and

B 3 On the rail
HZS60F the other on the bottom.
At one end of
Send an alarm signal (rope messing or
the steel wire
C 1 breaking), and control the winch motor to
rope (upper part
stop.
of the elevator)

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Operation HZS60 Concrete Batching Plant

2. Installation position of the proximity

switch in HZS90K batching

In III-generation batching plant, proximity

switch is installed on a long installation
seat (see Fig. 4-100). It can be adjusted up
and down. Inductive head of the proximity
switch faces the upper rail to induce the
pulling rod frame.

Fig. 4-100 P r o x i m i t y s w i t c h i n H Z S 9 0 K
batching plant

a) Ensure the proximity switch installation

seat be welded on the rail before hanging.
b) Ensure that the number and position
of the proximity switches accord with the
requirements. Distance of the proximity
switch and test plate is better about 20
mm. Pay attention that the test plate
should not touch the proximity switch.

3. Installation diagram of steel wire

rope anti-loosing device
Steel wire rope anti-loosing device is to
prevent steel wire rope from damage by
loosing, and it will alarm when the rope
is loosing. There is a spring inside the
cylinder of the anti-loosing device. It is
always pressed, and it will upspring to
touch the anti-loosing position limit switch.
Then the switch will cut off power of the
elevator reducer. Anti-loosing device is
shown in Fig. 4-101.
Fig. 4-101 Anti-loosing device

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Bouncing height of the spring in anti-

loosing device is about 20mm. Please
adjust the position of the anti-loosing
position limit switch to make it effective.

4. Notes
a) Check the upper limit position of the
elevator bucket in the work site. Check
whether material in the bucket is totally
discharged. If not, please adjust position
of the upper stop position switch. Distance
between pulling rod assembly and buffer is
about 30 mm (see Fig. 4-102).
Fig. 4-102 Upper limit position
b) Check the lower limit position of the
elevator bucket. Check whether the bucket
receive material fluently. If there is leakage
in the belt weigher head, please adjust
position of the lower stop position switch.
When the bucket reaches the bottom of
the elevator, distance between the bucket
body and buffer in the steel structure
base is about 100 mm. If the scraper on
the level belt head scrapes material into
the elevator bucket, please add guiding
material plates (see Fig. 4-103).
Fig. 4-103 Head of the belt weigher
c) When adjust switches of the upper and
lower stop position, please adjust upper and
lower position limit switch at the same time.

d) After all the proximity switches are

installed, test for several times to ensure
whether they are effective. Carry out
producing after all the switches are effective.

e) During testing proximity switches, in

order to prevent proximity switches from
breaking or running out of control, inching
press the upper and lower running buttons
of the elevator to control climbing length or
descending length.

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4.6.2.3 Other precautions of the elevator

1. Material leaking of the level belt

If level belt head leaks material, it is to say

there are sand and stone material leaked
into the pit. Add material guiding plate to
the material receiving position. The guiding 1
plate should be welded firm and reliably,
and it should never interfere running of the
elevator (see Fig. 4-104).

Fig. 4-104 Material guiding plate on the

belt weigher head
1-Mateiral guiding plate

2. Guide rail of the elevator

Verticality: the verticality of the guide rail crashing point

should be less than 25 mm. The flatness
allowance in the connecting position is 0.5.

Small guide rail: live pulley should not

crash the small guide rail. Fig. 4-105
shows the crashing situation.

Fig. 4-105 Live pulley and small guide rail

crashing

Position limit plate can prevent live pulley

of the bucket from slipping out of the Enclosure plate
bottom guide rail and causing accident. If of the guide rail
there isn’t a position limit plate, please use
other material to enclose the guide rail. It
is required that thickness of the material is
above 10mm, and the weld line is reliable,
as is shown in Fig. 4-106.

Fig. 4-106 Enclosure plate in the HZS90K

batching plant guide rail

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HZS60 Concrete Batching Plant Operation

3. Pulley and live pulley

Pulley and live pulley as shown in Fig. 5-88

on page 5-67need enough lubrication.

Screws and bolts of them should be firm

and reliable.

There should not exist interference

between pulleys and shaft sleeve.

4.6.2.4 Special statement

a) If there are conflicts between the

content above and “GB/T 5972-2009
maintenance, installation, test and
abandon of steel wire rope for crane”,
please carry out according to the latter.

b) Refer to electrical direction for detailed

test information of the proximity switch.

4.6.3 Operation of mixer

4.6.3.1 Delivery of the mixer

1. State of leaving factory

Sufficient lubricant has been added into

the reducer on the shaft when the mixer is
delivered, and sufficient lubricating grease
has been applied on the bearing and shaft
end seal at the same time.

2. Test run

Test run has been performed on the mixer

under no-load condition before the mixer
is delivered. However, the operation in the
adjustment period is not performed yet.
Follow the instructions for operation in the
adjustment period strictly.

4.6.3.2 Transport of the mixer

The cylinder body of the mixer is equipped
with four lifting eyes (see Fig. 4-107).

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Operation HZS60 Concrete Batching Plant

Fasten the mixer with ropes during the

transportation and do not tie the rope to
other positions.

For detailed information of the mixer

weight, see: “7.2 Specifications of
Mixer” on page 7-5.

Furthermore, check the discharge gate,

maintenance platform for fastness to
prevent damage during the transportation.

4.6.3.3 Installation of the mixer

1. Installation base

The mixer should be installed on the 1

level, firm and safety installation base. Fig. 4-107 Transport of the mixer
Manufacture the installation base 1-Lifting eye
according to the installation location of the
base, and take into consideration the load
and other factors during operation.

2. Installation

When installing the mixer, secure the mixer

body onto the installation base (see Fig.
4-108). Check the level positions at four
installation bases before securing with the
bolts. In case of unevenness, use thin iron
sheets to adjust the level height.

During the installation, unevenness could

result in troubles, such as distortion of
mixer body, extra force on drive part of
the mixer, and hard opening/closing of the
discharge gate.

Besides, the two reducers of the mixer is Fig. 4-108 Installation of the mixer
connected by coupling. Check the level
position of the coupling, too.

3. Caution items of installing the

discharge gate edge

During installing the edge of discharge

gate, the clearance between the edge

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HZS60 Concrete Batching Plant Operation

and the liner plate shall be adjusted to clearance 0.5~1.5 mm 1 2

0.5~1.5mm. If the clearance is too small,
the discharge cannot be opened and
closed smoothly (see Fig. 4-109).

Fig. 4-109 Clearance of discharge gate

installation
1-discharge gate 2-discharge gate edge

4.6.3.4 Drive of the mixer

1. Method to drive the motor

Generally, Y-∆ startup is adopted. In normal

operation, begin with Y-start firstly and
then automatically switch into ∆-startup
with delay to connect the motor.

However, in case of stop due to power

failure or other abnormal conditions, and
the motor is started again artificially, the
∆-startup with great starting torque shall
be applied.

For safety reason, the motor shall be

stopped with the E-STOP button on the
mixer as shown in Fig. 2-43 on page 2-30
under emergencies.

2. Cable connection and confirming

rotation direction of the motor

Check the rotary direction under no-load

condition. Switch off one motor and switch
on another to check the rotary direction,
and then perform the check vice versa.
The rotary direction of the main shaft shall
be counterclockwise from the left side and
clockwise from the right side at both ends
of the shaft as shown in Fig. 4-110.
Fig. 4-110 Rotation direction of main shaft

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Operation HZS60 Concrete Batching Plant

4.6.4 Operation of the air compressor

An air compressor (see Fig. 4-111)

compresses the air via the upward and
downward movement of the piston in the
cylinder. During the downward stroke
of piston, the air is sucked via the inlet
valve and the exhaust valve is closed.
During the upward stroke of piston, the air
is compressed, the inlet valve is closed
and the exhaust valve is opened; and the
compressed air flows into the air tank via
one-way valve. The compressed air cannot Fig. 4-111 Air compressor
be utilized until the pressure in the air tank
raises to the required pressure.

4.6.4.1 Preparation and installation of

the air compressor

1. Location to set the air compressor

a) A location with low humidity, less dust,

less pollution, clean air and good ventilation
can prolong the service life and improve
the efficiency of the air compressor.

b) A location with sufficient light, easy

to check and convenient to add oil is
suitable. The maintenance room should be
reserved. Place the air compressor levelly
as much as possible. The belt side should
be placed toward the wall with sufficient
distance; otherwise it will impact the
cooling function of the fan. 1

2. Installation of motor 2

a) If you assemble a motor bought yourself,

select the motor with corresponding
horsepower (HP) of the air compressor.
3 4
b) Pay attention to indication as shown in
Fig. 4-112 when installing the V-belt. Fig. 4-112 Indication of V-belt installation
1-Right angle 2-V-belt 3-Air compressor
4-Motor

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HZS60 Concrete Batching Plant Operation

c) Adjust the tension of belt properly

to such an extent that the V-belt is
10mm~15mm lower than the original height
when force (about 3kg~4.5kg) is applied
between the two pulleys.

Adjust the tension of belt properly.

a) An excessively tight V-belt increases
the load as well as the heat and power
consumption of the motor; and the
belt is likely to break due to excessive
tension.
b) An excessively loose V-belt causes
high temperature of belt due to sliding
and damage on belt, resulting in
unstable speed of the air compressor.
Standard lubricant oil level

3. Lubricant

a) Keep the oil level between the two red

lines of the oil level sight glass or between
the upper and lower edges of the red line
as shown in Fig. 4-113.

b) Lack of oil could cause abnormal

Fig. 4-113 Oil level sight glass
operation or even burnout.

c) Excessive oil could cause waste and

carbon deposition at the exhaust valve,
thus shortening the service life of the
entire machine.

d) Make sure the oil is supplied when the

air compressor stops.

4.6.4.2 Operation of the air

compressor

1. Check the following items before

startup:

a) Check the screw and nut each position

for loose.

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Operation HZS60 Concrete Batching Plant

b) Check the tension of belt.

c) Check the pipeline.
d) Check the lubricating surface (see Fig.
4-113 on page 4-91).
e) Check that the belt pulley of air
compressor can be rotated by hand easily.

2. Precautions for operation

a) Switch on all the exhaust switches after

the check is completed, and then press the
start button to operate the machine under
no load. This could prolong the service life
of the air compressor and motor.

b) Check that the operating direction is

same as the arrow indication on the belt
cover. Otherwise, exchange any two wires
of the three-phase power line.

c) Switch off the exhaust switches if there

is no abnormal noise after three minutes
since startup. Increase the pressure in
the air tank to the preset value, and then
implement protection function test.

d) Protection function test (A: Semi-auto

type B: Full-auto type) Handle ring1

● ● Semi-auto type: the pilot valve (see Fig.

Pressure 2
4-114) is actuated when the pressure regulating nut
reaches the preset value to operate the
air compressor under no load.
3
● ● Fully-auto type: the pressure switch Retaining nut
cuts off the power supply automatically
to stop the motor when the pressure
reaches the preset value.

3. Regulation of pressure control Fig. 4-114 Pilot valve

system
1-Handle ring 2-Pressure regulating nut
a) Adjustment of pilot valve (details are 3-Retaining nut
instructed on the air storage)

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When modifying the preset pressure,

the preset pressure cannot exceed the
following specifications: 7kg/cm 2 for low
pressure type 12kg/cm 2 for high pressure
type. Regulation steps are as below:

● ● Loosen the retaining nut (see Fig.

4-114);
● ● Rotate the pressure regulating
nut, clockwise for pressurizing and
counterclockwise for depressurizing;
● ● Tighten the retaining nut.

b) Valid regulation range of pressure Pressure Pressure difference

regulating screw 2regulating screw
1
(Single section) low pressure type: 5~7kg/
cm 2 (double section) high pressure type:
8~12kg/cm 2.

c) Control and regulation of pressure

switch (see Fig. 4-115)

● ● Rotate the pressure regulating screw

clockwise for pressurizing;
3 wire
Grounding
● ● Rotate the pressure difference
regulating screw counterclockwise for Fig. 4-115 Pressure switch
decreasing the pressure difference. 1-Pressure regulating screw 2-Pressure
difference regulating screw 3- Grounding wire

4. Safety valve

The relieving pressure of the safety valve

is already set in the factory, so do not
regulate without authorization.

4.6.5 Operation of additive pump

4.6.5.1 Startup of additive pump

1. Fill additive pump with water (or

delivery liquid) fully

Fill the pump as shown in Fig. 4-116 on

page 4-95 with water in the flow backward
system: close the valve on the pump outlet,

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Operation HZS60 Concrete Batching Plant

open the screw block on the pump head,

open the water inlet valve slowly until the
water flows out from the air exhausting
screw block, and then screw down the air
exhausting screw block. Fully open the
retaining valve on the sucking pipeline.

Fill the pump with water if the liquid level

in the pump is lower than it in the open
system: close the valve of pump outlet,
open the screw block on the pump head,
inject liquid into the pump via screw block
hole until the pump and suction inlet
pipeline are full filled with water, and then
screw down the screw block again.

a) Before pump full filled with liquid and

drain out air thoroughly, do not start up
the pump!

b) Take care of the air exhausting hole

direction of exhaust screw block, ensure
the overflow water not injure persons.

2. Check the rotating direction

Switch on the power supply, observe the

rotating direction according to the fan’s
turning. The correct rotating direction of
pump shall be anticlockwise if look from
the motor end as shown in Fig. 4-116.

3. Checking before pump startup

Check whether the foundation bolts is

screwed down;

Check whether the pump is full filled with

water;

Check whether the voltage of the power

net is correct;

Check whether the rotating direction is

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HZS60 Concrete Batching Plant Operation

correct;

Check whether all the pipelines are

connected well, and whether the water
10
supply is normal;
11
Check whether the valve on the water inlet 1 12
13
is fully opened. Outlet valve shall be open
14
slowly after pump startup. 2 15
3 16
Check all the controls needed by normal 17
running. If pump is controlled by pressure 4 18
5 19
switch, check and adjust starting and
cutting pressure. Check the current of 6 20
full loading via pressure switch to ensure 7 21
the current not exceed the max allowable 8
9
current. 22
4. Startup times of pump
Fig. 4-116 Additive pump
It is prohibited that start the pump as 1-Motor 2-Mechanical sealing 3-Shaft coupler
shown in Fig. 4-116 in high frequency. It 4-Pump head 5-Pull rod 6-Wire spring 7-Water
is suggested that startup times are not outlet guidance blade 8-Pump shaft 9-Water
more than 100 with motor power ≤ 4kW, in/out section 10-Snap ring sleeve 11-Seal
distance piece 12-Impeller distance piece
and startup times are not more than 20
13-Guidance blade 14-Impeller short distance
with motor power ≥ 4kW. If the pump is
piece 15-Wearing shaft sleeve 16-Supporting
started up in high frequency, adjust the
guidance blade 17-Impeller 18-Pressure cover
control device and reduce the starting and
of impeller 19-Flow guider 20-Pressure proof
stopping frequency. At this time check the
tube 21-Seal ring 22-Bottom seat
installation circumstance.

4.6.5.2 Disassembly and assembly of

additive pump

1. Installation of additive pump

a) Install the snap ring sleeve cover

on the shaft. Install seal distance piece,
impeller, impeller distance piece, guidance
blade, supporting guidance blade and until
the last impeller, and then install pressure
cover of impeller and washer. Screw
down the nut. Take care of the position of
supporting guidance blade. See Fig. 4-116
on page 4-95.

b) Install the flow guider to the water in

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Operation HZS60 Concrete Batching Plant

& out section and bottom seat, and then

install the assembled parts to the flow
guider.

c) Install seal ring and pressure proof

tube to the water in/out section, and then
install the water outlet guidance blade.

d) Install the pump head assembled seal

ring, pump head liner and wire spring to
the pressure proof tube. Screw down the
four pull rod nuts. Screw down the nut
symmetrically in turn instead of screwing
down one nut once.

e) Install mechanical sealing and screw

down. Install motor and shaft coupler,
screw the blots on the coupling (do not
screw down), push the coupler including
pump shaft to the bottom in direction of the
seat, and then move 1mm in a reversing
direction. Screw down the blots and keep
the space between of two coupler blocks
equal.

f) Screw the fixing bolts on the

mechanical sealing. Rotate the coupler.
Ensure the shaft should rotate flexibly
without clamping and improper degree of
tightness.

2. Disassembly of additive pump

Disassembly steps are in a sequence

reverse to assembly.

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HZS60 Concrete Batching Plant Maintenance

Maintenance
5 Maintenance
5.1 Preparing for Maintenance.....................................................................................5-5
5.1.1 Before maintenance.......................................................................................5-5
5.1.2 After maintenance..........................................................................................5-7
5.2 Precautions during Maintenance...........................................................................5-7
5.2.1 Precautions of producing operation................................................................5-7
5.2.2 Precautions during operation of liquid and air delivery...................................5-8
5.2.3 Precaution during oil selection.......................................................................5-9
5.3 Daily maintenance.................................................................................................5-9
5.3.1 Daily inspection..............................................................................................5-9
5.3.2 Replacement of wearing parts......................................................................5-13
5.3.3 Inspection and maintenance intervals..........................................................5-14
5.4 Maintenance of Main Parts..................................................................................5-16
5.4.1 Maintenance of the mixer.............................................................................5-16
5.4.1.1 Inspection and adjustment before operation.......................................5-16
5.4.1.2 Motor of the transmission system.......................................................5-20
5.4.1.3 Transmission system..........................................................................5-24
5.4.1.4 Shaft end sealing................................................................................5-35
5.4.1.5 Liner plate assembly...........................................................................5-42
5.4.1.6 Mixing device......................................................................................5-43
5.4.1.7 Discharging device..............................................................................5-45
5.4.1.8 Upper cover of the mixer.....................................................................5-47
5.4.1.9 Electrical control system.....................................................................5-48
5.4.1.10 Monthly inspection of the mixer.........................................................5-48
5.4.2 Maintenance of measuring system...............................................................5-50

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Maintenance HZS60 Concrete Batching Plant

5.4.2.1 Weighing sensor.................................................................................5-50

5.4.2.2 Replacement of five-pore junction box/signal inverter ST-001............5-52
5.4.2.3 Weighing instrument...........................................................................5-53
5.4.2.4 Maintenance of measuring system.....................................................5-54
5.4.3 Maintenance of belt conveyor......................................................................5-59
5.4.3.1 Helical-bevel gear reducer..................................................................5-59
5.4.3.2 Turnabout drum...................................................................................5-63
5.4.3.3 Maintenance of the belt conveyer.......................................................5-64
5.4.4 Maintenance of elevator...............................................................................5-67
5.4.4.1 Precautions before maintenance........................................................5-67
5.4.4.2 Replacement the steel wire rope........................................................5-67
5.4.4.3 Adjustment of brake motor..................................................................5-68
5.4.4.4 Maintenance of elevator......................................................................5-69
5.4.5 Maintenance of the powder silo....................................................................5-71
5.4.5.1 Silo-top filter core................................................................................5-71
5.4.5.2 Level gauge........................................................................................5-79
5.4.5.3 Aeration pad........................................................................................5-80
5.4.5.4 Maintenance of powder silo................................................................5-81
5.4.6 Maintenance of screw conveyor...................................................................5-84
5.4.6.1 Installation of screw conveyor.............................................................5-84
5.4.6.2 riving head and seal in end bearing....................................................5-86
5.4.6.3 Replace middle hanging shaft assembly............................................5-86
5.4.6.4 Maintenance of screw conveyor.........................................................5-88
5.4.7 Maintenance of control room........................................................................5-88
5.4.8 Maintenance of aggregate storage discharging system...............................5-89
5.4.8.1 Discharge gate of aggregate storage bin............................................5-89
5.4.8.2 Discharge gate of aggregate weighing hopper...................................5-90
5.4.9 Maintenance of addtive pump......................................................................5-91
5.4.9.1 Anti-freezing measure.........................................................................5-91
5.4.9.2 Pump needs check as followings periodically.....................................5-91
5.5 Maintenance of Liquid and Air Supply System.....................................................5-92
5.5.1 Liquid supply system....................................................................................5-92
5.5.1.1 Impeller of water pump and mechanical seal......................................5-92
5.5.1.2 Bearing of water pump........................................................................5-93
5.5.2 Air supply system.........................................................................................5-94
5.5.2.1 Air compressor....................................................................................5-94

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HZS60 Concrete Batching Plant Maintenance

5.5.2.2 Pneumatic triplet...............................................................................5-100

5.5.2.3 Solenoid valve...................................................................................5-104
5.5.2.4 Spherical vibrator..............................................................................5-106
5.5.2.5 Pneumatic cylinder............................................................................5-107
5.6 Maintenance of Control System.........................................................................5-109
5.6.1 Computer ................................................................................................
. 5-109
5.6.2 Monitor....................................................................................................... 5-111
5.6.3 UPS power.................................................................................................5-112
5.7 Maintenance of Lubrication System...................................................................5-113
5.7.1 Lubrication part of the batching plant.........................................................5-113
5.7.2 Lubrication for main parts...........................................................................5-114
5.7.2.1 Lubrication of the mixer.....................................................................5-114
5.7.2.2 Lubrication of the screw conveyor....................................................5-120
5.7.3 Grease for centralized lubrication...............................................................5-121
5.7.3.1 Replenishment of bearing lubricant greases.....................................5-121
5.7.3.2 Replenishment of lubricant grease at the shaft end seal..................5-121
5.8 Warranty Clauses of the Concrete Batching Plant.............................................5-122
5.8.1 General.......................................................................................................5-122
5.8.2 Detailed regulations....................................................................................5-123

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Maintenance HZS60 Concrete Batching Plant

WARNING
Always read the Safety section of this
manual before attempting to operate
this equipment. Failure to do this could
result in machine damage, personal
injury or death.

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HZS60 Concrete Batching Plant Maintenance

5 Maintenance

Maintainers in the plant must wear

necessary overalls and safety equipment.

5.1 Preparing for Maintenance

5.1.1 Before maintenance

Before performing any maintenance on the

equipment:

Controls, and power source, should be

properly tagged. During all maintenance
or repair, lockout tagout procedures must
be used to ensure the safety of service
personnel involved in the maintenance
process of the machine. All power sources
must be disabled, locked and tagged with
warning labels (see Fig. 5-1and Fig. 5-2).

Fig. 5-1 Do not operate

Fig. 5-2 Maintenance alert tag

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Maintenance HZS60 Concrete Batching Plant

Only authorized personnel performing

repairs on the machine shall perform
lockout tagout in accordance with the
procedure listed below.

If the employee performing repairs to

the machine is issued a lock and key,
the employee shall not share the lock or
key with other personnel until all repair
procedures are complete and the machine
is ready to put back into service.

The following steps shall be performed in

the sequence listed when the equipment is
to be locked-out and tagged-out for service
or repair.

1. Locking out of service

● ● Notify all personnel who may be

potentially affected by the repair or
maintenance on the machine.
● ● Secure the machine in a safe position.
If so equipped, set the parking brake
or hydraulic lock lever in the parked (or
locked) position.
● ● Identify, remove or disconnect all
power or energy sources and be sure
to install a lockout tagout device on
them.
● ● If the machine is equipped with a
maintenance alert tag as shown in
Fig. 5-2 on page 5-5, attach it to the
machine controls.
● ● Be sure all personnel involved in the
repairs have installed their own locks
on the power source before performing
any repairs. Each employee who
completes a repair must remove his
own lock and not access the machine
further.

2. Returning to service
● ● The authorized person who performed

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HZS60 Concrete Batching Plant Maintenance

the lockout tagout procedure shall

check the area around the machine to
ensure that no one is exposed to any
hazard before start-up.
● ● The authorized person who performed
the lockout tagout shall ensure that all
guards have been properly reinstalled
to their respective locations, all tools,
equipment and locks have been
removed.
● ● The authorized person who performed
the lockout tagout shall verify that
all controls are in the neutral or “off”
position and that all personnel are
aware of the time the machine will be
back in service.
● ● Remove the lockout tagout mechanisms
and all tags and re-energize the
machine for return to service.

5.1.2 After maintenance

After maintenance or repairs:

1. Fill out the required maintenance

record form. See maintenance section of
this manual for information about this.

2. Replace all guards and covers that

have been removed.

3. Remove all tags, connect the battery,

and perform a function check of all
operating controls.

5.2 P r e c a u t i o n s d u r i n g
Maintenance
5.2.1 P r e c a u t i o n s o f p r o d u c i n g
operation

1. Please backup data to other storage

medium periodically (1 or 2 months,

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Maintenance HZS60 Concrete Batching Plant

customer determines the period according

to the data amount) (see Fig. 5-3).

Fig. 5-3 Backup data

2. After replacing the sensor or improving

the measuring system, calibrate the
weigher (see Fig. 5-4).

Fig. 5-4 Calibrate the weigher

5.2.2 Precautions during operation

of liquid and air delivery

1. Liquid supply system includes additive

supply system and water supply system.
Water for mixing is always clean water. But
clean industrial water recycled from the
flushing device is adopted too.

2. The inlet of the air filter must be kept

clean to prevent decreasing of the air
supply caused by jam.

3. Open the exhaust valve to discharge

the air before the machine is started and
after it is shut off.

4. Prevent scrap iron, dust and fragments

of sealing material from entering into the

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HZS60 Concrete Batching Plant Maintenance

pipes during maintenance. Blow and clean

the pipeline with compressed air.

5. Pay attention to not leave the sundries

and fragments like adhesive tape in the
tube during maintenance.

5.2.3 Precaution during oil selection

It is forbidden to mix the different

lubricants together, or the service life
of device will be affected.

5.3 Daily maintenance

5.3.1 Daily inspection

1. Check the working conditions of

lubrication points of all rotating parts every
day and add lubricant in time (see Fig.
5-5).

Fig. 5-5 C h e c k l u b r i c a t i o n p o i n t s o f a l l
rotating parts

2. Check the lubricant in the mixer oil cup

every day and add lubricant if the oil lever
is lower than the middle of the oil indicator
in time (see Fig. 5-6).

Fig. 5-6 Check the lubricant in the mixer

oil cup

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Maintenance HZS60 Concrete Batching Plant

3. Check the oil level of oil mist device on

the pneumatic system once a week, and
apply lubricant with viscosity of 2.5 ~ 7°E
(see Fig. 5-7).

Fig. 5-7 Check oil mist device

4. Open the drain valve once before

startup and after shutdown respectively,
to drain water accumulated in the air
compressor and air reservoir (see Fig.
5-8).

Fig. 5-8 Open the drain valve

5. Check fasteners (as bolts and nuts)

weekly for looseness. In case of looseness,
tighten in time, especially the parts bearing
variable amplitude load (see Fig. 5-9).

Fig. 5-9 Check fasteners for looseness

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HZS60 Concrete Batching Plant Maintenance

6. Frequently check whether the

equipment of water supply, air supply and
additive systems are normal every day
(see Fig. 5-10).

Fig. 5-10 Check the equipment

7. Check whether the electric control

system and instrument are normal (see
Fig. 5-11).

Fig. 5-11 C h e c k t h e e l e c t r i c c o n t r o l
system and instrument

8. Check the mixing shaft and drum of the

mixer daily for cleanness. Clean manually
if excessive concrete coagulated on the
mixing shaft (see Fig. 5-12).

Fig. 5-12 Check the mixing shaft and drum

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Maintenance HZS60 Concrete Batching Plant

9. Check two pressure safety valves

installed on the powder silo every week.
Observe whether there is dust accumulated
around the valves. Open the pressure
safety valve and clean immediately if there
is dust accumulated. Stop blowing powder
and clean the top filter of silo if the powder
emits from silo top.

10. Clean or replace filter screen in the

silo-top filter regularly. It is forbidden to
wash the filter core with water. Use blowing
air or soft brush to clean instead (see Fig.
5-13).

Fig. 5-13 Clean or replace filter screen

11. Clean the filter bag in the deduster

every 3 days. Replace the filter bag and
flexible connection of the weighing devices
every 3 months.

12. Clean the filter core of the deduster

every 3 months, and ensure to replace it
every year (see Fig. 5-14).

Fig. 5-14 Clean the filter core

13. Discharge materials (such as cement,

water, additive and various aggregates)
from all weighing hoppers if the stop time
of the plant exceed one week. Clean the
mixer and discharge hopper and so on to

5-12 Safety, Operation & Maintenance -Manual - October, 2014

HZS60 Concrete Batching Plant Maintenance

prevent materials from hardening.

5.3.2 Replacement of wearing parts

1. Mixing blades and liner plates

Mixing blades (see Fig. 5-15) and

liner plates are made of wearable cast
iron. Replace fittings as required in
the maintenance manual (For detailed
information, see: "5.4.1.6 Mixing
device" on page 5-43 and "5.4.1.5 Liner
plate assembly" on page 5-42).

Fig. 5-15 Mixing blades

2. Conveying belt

For load and service conditions, the

conveying belt may be aging or damaged 1 2
see Fig. 5-16). Replace it if the production
is affected.

Replacement of conveying belt:

a) Firstly dismount the old belt:

● Disassemble outer wrapping and

●
frame.
● Remove the upper idler.
● 3 4 5
● Loosen the reducer.
● Fig. 5-16 conveying belt
● Loosen the drive drum assembly. 1-Belt 2- Upper idler 3-Reducer
●
● Loosen the belt. 4-Frame 5-Drive drum assembly
●
b) Assemble new belts on belt conveyor.
Tighten the drive drum assembly and motor
assembly. Assemble the upper idler, frame
and outer wrapping. The replacement is
completed.

3. Seal of discharge gate of the mixer

If the seal is worn, adjust the discharge gate

upwards to compensate. After adjustment,
if discharge gate can’t compact the seal to
prevent leakage, it indicates that the seal

Safety, Operation & Maintenance Manual - October, 2014 5-13

Maintenance HZS60 Concrete Batching Plant

is worn out and must be replaced.

4. Filter core in silo-top filter

If the dedusting performance is still bad

after cleaning, the filter core in the silo
top filter must be replaced. For detailed
information, see "5.4.5.1 Silo-top filter
core" on page 5-71.

5.3.3 Inspection and maintenance

intervals
Table 5-1 Daily maintenance items

Intervals

Running time, hours/month (meaning:

Items
running hours/running months)

500/3 1000/6 1500/9 2000/12 2500/15

Compressor
Inspection of oil level
Daily
in crank shaft box
Inspection and cleaning
Weekly
of air-inlet filter
Inspection and cleaning
Monthly
of lubricant
Petroleum type lubricant √ √ √ √ √
Change lubricant of
√
crank shaft box
O-ring of loading relief piston √
Valve of compressor
- inspection, cleaning √
and replacement

Cleaning of appearance
Monthly
of inter-cooler
Inspection of low oil level
√ √ √ √ √
switch (if selected)
Manual safety valve Monthly
Cleaning of cylinder blade Monthly
V-belt
Tension inspection of belt Monthly

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HZS60 Concrete Batching Plant Maintenance

Motor
Inspection and lubrication
√
of motor bearing
Cleaning motor Monthly (weekly under bad ambient conditions)
Rear-cooler
Cleaning the outside
Monthly (weekly under bad ambient conditions)
of the rear-cooler
Cleaning the inside of
√
the rear-cooler
Air reservoir
Manual drainage valve Drain water manually once every 8 hours of running
Safety valve Monthly
Other
Inspection and
Monthly
tightening all blots
Inspection of abnormal
Monthly
sound and vibration
Leakage inspection Monthly

Table 5-2 Inspection items and intervals

Intervals Every 2,000 Every 10,000 Every 30,000 Every 50,000

Daily tanks of tanks of tanks of tanks of
Items running running running running
Oil level in oil cup √
Each lubrication point √
Cleaning of mixing shaft √
Mixing blades and
√ √
liner plates
Filter core of silo-top filter √
Conveying belt √
Looseness of
√
bolts and nuts
Drainage of air reservoir
√
of air compressor
Oil level of oil mist device √
Pneumatic butterfly valve √
Pneumatic solenoid valve √
Once a
Deduster system
week

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Maintenance HZS60 Concrete Batching Plant

5.4 Maintenance of Main Parts

5.4.1 Maintenance of the mixer

5.4.1.1 Inspection and adjustment

before operation

Before operation of the mixer, please

check as below:

1. Requirements on raw materials

The mixer is applicable to powdery or

granulose inert substance, whose diameter
should not exceed 80mm; and 80mm
medium may not exceed 12% of the total
capacity (see Table 5-3 for proportion).

Table 5-3 Features of the mixer

Model 2250/1500 3000/2000 4500/3000 Remark

Aggregate
0~80 0~80 0~80
diameter (mm)
0~32≌50% 0~32≌40% 0~32≌40% Special mixing
32~63≌20% 32~100≌35% 32~100≌35% blade is
Volume percent 63~80≌10% 100~120≌13% 100~120≌13% necessary
80~100≌10% 120~150≌12% 120~150≌12%
100~125≌10% 150~180≌6%* 150~180≌6%

Using restrictions: The mixer is not

applicable to inert substance with diameter
exceeding 80mm, or adhesive medium
like soil with amount exceeding 12%, or
humidity in proximity to 15%. Damp-dry
concrete mixture sticking on the mixing
shaft will increase the diameter of the
mixing shaft, which will consequently
reduce the efficiency of the mixing arm.
Therefore, the mixing shaft must be kept
clean.

2. Lubricant level inspection of the

reducer

Check whether the oil level is in the

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HZS60 Concrete Batching Plant Maintenance

designated position, when the mixer is

stopped.

If the oil level is lower than the designated

position, you must add gear lubricant.
Please inject the same lubricant as before.

3. Add grease at each lubrication point

The specified quantity of grease shall be

added into each lubrication point. Four
points on the bearing of the mixing shaft;
four points on the shaft end seal (inner
side) and four standby points; four points
on the shaft end seal (outer side); two
points on the bearing of the discharge gate.
For detailed information, see: "5.7.2.1
Lubrication of the mixer" on page 5-114.

4. Inspection on the discharge gate

a) Check on the switch operation:

Check the discharge gate for smooth

operation and check the limit switch for
normal operation.

If the discharge gate cannot operate

smoothly, adjust the bolts at four legs for
levelling. Place thin iron sheet under the
leg with maximum clearance and tighten
the bolt.

5. Continuous feeding setting

Feed the aggregate, cement, and water into

the mixer to mix for concrete production.
The materials shall be fed into the mixer
in correct sequence. The sequence varies
with different equipment structure, but in
principle the following sequence shall be
followed.

Because that cement is lighter in weight

and less in quantity than aggregate, if the
cement and aggregate are fed into the mixer
at the same time, the cement is likely to be

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Maintenance HZS60 Concrete Batching Plant

pushed to the edge of the cylinder body

by the aggregate, and attached onto the
cylinder body walls, mixing arms or mixing
blades. Therefore, the delivery of cement
shall be started when 80% aggregate is
delivered, and the water shall be delivered
with the aggregate at the same time.

Feeding water earlier has no negative

influence on the mixing effect and can
decrease the load of motor during mixing.

6. Operation of the mixer in running-in

period

A newly purchased mixer cannot be

operated under full load during its initial
operation. The service life of reducer
may be shortened greatly if the running-
in operation is not implemented (see Fig.
5-17).

The sequence of running-in operation

is specified as follows: Operate for 30
minutes ~ 1 hour under no-load condition Fig. 5-17 Adjust the mixer
initially, and then shift into operation under
a loaded condition. Firstly, operate twice
with 50% of the load, and then operate
once with 100% of the load. Repeat the
procedure above for 30 times at least
and thus the running-in operation can be
completed.

7. Other daily inspection items

a) Tension of bolts

Check the tension bolts of blade, mixing

arm and liner plate after working for a
week. Check the tension of the connecting
blots between belt pulley and coupler after
working for 2000h.

b) Tightening torque of bolts

Mixing arm 420N•m; Blade 200N•m; Liner

plate 100N•m; Belt pulley 130N•m; Coupler

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HZS60 Concrete Batching Plant Maintenance

100N•m; Shaft end 450N•m.

c) Abrasion of wearing parts

Replace the mixing arm worn for 50%.

Replace the end liner plates and bottom
liner plates with abrasion more than 8mm.
Replace the side scratch plate, scratch
plate and blade with abrasion more than
8mm or when its clearance cannot be
adjusted.

d) Check and adjust the tension of drive

belt

The method of checking the tension of belt

is as below:

(1) Dismantle the cover of flywheel;

(2) Carefully inspect whether all belts are

intact, and whether there's any belt aged
or degummed. If one or more belts are
aged, replace belts in groups;

(3) When apply 100N (10kg) pressure on

the belt in the middle of two belt pulleys
(see Fig. 5-18), the deformation of belt in
this direction should not exceed 15mm.

Fig. 5-18 Apply pressure on the belt

Adjust tension of belt:

(1) Loosen nut of the adjusting bolt;

(2) Turn the nut to move down the bottom

plate of the motor, in order to tense the
belt;

(3) If the belt is too tense, loosen the nut

as steps above.

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Maintenance HZS60 Concrete Batching Plant

E-STOP buttons are set on the two ends

of the belt conveyor shown in Fig. 2-42
on page 2-29. During conveying belt
maintained, press E-STOP button to
prevent injuries.

8. Notes during mixer maintenance:

a) Generally, cut off the main power and

breaker of the maintained motor. Lock the
power cabinet door and put up a warning.

b) When cleaning and maintaining in

the mixer, keep the overhaul door open,
and check the overhaul door frequently to
ensure it is in a good condition.

5.4.1.2 Motor of the transmission

system

As shown in Fig. 5-28 on page 5-27,

transmission system of the mixer is mainly
composed of transmission shaft, reducer
pulley, planetary reducer, spline shaft,
spline shaft sleeve, motor, motor pulley
and v-belt. This section will introduce the
motor of the transmission system.

1. Structure of the motor

As shown in Fig. 5-19 on page 5-21, motor

of the transmission system is composed of
bearing, stator, rotor and fan, etc.

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HZS60 Concrete Batching Plant Maintenance

7 8 9 10 11 12 13 14

1
2

3
4
5
6

15

Fig. 5-19 Structure of the motor

1-Oil cup cap 2-Oil cup (oil-inlet hole) 3-Bearing 4-Wave spring 5-Oil sea
6-Key 7-Terminal box 8-stator 9-Rotor 10-Bearing cover-inside
11-Plug 12-Bearing cover-outside 13-Fan cover 14-Fan 15-Rataining ring

2. Depositing

Motor should be deposited at a well

ventilated place which is also clean, shady
and dry. Prevent it from rain and water if it
is laid outside, and make sure there is no
acid, alkali or corrosive gas.

3. Running

a) Before starting, make sure that the

rotating parts of the machine set are free
from any trouble. It may be carried out by
turning the rotor of the machine with hand.

b) The motor can be direct-on-line started.

For the purpose of reducing the starting
current, it also can be started under a
reduced voltage. In such condition, the
start toque is nearly directly proportional

Safety, Operation & Maintenance Manual - October, 2014 5-21

Maintenance HZS60 Concrete Batching Plant

to the square of the applied voltage on

the motor. Therefore the motor may be
started sluggishly or even not reach the
full speed if the voltage drop too much. In
this condition it may lead to burn the motor
easily and should take noticed.

c) △ connected motor can be started

with Y-△ starting, but the starting torque
is consequently about 1/3 of the starting
torque when the motor was direct on line
started.

Remark: The three-phase asynchronous

motor of which the frame size is can be
started twice continually in cold state and
only once in hot state.

d) Before running with load, please run

the motor first without load as possible
as you can to make sure the whole set of
motor running well. After that you can run
the motor with load.

e) Check whether the motor runs stably,

free of abnormal noise.

f) The maximum temperature at bearing

should not exceed 95℃; No abnormal
noise can be heard.

g) When the mixer shuts down for more

than six months, clean the bearing parts of
motor and change with new grease.

h) When there are materials in the mixer,

firstly open the discharge gate to discharge
electrically or manually, and then start the
motor.

4. Maintenance

Proper maintenance of the motor will

prolong its life. And to make sure the motor
can be running normally and prevent the
phenomenon of the motor’s breakdown,

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HZS60 Concrete Batching Plant Maintenance

the motor should be inspected periodically.

If you found some bad phenomenon
you should correct it immediately. The
inspecting items consist: The lubrication
and ventilation condition; the existence of
dirt and dust or not; adjust the load of the
motor or not; the condition of the belt, gear
and coupling when the motor is running
with a varying load; and fasten the hold-
down bolts.

a) Clean the bearing with gasoline and

renew the grease every 2000 hours. The
grease suitable for motor bearings is the
lithium grease (or its equivalent), the
quantity of grease filled in is about 1/2 (2-
pole) or 2/3 (4, 6, 8, 10-pole) of the bearing
room, the empty volume of the bearing
house may be considered adequate.

Grease penetrates into the electric motor.

The motor winding will sustain damage.
Drain old grease through the drain plug.

Steps for replacing grease for the bearing

of the electric motor are shown in Fig.
5-20:

Switch off Unscrew Squeeze in Switch on

the plant the drain Screw the the plant
grease at the
main switch plug drain plug main switch
grease nipple

Start up the S w i t c h o ff t h e Switch off Unscrew Squeeze in

mixer in manual mixer for approx the plant the drain grease at the
opertaion 1 minute main switch plug grease nipple

Screw the Switch on Dispose of the

drain plug the plant old grease in an
main switch appropriate manner

Fig. 5-20 Steps for replacing the bearing grease

b) Replace the bearing with a new one if

it appears to be worn or damaged.

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Maintenance HZS60 Concrete Batching Plant

c) See Table 5-4 for detailed information

about the bearing and oil seal (DaLian
Electric Motors Group Co.).

Table 5-4 Mode of bearing and oil seal

Bearing Oil Seal

The Frame Size
DE NDE DE DE
H180 6311 C3 6311 C3 B55 75 8B B55 75 8B
H200 6312 C3 6312 C3 B60 80 8B B60 80 8B
H225 6313 C3 6313 C3 B65 90 10B B65 90 10B
H250 6314 C3 6314 C3 B70 95 10B B70 95 10B
H280 6316 C3 6316 C3 B80 100 10B B80 100 10B
H315-4~10 NU319 6319 C3 B95 120 12B B95 120 12B

d) Clean the motor before dust overcast

more than 5mm, to prevent the motor from
heating. You can clean the motor with a
half dry and wet dishcloth. It is forbidden
to flush the motor.

5.4.1.3 Transmission system

1. Steps of replacing motor

a) Dismantle belt cover (see Fig. 5-21).

Fig. 5-21 Dismantle belt cover

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HZS60 Concrete Batching Plant Maintenance

b) Loosen the bolts on motor base to

lift the base for 50mm or about (see Fig.
5-22).

Fig. 5-22 Lift the motor base

c) Dismantle V-belt and belt pulley (see

Fig. 5-23).

Fig. 5-23 Dismantle V-belt and belt pulley

d) Install a new motor and connect wires

correctly, assemble the belt pulley and
V-belt, and then tighten the motor base
(see Fig. 5-24).

Fig. 5-24 Install motor belt pulley

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Maintenance HZS60 Concrete Batching Plant

e) Assemble V-belt (see Fig. 5-25). For

detailed information, see: "3. Steps of
replacing V-belt" on page 5-31.

Fig. 5-25 Install V-belt

f) Limit end face flatness of motor and

belt pulley within 1mm (see Fig. 5-26).

Fig. 5-26 Adjust the face flatness

g) Reassemble belt cover (see Fig. 5-27).

Fig. 5-27 Reassemble belt cover

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HZS60 Concrete Batching Plant Maintenance

2. Steps of wiring

a) Properly arrange the motor according 1 2 3 4

to Fig. 5-28.

b) Connect wire separately and properly

according to the arrow direction of motor 8 5
pulley as shown in Fig. 5-28.
6
c) Assemble V-belt: the left and right
motor pulleys should run in coincident
direction and synchronously. For detailed 7
information, see: "3. Steps of replacing
V-belt" on page 5-31. Fig. 5-28 Transmission system
1- Transmission shaft 2- Reducer pulley
3- Planetary reducer 4- Spline shaft
Requirement: 5- Spline shaft sleeve 6- Motor
7- Motor pulley 8- V-belt
(1) Keep the motor clean, to prevent the
wind inlet from dust and fibre entering.

(2) Check whether the motor runs stably,

free of abnormal noise.

(3) The maximum temperature at bearing

of the reducer should not exceed 95°C; no
abnormal noise can be heard.

(4) When the protect device of motor acting

continually, check whether the motor is
working over loading or the setting of the
protect device is too small. Restart the
motor while all malfunctions eliminated.

(5) After running for 2500h, replenish

grease for the motor with an amount about
1/2~2/3 of bearing chamber’ capacity.

(6) When the mixer will shut down for a

long time, clean the bearing parts of motor
and change with new grease.

(7) When there are materials in the mixer,

firstly open the discharge gate to discharge
electrically or manually, and then start the
motor.

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Maintenance HZS60 Concrete Batching Plant

3. Steps of replacing reducer

SANY special planetary reducer adopted

in the batching plant features compact
structure, high reliable and easy to
maintain.

1. Installation of the reducer

a) Dismantle belt cover (see Fig. 5-29).

Fig. 5-29 Dismantle belt cover

b) Loosen the bolts on motor base to lift

the base about 50mm (see Fig. 5-30).

Fig. 5-30 Lift the motor base

c) Dismantle V-belt, synchronous

transmission shaft and belt pulley (see
Fig. 5-31).

Fig. 5-31 Dismantle belt pulley

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HZS60 Concrete Batching Plant Maintenance

d) Install a new reducer (see Fig. 5-32).

Tighten blot M16 between the reducer and
base frame with torque of 220 N•m.

Fig. 5-32 Install reducer

e) Assemble V-belt, synchronous

transmission shaft and belt pulley, and
then tighten the motor base (see Fig.
5-33). For detailed information, see: "3.
Steps of replacing V-belt" on page 5-31.

Fig. 5-33 Install belt pulley

f) See steps of V-belt replacement for

installation. Rotate the mixing shaft for
360 degree manually, and the mixing arms
should not interfere (see Fig. 5-34).

Fig. 5-34 Rotate the mixing shaft manually

Safety, Operation & Maintenance Manual - October, 2014 5-29

Maintenance HZS60 Concrete Batching Plant

g) Limit end face flatness of motor and

belt pulley within 1mm (see Fig. 5-35).

Fig. 5-35 Adjust the face flatness

h) Reassemble belt cover (see Fig. 5-36).

Fig. 5-36 Install the belt cover

2. Maintenance of reducer

a) Regularly inspect whether all

connecting bolts are tightened.

b) Check whether the reducer runs stably

and without abnormal noise.

c) Measure the temperature of housing

after the reducer’ initial running for 6h,
and the maximum temperature should not
exceed 80°C.

d) Change oil after initial running for 100h.

Oil in the gearbox should be changed once
every 1000h or half a year running. When
change the oil, clean the reducer by adding
2 liters lubricant after draining old oil.

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HZS60 Concrete Batching Plant Maintenance

Clean the left dirty oil and cupreous scraps

in the gearbox and never mix sundries in.
Check the oil level frequently, and supply
oil if necessary.

e) Inspect bearing parts of transmission

shaft every 300h running, and lubricate
transmission shaft (three positions) with
industrial No.2 lithium-based grease
if necessary. When transmission shaft
sounds abnormally, shut down to inspect
in time to avoid damaging transmission
shaft or mixing blade. Tightening torque
of bolt M12 for transmission shaft is 100
N•m.

f) If the reducer has shut down for a long

time, firstly fill up with lubricant, and drain
excessive oil for reuse to maintain proper
level.

g) Air-outlet of the reducer should not be

blocked by dirt or paint.

Pay special attention to high temperature

of reducer, which may cause burns.

3. Steps of replacing V-belt

After a long time for use, some V-belt is

aging or loose. They need replacement
whole set in time. Steps are as below:

a) Open the front cover of belt (see Fig.

5-37).

Fig. 5-37 Open the front cover of belt

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Maintenance HZS60 Concrete Batching Plant

b) Dismantle synchronous transmission

shaft between two reducers (see Fig.
5-38).

Fig. 5-38 Dismantle synchronous transmission

shaft

c) Regulate the adjusting bolts on the

motor base to lift the base about 50 mm at
the same time (see Fig. 5-39).

Fig. 5-39 Lift the motor base

d) Disassembly the old V-belt and install

a new V-belt. See Table 5-5 on page 5-33
for the spec of V-belt (see Fig. 5-40).

Fig. 5-40 Install new V-belt

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HZS60 Concrete Batching Plant Maintenance

Table 5-5 Spec of V-belt

Model Spec of V-belt Quantity

JS1000 Triangle belt, V-belt SPB2240GB11544 2×4
JS1500 Triangle belt, V-belt SPB2240GB11544 2×4
JS2000 Triangle belt, V-belt SPB2240GB11544 2×5
JS2000CK Triangle belt, V-belt SPB2240GB11544 2×5
JS2000D Triangle belt, V-belt SPB2240GB11544 2×5
JS3000 Triangle belt, V-belt SPC2240GB11544 2×5
JS3000D Triangle belt, V-belt SPC2500GB11544 2×6
JS4500 Triangle belt, V-belt SPC2500GB11544 2×6

e) Tighten bolts on motor base to strain

V-belt. When apply 100N (10kg) pressure
on suspend middle part of V-belt, the
deformation distance of belt along the
force is about 15mm (see Fig. 5-41).

Fig. 5-41 Tighten bolts

f) Assemble transmission shaft, and

make sure phase angles of mixing arms on
the two mixing main shafts are the same
as the positions shown in manual. Rotate
belt pulley manually to rotate mixing main
shaft for 360° and check whether mixing
arms interfere (see Fig. 5-42).

Fig. 5-42 C h e c k w h e t h e r m i x i n g a r m s
interfere

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Maintenance HZS60 Concrete Batching Plant

g) Limit end face flatness of motor and

belt pulley within 1mm (see Fig. 5-43).

Fig. 5-43 Adjust face flatness

h) Install the belt cover (see Fig. 5-44).

Fig. 5-44 Install the belt cover

a) Do not rotate the belt pulley

separately during V-belt's assembly, so
as to avoid interference between mixing
blades of the two mixing shafts;

b) After a new V-belt running for 8~10h

or the run-in V-belt running for 40~50h,
inspect tension of V-belt in time. If
loose, tighten in time.

c) Replace aging V-belt whole suit, to

prevent affecting normal operation.

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HZS60 Concrete Batching Plant Maintenance

5.4.1.4 Shaft end sealing

As shown in Fig. 5-45, shaft end sealing 3 4 5
is mainly composed of dust proof, wearing A
ring, shaft sleeve, seal and lubricant line 2 6
etc. The shaft end sealing includes drive
end and driven end. B 7

1 8

Main
Shaft

Fig. 5-45 Diagram of shaft end sealling

1. Shaft ends sealing (drive end or
1-Shaft sleeve 2-Dust proof 3-Wearing ring
driven end) leakage
4-Seal cushion 5-Locating ring 6-Floating
Replace locating ring, shaft sleeve, shield,
seal ring 7-Floating ring 8-Seal ring
wearing ring, seal ring, floating ring and
floating seal ring in time.

2. Drive end sealing leakage

Take Fig. 5-46, Fig. 5-47 on page 5-36
and Table 5-6 on page 5-36 as reference.

1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22

25 11 24 23
Fig. 5-46 Cutaway view of the shaft end sealing parts

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Maintenance HZS60 Concrete Batching Plant

19 3 20 21 22 23 24
16 15 17 12 13 13 12 11 10 9 18

25

rt s
rin g pa
a l wea
e n d se
haf t
es rt s
Driv g pa
rin
l wea
nd sea
s h aft e
en
Driv

25

11 12 13 13 12 10 14 15 16

1 2 3 4 5 6 3 7 8 9
Fig. 5-47 Diagram of shaft end sealing parts
Table 5-6 Main parts of the shaft end sealing

No. Designation Remark No. Designation Remark

1 Reducer base frame Different spec 14 Shaft sleeve 1 Different spec
2 Connecting flange Different spec 15 Shield Different spec
3 Seal ring Different spec Only for
16 Seal ring
4 Separating sleeve 1 Different spec JS2000CK mixer
5 Rolling bearing Different spec 17 Shaft sleeve 2 Different spec

6 Distance piece 1 Different spec 18 Separating sleeve 3 Different spec

7 Bearing seat 1 Different spec 19 Bearing seat 2 Different spec

8 Separating sleeve 2 Different spec 20 Distance piece 2 Different spec
9 Locating ring Different spec 21 Rolling bearing Different spec
10 O-ring Different spec 22 Shaft end baffle Different spec
11 Seal ring Different spec 23 O-ring Different spec
12 Floating seal ring Different spec 24 Cap Different spec
13 Floating ring Different spec 25 Wearing ring Different spec

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HZS60 Concrete Batching Plant Maintenance

Replacement steps:

a) Dismantle transmission parts (see Fig. 7

5-48). Take off belt cover, transmission 5
shaft, V-belt, reducer, reducer base frame, 6
2
spline shaft and spline sleeve in sequence.

4 3 1
Fig. 5-48 Dismantle transmission parts
1-Belt cover 2-Transmission shaft
3-V-belt 4-Reducer 5-Reducer base frame
6-Spline shaft 7-Spline sleeve

b) Dismantle bearing parts (see Fig. 1 2 4

5-49). Take off connecting flange,
separating sleeve, bearing seat and
bearing in sequence.

3
Fig. 5-49 Dismantle bearing parts
1- Connecting flange 2- Separating sleeve
3- Bearing seat 4-Bearing

1 4 6 5 3
c) Dismantle sealing parts (see Fig. 5-50)
(measure the clearance T as shown in
Fig. 5-46 on page 5-35 and record before
dismantling). Take off the dust proof,
wearing ring, separating sleeve, locating
ring and shaft sleeve in sequence, and
dismantle mixing arms adjacent to dust
proof before dismantling it.
2
d) Inspect damage and parts to be
replaced.
Fig. 5-50 Dismantle sealing parts
1-Seal ring 2-Dust proof 3-Wearing ring
4-Separating sleeve 5-Locating ring 6-Shaft sleeve

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Maintenance HZS60 Concrete Batching Plant

e) Install sealing parts (see Fig. 5-51).

Firstly, press the floating ring and floating 1 2 4 3
seal ring into shaft sleeve, which is on the
mixing shaft, and then press the seal ring,
floating ring and floating seal ring into
locating ring, which is on the mixing shaft
together with O-ring (adjust clearance
T as shown in Fig. 5-46 on page 5-35
according to the measuring record before).
Finally, assemble the dust proof, wearing Fig. 5-51 Dismantle sealing parts
ring and mixing arm. 1-Seal ring 2-Floating ring
3-Floating seal ring 4-Locating ring

f) Install bearing parts (see Fig. 5-52). 3

Firstly, put the seal ring into the bearing 4
seat, which is set in the mixing shaft 2
together with separating sleeve, and then 1
assemble bearing and separating sleeve. 5
Finally, assemble the connecting flange.

6 7

Fig. 5-52 Install bearing parts

1-Seal ring 2-Bearing seat 3-Separating sleeve
4-Mixing shaft 5-Bearing
6-Separating sleeve 7-Connecting flange
g) Finally, install transmission parts
(see Fig. 5-53). Assemble spline sleeve,
spline shaft, reducer base frame, reducer, 1
V-belt, transmission shaft and belt cover in 3
sequence. 2
6

7 5 4
Fig. 5-53 Install transmission parts
1-Belt cover 2-Transmission shaft 3-V-belt
4-Reducer 5-Reducer base frame
6-Spline shaft 7-Spline sleeve

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HZS60 Concrete Batching Plant Maintenance

3. Driven end sealing leakage

Replacement steps:

a) Dismantle bearing parts (see Fig.

5-54). Take off cover, shaft end baffle,
bearing seat and bearing in sequence.

3 4 2 1
Fig. 5-54 Dismantle bearing parts
1-Cover 2-Shaft end baffle
3-Bearing seat 4-Bearing

b) Dismantle sealing parts (see Fig. 5-55)

(measure the clearance between locating 2
ring and cylinder body T and record before 6
dismantling). Take off dust proof, wearing 1
ring, separating sleeve, locating ring and
shaft sleeve in sequence, and dismantle
the mixing arms adjacent to dust proof
before dismantling it.

4 5 3 7

Fig. 5-55 Dismantle sealing parts

1-Seal ring 2-Dust proof 3-Wearing ring
4-Separating sleeve 5-Locating ring
6-Shaft sleeve 7-Mixing arm

c) Inspect damage and parts to be

1 2 4 3
replaced.

d) Install sealing parts (see Fig. 5-56).

Firstly, press the floating ring and floating
seal ring into the shaft sleeve, which is on
the mixing shaft, and then press the seal
ring, floating ring and floating seal ring
into locating ring, which is on the mixing
shaft together with O-ring (adjust clearance
according to T shown in Fig. 5-46 on page Fig. 5-56 Install sealing parts
5-35 recorded before). Finally, assemble 1- Seal ring 2- Floating ring
the dust proof, wearing ring and mixing arm. 3- Floating seal ring 4- Locating ring

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Maintenance HZS60 Concrete Batching Plant

e) Finally, install bearing parts (see Fig.

5-57). Firstly, put the seal ring into bearing 4 3 1
seat, which is set in the mixing shaft
together with separating sleeve, and then
assemble bearing and separating sleeve.
Finally, assemble shaft end baffle and
cover.

4. Maintenance of shaft end sealing

a) Replace when the clearance between

dust proof and wearing ring is 6mm. 2 5 6 7
b) Limit the clearance between dust proof Fig. 5-57 Install bearing parts
and wearing ring within 0.5~1 mm, and 1- Seal ring 2- Bearing seat
dust proof should be parallel to the outer 3- Separating sleeve 4- Mixing shaf
end face of wearing ring. 5- Bearing 6- Shaft end baffle 7- Cover

c) Tighten bolt of spline sleeve M20 with

torque of 520 N•m.

d) After replacing shaft end seal at the

drive end, rotate the mixing shaft for
360° manually to ensure the mixing arms
not interfere (see Fig. 5-58). If there is
interference, adjust mixing arm phase
according to the diagram of mixing arms.
For detailed information, see: "4. Mixing
device" on page 3-24.

e) Locating ring and shaft sleeve should

be assembled properly, and clearance T as
shown in Fig. 5-46 on page 5-35 among Fig. 5-58 Structure of mixing cavity
surroundings of locating ring and cylinder
body should be at 4~5mm.

f) Assemble and disassemble with torque

spanner, and measure with feeler gauge.

g) After installation, inject grease

electrically or manually, and check
whether oil line is fluent. Shaft end sealing
lubrication system can improve the sealing
effect and service life. Therefore, inspect
whether the grease reach to shaft end of
the mixer periodically.

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HZS60 Concrete Batching Plant Maintenance

●● In the full-automatic lubrication system

for shaft end sealing, check whether
grease reaches shaft end of mixer as
follows:
Inspect indication of the pressure gauge as
shown in Fig. 5-59 (10~60bar): if it is lower 1
than 10bar, the valve core is blocked; if
2
higher than 60bar, the diverter valve core
is blocked.
Inspect grease consumption of the lubricant
pump as shown in Fig. 5-59 (≥42ml/h): it
consumes 1/4 of one tank. If lower than
this consumption, check if the four shaft
ends have lubrication reached.
Fig. 5-59 Lubriacation system
Inspection method: spare grease nozzle 1-Lubricant pump 2- Pressure gauge
is installed on each shaft end respectively
shown in Fig. 5-151 on page 5-116. Press
ball core of grease nozzle by nail. If grease
comes out from the ball core, it indicates
that lubricant pump is working normally.
If the shaft end is lack of grease, firstly
check whether shaft end oil pipe is smooth.
Then check whether diverter valve is
blocked. Finally check whether pump core
is working normally. If troubles can not be
remedied during down time, grease should
be filled from grease nozzle of shaft end
by grease gun at least twice a day.

● ● If air pressure protection of shaft head

is provided:
Regulate the pressure of the relief valve
to 1~1.5bar. Check the pressure of the
wind pressure solenoid valve with power
on (0.2~0.5bar). This valve is energized
during charging, and de-energized during
discharging.

Clearance between liner plate and blade

adjustment: measure the clearance
between blade and highest point of the
mixing cylinder. Normal working clearance

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Maintenance HZS60 Concrete Batching Plant

is 3~8mm. Adjust torque of the blade bolt

is 200 N·m. After adjustment, working for
several cycles, check the bolt again.

5.4.1.5 Liner plate assembly

1. Steps of gate edge replacement:

a) Dismantle the nuts on gate edge.

b) Dismantle the edge of discharge gate. 1
0.5~1.5mm
c) Assemble the new discharge gate clearance
edge and nuts.
Requirement:
(1) The clearance between gate edges is
0.5~1.5mm.
(2) As shown in Fig. 5-60, clearance 2
between gate edge and arc plate of
discharge gate is 0.5~1.5mm.
Fig. 5-60 Gate edge liner plate
(3) If the gate edge or discharge gate leaks
1-Discharge gate edge
for wearing, readjust or replace gate edge.
2-Liner plate of discharge gate
(4) Clearance between cover tile and arc
plate of discharge gate is within 0.5~2mm.

2. Steps of liner plate replacement:

a) Dismantle the nuts on liner plate.
b) Dismantle the liner plate.
c) Assemble the new liner plate and nuts.
Requirements:
(1) The clearance between liner plate and
blade is 2~5mm.

(2) Apply adhesive to the thread of bolts

M16, and its tightening torque is 180 N•m.

(3) Replace the liner plate worn out

immediately.

(4) Replace the plate with wearing parts

exceeding 1/2 immediately.

(5) Clean the mixer in time and inspect

abrasion of the plate monthly.

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HZS60 Concrete Batching Plant Maintenance

5.4.1.6 Mixing device

Detailed steps of replacing mixing unit,

main mixing unit and side mixing unit:

a) Dismantle nuts and bolts.

b) Dismantle blade, mixing arm and base

frame.
c) Assemble new base frame, mixing
arm, blade, bolts and nuts (see Fig. 5-61).

Fig. 5-61 Install new parts

Requirements:
(1) Clearance between the blade and liner 2 0.5~1.5mm clearance
plate is 2~5mm (see Fig. 5-62), and axial
gap within 10mm for each mixing unit is
allowed. Gap of four angle points that 1
mixing arm does not contact main shaft
must exceed 3mm. 3

4
Fig. 5-62 Clearance between each part
1-Discharge gate edge 2-Fixed angle iron
3-Discharge gate plate 4-Nut

(2) Gap between side scraper and side

2~5mm
liner plate is uniform at 2~5mm (see Fig.
5-63).

2~5mm

Fig. 5-63 Gap between side scraper and

side liner plate

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Maintenance HZS60 Concrete Batching Plant

(3) Tightening torque of blade bolt M24 is

720 N•m, and that of connected bolt M20
is 400 N•m (see Fig. 5-64).

(4) Alternate angle and arrangement of

mixing arm and blade are up to number of
arms. For detailed information, see: "4.
Mixing device" on page 3-24, Fig. 3-24
on page 3-25.

(5) Replace broken or badly worn blade,

Fig. 5-64 Tightening bolts of blades and
base frame or mixing arm immediately
connected seat
(see Fig. 5-65).

(6) If the mixer will be shut down for more

than 1h, clean the inner mixer with high
pressure water, or cement on mixing shaft
and blade will agglomerate to stop its
running with the drain open. After working,
input coarse aggregate (25~40mm) and
water to mix for 5min, and discharge the
coarse aggregate after removing concrete
adhered. Then, clean inside with high
pressure water (see Fig. 5-66). If there is
waste oil or concrete remover applied into
the mixer, the next cleaning will be easy.
Fig. 5-65 Replace broken or badly worn
The Journal sticking of the mixer is that blade
the axle is wrapped by the binder content
which consists of fly ashes, sands and
liquids.Usually, the dimension of the
biggest diameter arranged from 500mm to
600mm, and which increased as the output
of the mixer.The micro mechanism is that a
high hydrophilic property hydrate material
will be produced when the cement comes
cross the water. The hydrophilic property
hydrate will wrap the sands and stones to
develop cluster and the cluster will stick to
the axle.

There are many reasons for the journal Fig. 5-66 Clean the mixer
sticking, such as making up of the
materials , sequence and position to
discharge the materials, the formulation

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HZS60 Concrete Batching Plant Maintenance

and the maintenance of the plant. And all

of those reasons interact with each other.
The journal sticking is common so it is
necessary to maintain the plant following
the requirement and cleaning the mixer in
a fixed interval.

(7) Clean the mixer in time, and inspect

abrasion of the mixing unit and tension of
the bolts monthly (see Fig. 5-67).

Fig. 5-67 Check abrasion of the mixing uniit

5.4.1.7 Discharging device

As shown in Fig. 5-68 , discharge device

is composed of discharge gate body, shaft,
bearing, swing rod, oil cylinder, cylinder
and proximity switch, etc.

1
2
3
5
6 4

7
Fig. 5-68 Discharge gate body
1-Bearing 2-Shaft 3-Arc plate of discharge gate
4-Nut 5-Discharge gate body
1. Detailed steps to replace discharge 6-Nut 7-Discharge gate edge
gate arc plate

a) Dismantle nuts and discharge gate

edge.

b) Fix discharge gate body with cylinder,

and dismantle nuts and discharge gate arc
plate.

c) Replace with a new discharge gate arc

plate, and assemble nuts.

d) Assemble discharge gate edge and

nuts.

2. Detailed steps to replace discharge

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Maintenance HZS60 Concrete Batching Plant

gate body

a) Dismantle pin shaft, oil cylinder,

proximity switch, key and swing rod.

b) Fix discharge gate body with rope, and

dismantle bolts and bearing.

c) Take off the original discharge door

body, and replace with a new one.

d) Assemble discharge gate body, bolts

and bearing with rope.

e) Assemble swing rod, key, cylinder, pin

shaft and proximity switch.

Requirements:

(1) Clearance between discharge gate clearance 0.5~1.5 mm 1 2

arc plate and its edge is 0.5~1.5mm (see
Fig. 5-69). If the clearance is too small,
discharge gate will not open or close
smoothly.

Fig. 5-69 C l e a r a n c e o f d i s c h a r g e g a t e
installation
1-Discharge gate 2-Discharge gate edge

(2) When the arc plate of the pneumatic

drive is badly worn, leakage will happen.
Replace it in time. When abrasion of
liner plate in the cylinder end and bottom
exceeds 8 mm, abrasion of side liner plate,
liner plate and blade exceeds 16 mm, or
the clearance can't be adjusted, replace
them. During replacing the liner plate,
difference between the liner plates should
be less than 2 mm.

(3) When the gate is maintained, pull out

the key and press the safety button.

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HZS60 Concrete Batching Plant Maintenance

(4) It is prohibited to stand under the

discharge gate, when the fixing pin shaft
of the cylinder is pulled out.

5.4.1.8 Upper cover of the mixer

As shown in Fig. 5-70, a safety switch

called inspection switch is arranged at
the overhaul door. When the door is open,
the mixer stops working, so as to ensure 1
the safety of maintenance personnel in 2
cylinder. Another observation door is set
for observing. 3
Fig. 5-70 Upper cover
1-Overhaul door 2-Observation door
3-Inspection switch
Detailed steps to replace proximity switch:
2 3
a) Dismantle guard plate. Dismantle limit
switch and take off wires.

b) Install a new inspection switch, connect

wires and install guard plate as shown in
Fig. 5-71 and Table 5-7.
4
1
Requirements:
5
(1) Do not knock on limit switch.

(2) Clean cement accumulated on the

upper cover of the mixer in time.
Fig. 5-71 Mixer inspection switch
(3) Replace if pneumatic spring is 1-Overhaul door of mixer 2-Limit pressure plate
inflexible. 3-Guard plate 4-Limit switch
5-Switch mounting plate

Table 5-7 List of accessories for limit switch

Code Designation Quantity Remark
10265717 Guard plate 1
10121673 Switch mounting plate 1
10121731 Limit pressure plate 1
B241200001166 Limit switch ZV14H-235-11z 1 Same electrical connection
A210203000003 Screw M4×8GB68 4
A210202000014 Screw M4×25GB67 4

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Maintenance HZS60 Concrete Batching Plant

5.4.1.9 Electrical control system

The electric control system is mainly

composed of mixing motor control,
discharge gate control, monitor and cable
box etc.

Overhaul switch: as shown in Fig. 2-42

on page 2-29, there is an E-STOP button
beside the solenoid valve prepared for
maintenance.

Safety switch for upper cover: as shown

in Fig. 5-70 on page 5-47, contact-type
safety switch is installed on the overhaul
door. When the overhaul door of mixer's
upper cover is opened for inspection, the
main mixing motor can not be started to
ensure safety of personnel working in the
mixing cylinder.

Requirement:

(1) Users provide 380V AC power

connecting to the motor.

(2) Users provide 24V DC power connecting

to the lubrication pump, solenoid valve,
proximity switch and safety switch.
DANGER
When the overhaul door of mixer's upper
cover is opened for inspection, the
main mixing motor can not be started to
prevent injuries.

5.4.1.10 Monthly inspection of the mixer

Inspect the running conditions and

mechanical abrasion of each main
component of the mixer monthly, and
make detailed records for maintenance
reference. See Table 5-8 on page 5-49
for details.

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HZS60 Concrete Batching Plant Maintenance

Table 5-8 Monthly inspection of the mixer

Name of concrete batching plant: Mixer No.:
Recorded by: Telephone: Time:

Condition
No. Description Inspection items Remark
(yes/no)
Whether V-belt is loose or badly worn
Whether motor or reducer sounds abnormally.
Transmission
1 Whether oil level of the reducer exceeds a half.
system
Whether end face flatness of motor
and belt pulley is among 0~1mm.
Whether the 4 shaft ends leak.
Whether the dust proof is badly worn
(clearance of between dust proof and
wearing ring less than 6mm).
2 Shaft end seal
Whether the wearing ring is badly worn
(clearance of between dust proof and
wearing ring less than 6mm).
Whether the grease flows fluent.
Whether the discharge gate edge is badly
worn (wearing less than 6mm).
Whether the clearance between discharge
gate edge and its arc plate exceeds 2mm.
Whether the clearance between discharge gate
Liner plate
3 cover tile and its arc liner plate exceeds 2mm.
assembly
Whether the worn thickness of left, right, middle
or outer end liner plates exceeds a half.
Whether the worn thickness of trapezoid, rhombic
or upper arc liner plates exceeds a half.
Whether bolts and screw are badly worn.
Whether the main shafts seize.
Whether bolts are badly worn.
4 Mixing device
Whether the mixing arm is badly worn or broken.
Whether the blade is badly worn or broken.
Whether lubrication of each
Lubrication
5 lubrication point is normal.
system
Whether the electric lubrication pump is normal.

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Maintenance HZS60 Concrete Batching Plant

Condition
No. Description Inspection items Remark
(yes/no)
Whether the discharge gate leaks
Whether the proximity switch is broken or loose
Whether the external ball bearing
with seat is normal
Discharge
6 Whether the pneumatic
device
cylinder and pressure
Pneumatic type relief valve leak.
Whether the pneumatic
cylinder is damaged or loose.
Mark or
7 Whether mark or name plate is damaged or lost.
name plate
Whether excessive materials are accumulated
on upper cover of the mixer.
8 Upper cover
Whether limit switch or pneumatic
spring are damaged.
Electric
9 Whether safety switch is normal.
system

5.4.2 Maintenance of measuring system

5.4.2.1 Weighing sensor

1. Checking method:

When a weigher of the weighing system

(as introduced in "3.4 Upper box
componetn" on page 3-15) of the concrete
batching plant does not work accurately,
has drifted reading and encounters other
problems, first remedy the faults of the
weighing instrument, junction box and
shielded cable. After it is confirmed that
it is the fault of the weighing sensor (see
Fig. 5-72), the following methods may be
used to examine the weighing sensor: Fig. 5-72 Weighing sensor

a) Measure whether the insulation

impedance of the weighing sensor is out
of tolerance (the impedance between
the color streak and metal surface of the
weighing sensor: <200MΩ; it is considered

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HZS60 Concrete Batching Plant Maintenance

abnormal).

b) Measure whether the input and output

impedances of the weighing sensor are
out of tolerance. The output impedance is
350±1Ω and input impedance>400Ω, and
then they are considered abnormal.

c) Measure whether the voltage output of

the weighing sensor when it is at the empty
scale or full scale. Empty scale: >2mV
or <0mV; it is considered abnormal. Full
scale: >20mV; it is considered abnormal.

d) Measure whether the weighing sensor

has any angular difference. Sometimes, it
is impossible to reach a definite judgment
only by weighing the output of the weighing
sensor, and then it may be confirmed by
weighing the angular difference. With
identical weights put on the supporting part
of each weighing sensor, observe whether
the weights indicated by the meter are
consistent.

e) Measure whether the surface of the

weighing sensor is electrified (color streak
vs. the weighing sensor surface). Surface
electrification is prohibited since it will
impact the service life of the weighing
sensor.
Tools Multimeter

2. Replacing steps:
Shut off the control power supply, dismount
the weighing sensor cables that must be
replaced from the five-pore junction box
shown in Fig. 5-73 on page 5-52, and
then dismount the weighing sensor.

3. Assembly method:
Fix the new weighing sensor well and
connect the cell cables to the five-pore
junction box shown in Fig. 5-73.

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Maintenance HZS60 Concrete Batching Plant

Tools Spanner; Screwdriver

NOTE
1) The weighing sensor must be
connected in accordance with the
instrument instructions, without joints.
2) The weigher must be calibrated again
after the replacement of a weighing
sensor.

5.4.2.2 Replacement of five-pore junction

box/signal inverter ST-001

1. Checking method:

When the insulation of the five-pore junction

box (see Fig. 5-73) declines during the
process of using after water comes into
the box owing to raining or washing, etc.,
and the weighing instrument has faults
(such as drifted reading) as a result, the
junction box must be replaced if it cannot
get right after drying. Fig. 5-73 Five-pore junction box

Signal inverter ST.001 must be replaced

when it is damaged by water entry in owing
to raining or washing, and the inverter
cannot change signals or communicate
with the weigher indication controller
(SWD) as a result.

2. Replacing steps:

Five-pore junction box: first shut off the

power supply of the control system, then
disassemble the double-layered shielded
cable of the weighting instrument and
cable of the weighing sensor, and finally
disassemble the securing bolts of the
junction box.

Signal inverter ST-001: first shut off the

power supply of the control system, then

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HZS60 Concrete Batching Plant Maintenance

dismantle the power and communication

cables, and finally disassemble the
securing bolts of the signal inverter.

3. Assembly method:
First fix the new five-pore junction box /
signal inverter ST.001 well (addresses
have been set) and then connect the
cables.

Tool Screwdriver

NOTE
The weigher must be examined after
replacement, and re-calibrated in case
of any error.

5.4.2.3 Weighing instrument

1. Checking method:
When the weighing instrument as shown in
Fig. 5-74 has faults, such as black screen,
failure in starting up, abnormal input and
output signal, the weighing instrument
should be replaced after the external
causes are excluded.

2. Replacing steps:
Shut off the power supply of the control
Fig. 5-74 Weighing instrument
system. Pull out all plugs at the rear of
the weighing instrument. Disassemble the
mandrels on both flanks of the instrument;
thus, the instrument may be taken out of
the mounting hole.

3. Assembly method:
Put the instrument into the mounting hole,
install the mandrels on both flanks to fix
the instrument. Push in all plugs, start
the control power, and set the instrument
parameters according to the parameter
table.

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Maintenance HZS60 Concrete Batching Plant

Tool Screwdriver

NOTE
The weighing instrument must be
calibrated after replacement.

5.4.2.4 Maintenance of measuring system

1. Check before production

Before production of the concrete batching

plant, calibrate the weigher in local
measuring institute (station).

2. Preparation before working

a) Poise checking
Before everyday work, check of the
measuring device with poise: using 1kg
poise to check additive weigher while
using 20kg or 25kg poise to check other
weighers.

b) Zero calibration
Before everyday work, carry out zero
calibration to the measuring device.

3. Maintenance of weigher

a) Check the weighers via qualified

measuring institute periodically. The
longest period is one year.

b) Require maintainer to check the

electrical weighers once every day. Mainly
check whether the sensors are clamped
with obstacle or loose.

c) Calibration should be carried out again

in circumstances below: replacing sensor,
replacing data collection box, replacing
weighing display terminal, and when the
weigher checking is abnormal.

4. Relative problems about powder

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HZS60 Concrete Batching Plant Maintenance

profit and loss

Powder used in the batching plant

transported by truck is weighed and then
delivered to the powder silo and batching
plant for production consumption. Purchase
data is often collected after measurement
by customer. Consumption data is collected
according to the record of batching plant
production detailed data. Difference of the
two data is profit and loss of the powder.

During collection, various aspects are

referred. As a reference, we only take
problems during consumption of batching Fig. 5-76 Proper soft connection
plant production.

a) Inaccurate measurement of powder

● ● Check static powder weigher accuracy

Check whether all the soft connections

(including screw conveyor and weigher,
connection between weigher and mixer,
and ventilation corrugated pipe) are soft
enough. For bag-type soft connection,
press it by hand, and the connection sinks
about 3~4mm around (see Fig. 5-76 and
Fig. 5-75). Powder in the soft connection
may be agglomerated. Clean it often. Fig. 5-75 Soft connection is too tigh
Ventilation corrugated pipe will be harden.
Ensure the pipe is retractile.

Fig. 5-77 Serious agglomeration of the sensor

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Maintenance HZS60 Concrete Batching Plant

Ensure there isn't any interference

between hopper and other parts. Clean all
the ventilation pipe and bottom of sensors
(see Fig. 5-77 and Fig. 5-78).

Use enough poise to check the weigher.

"Enough" is to say that the weight of
cement produced with full loading in one
cycle is more than 600kg for 2-steres
mixer, while it is 800kg for 3-steres mixer.
Steps: Firstly, use F1.5 button (instrument
by SANY as shown in Fig. 5-74 on page Fig. 5-78 Dust accumulated on collecting bage
5-53) to zero clear the instrument back
to normal status. Add 100kg poises to the
weigher and record the weigher checking
data. Put the poises on center of the
weigher as much as possible.

● ● Check the dynamic accuracy of powder

weigher during production

During normal production, switch to

manual mode after powder weighing
completed and reaching to the target
value. After a period of time steadying
(about 20~30s), observe whether the
weigher data changes. If it is decreasing
continuously, the butterfly valve may
leak, levelling the butterfly valve. Record
weigher value after adjustment. Compare
this value with database after production
to check whether they are accordant.

During production, observe whether the

negative pressure valve (if has) action is
normal. When waiting hopper or powder
begins to feed to the mixer, negative
pressure valve closes until 8 seconds after
feeding is completed. If the negative valve
action is incorrect, exchange its inlet and
outlet pipe.

During production, observe the changing

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HZS60 Concrete Batching Plant Maintenance

range and duration of the instrument, when

waiting hopper is feeding to the mixer. If
the changing range is more than 20kg, and
the dust collecting bag keep plumping for
a long time (see Fig. 5-79), increase the
aggregate waiting time about 1~2s to leave
some time for pressure releasing after
aggregate discharge. Waiting for feeding
time is generally 13~15s for 2-steres mixer,
while it is 14~16s for 3-steres mixer.

When mixer is discharging, check whether

the powder weighing of next cycle is Fig. 5-79 B a g p lu mp in g f o r a lo n g t i m e
completed. The initial seconds when obviously
mixer is discharging, pressure changes
obviously, and it has the most effect
to weighing. Avoid this period of time
when weighing is about to be completed.
Increase or decrease the mixing time to
realize according to the practical state.

During production with full load, if there

are materials in the waiting hopper and
mixer, open the mixer discharging door
after the powder measurement reaching
the target value. Check whether displaying
value on the powder instrument changes
before and after mixer discharging, and
how many is the change value. Then
feed the aggregate in waiting hopper to
the mixer (don't discharge powder at the
same time), and then compare the values
displayed on the powder instrument. It
is to check whether slight shape change
affects powder weighing.

b) Statistic data of weighing is inaccurate

Check whether there is any data left during

recording. Communicate with customer
and operator, check there are mistakes of
accumulating truck times or accumulating
steres during production. Inquire whether
there is any cycle data in manufacture list
(see: "4.4.3 Guidelines for recipe menu

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Maintenance HZS60 Concrete Batching Plant

operation" on page 4-39) left without

record. If there is any data without record,
statistic data will be decreased which
means powder loss.

Check whether operators or other

personnel delete the production detailed
record during statistic time. This may
reduce the statistic record.

Cement silo switching affects the statistic

data during production. For example:
Cement 1 is selected in the recipe. After
production started, cement 1# silo is found
empty. At the same time, there will switch
to cement 2 on the monitoring interface
as shown in Fig. 4-4 on page 4-13, to
continue production until this truck is
completed. It is noticed that, during this
time cement in 2# silo is recorded into the
cement 1. If record cement 1 and cement
2 separately, cement in 1# silo will be
excessive and cement in 2# silo will lack.

During statistic data, check whether manual

consumption is taken into consideration.
During statistic, the consumption data
should take "Total consumption table"
as reference, when inquire it from the Fig. 5-80 Ce me n t lo ss se rio u sly o n th e
computer. The total consumption includes silo top
manual consumption.

c) Others

Check whether there is powder emission

during powder delivery (see Fig. 5-80 and
Fig. 5-81), and whether there is any open
trace on pressure safety valve to cause
loss of the powder.

If the powder is affected with damp,

loss may occur during production of the
batching plant.

Customer production management should

Fig. 5-81 No cement loss on the silo top
strict. Operation regulation should be

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HZS60 Concrete Batching Plant Maintenance

established. During work shift, steres and

material consumption of this shift shall be
record. Delivery receipts should be filed.

5. Precautions

a) All the soft connections (including red

rubber pipe, polyester fabric tube and
corrugated pipe) are in the normal state
without pulling force, or the accuracy will
be affected.

b) Installed sensor can only bear positive

pressure (for cantalever type or pressing
type sensor) or positive pressure (for S
type or pulling type sensor). It can't bear
torque.

c) For the same weigher, its sensors (3 or

4) must be the same model.

d) When welding on the weighing hopper,

cut off the power, and make sensor in
short circuit state or join the earthing cable
to the weighing hopper directly to prevent
large current damages sensor.

e) After installing pulling type sensor

(S type), screw down the locking nut.
Hanging screw rod can't reach to trough
type bottom of the sensor. There must be
a clearance about 10mm between hanging
screw rod and trough type bottom of the S
type sensor.

5.4.3 Maintenance of belt conveyor

5.4.3.1 Helical-bevel gear reducer

Winch (elevator) as shown in Fig. 3-30 on

page 3-34 adopts bevel gear reducer, as
is shown in Fig. 5-82.

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Maintenance HZS60 Concrete Batching Plant

9 10
8
6 7
4 5
3
1 2
11

Fig. 5-82 Bevel gear reducer (elevator)

1-Key 2-Output shaft 3-Key 4-Oil sealing 5-Washer 6-Bearing
7-Shaft sleeve 8-Bearing 9-Clamp ring 10-Clamp ring 11-Washer

Belt weigher as shown in Fig. 3-28 on page

3-31 adopts helical-bevel gear reducer, as
is shown in Fig. 5-83 on page 5-61.

3
2

8 7
6
1
10 11

4
5

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Fig. 5-83 Helical-bevel gear reducer (level belt conveyor)

1-Small gear 2-Gear 3-Driving gear shaft 4-Gear 5-Driven gear shaft 6-Gear 7-Output shaft
8-Key 9-Shaft sealing ring 10-Rolling bearing 11-Clamp ring

1. Inspection and maintenance period

See Table 5-9 for maintenance of the

reducer.

Table 5-9 Inspection and maintenance period of reducer

Interval Maintenance items

Check the oil and the oil level

General check-up for leak caused
3000 working hours, at
by loose oil sealing ring
least half a year
Inclined reduction gear with torque arm: check
the Rubber ring, replace it if necessarily

Check up at least 3 years depend Replace mineral oil

on working condition(shown in Replace bearing lubricating oil (recommend)
the ) and oil temperature Replace axis seal ring ( don’t fix it on former place)

Check up at least 5 years depend Replace oil synthesized

on work condition(shown in the Replace bearing lubricating oil (recommend)
figures 1.4.7 ) and oil temperature. Replace axis seal ring ( don’t fix it on former place)

R07,R17,R27,F27 and Spiroplan® are lubricated in the whole

reduction gear running time, so They needn’t be replaced.

Dissimilarity( depend on
Mend or replace defend paint/ antirust paint
exterior influence )

Tools Monkey wrench, Copper rod, Puller

Consult SEW workers when assemble

accessory inside, because it need be
disassembled professionally.

2. Daily maintenance of reducer

a) Special person set to maintain the

reducer. Observe the oil level frequently,
replace oil periodically and monitor the

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Maintenance HZS60 Concrete Batching Plant

running state.

b) Reducer adopts splashing lubrication

of oil pool. Before operation, add
extreme pressure gear oil N220 or N320
to the regulation position and supply oil
periodically.

c) During initial 50 hours using of new

machine, discharge lubricant and clean the
gear box (don't disassemble the machine).
Then replace new oil. If worn parts are
too many, please check the reason. After
troubleshooting, add new oil and replace
oil once every half a year with continuously
running.

d) During using of reducer, check

tightening condition of screws in the
connecting position and the worn condition
of gears. Replace the parts if problems are
found.

e) During using of reducer, pay attention

to the rotating flexibility. Stop to check
immediately to prevent more losing if
abnormal condition occurs. If stop for a
long period add more oil to protect the
inner parts from rusting. Discharge the oil
before start.

f) Replace the oil sealing yourself if it

leaks or after 6 months using.

g) Analyse abnormal noise and high

temperature and deal with the potential
problems. If you can't deal with it yourself,
please consult SANY after-sale service.

Lubricant recommended by SANY is shown

in Table 5-10.
Table 5-10 Commendatory lubricant (mineral oil)

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Low speed Surrounding temperature (unit: °C)

rotating Standard From To From To From To
shaft -10 15 0 30 10 50
ISO
≤100 VG150 L.CKC150 4EP VG320 L.CKC320 6EP VG460 L.CKC460 7EP
GBAGMA
ISO
>100 VG100 L.CKC100 3EP VG220 L.CKC220 5EP VG320 L.CKC320 6EP
GBAGMA

5.4.3.2 Turnabout drum

Turnabout drum also is called belt tail drum

(see Fig. 5-84 on page 5-63). Adjusting
screw is to tighten and adjust the running
condition of the conveying belt to make it
at a proper position.

3 4 5
Fig. 5-84 Turnabout drum
1-Turnabout drum 2-Belt 3-Adjusting screw 4-M20 bolt 5-Bearing UCP214

1. Disassembly steps of turnabout 1 2 3

drum

a) Cut off power supply.

b) Adjust adjusting screw forwards for

40~50mm to loosen the belt.

c) Remove M20 bolt on the bearing so

that turnabout drum and bearing can be
dismantled.
Fig. 5-85 Separate the turnabout drum
d) As is shown in Fig. 5-85, loosen socket 1-Bearing
hexagon screw on the bearing, so as to 2-Socket hexagon screw
separate turnabout drum from bearing 3-Turnabout drum

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Maintenance HZS60 Concrete Batching Plant

seat.

2. Assembly steps

a) Cut off power supply.

b) Put the shaft end of turnabout drum

into the bearing.

c) Install the assembly on belt frame, and

the belt should round across the drum and
tighten the screw.

d) Adjust adjusting screw backwards,

tighten the belt and adjust belt center.

Monkey wrench and inner

Tools
hexagon spanner

5.4.3.3 Maintenance of the belt conveyer

1. Maintenance of transmission gear

(reducer)

Apply lubricant before use. The lubricant

is L.KC100,150# middle-load industrial
extreme pressure gear oil.

Fill up to the height specified in the

instructions.

2. Lubrication of drum bearing

Drum bearing belongs to UCP series (UCP

214 is usual). Lubricate with grease and
fill once everyday.

3. Cleaning of drum and idler

Clean materials accumulated on drum and

idler frequently to prevent bias running of
belt.

4. Maintenance of sand-scraper

Check wearing of the sand-scraper

regularly, and replace when it is worn to a
certain degree.

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5. Replacement of rubber capped edge

Replace rubber capped edge when it is

worn out, or materials running out belt.
Replace rubber capped edge when it is
worn out, or materials running out belt.

6. Adjustment of conveyor bias running

Method 1: adjust drum (turnabout drum Running direction of belt

and tension drum) as Fig. 5-86.
Bias running
direction of belt

Adjusting direction of drum Adjusting direction of drum

Fig. 5-86 Adjustment of drum

Method 2: adjust the idler (upper trough Running direction of belt

idler and level lower idler) as Fig. 5-87.

Bias running
direction of belt

Adjusting
Adjusting direction
direction of drum of drum

Fig. 5-87 Adjust direction of idler

7. Prevention and remedy of joint

breaking and transverse cracking

Causes: direction of the joint is not suitable

for the running direction of belt.
Harm: damage belt seriously.
Prevention and remedy:
a) Reduce the load as much as possible,
especially that of belts with counterweight
tension device, which should be limited
between 200kg~300kg. It’s better to

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Maintenance HZS60 Concrete Batching Plant

prevent sliding during rainy seasons.

b) Inspect more frequently, so as to

prevent belt from blocking or scratching
owing to foreign matters.

c) Enhance the training of person who

assembles belt to prevent mistake of belt
connection.

8. Prevention and remedy of surface

degumming

Causes: wearing results from relative

motion between belt and idler or scraper
and belt. Curing of rubber layer is
unacceptable. Impact abrasion of belt
results from materials (especially large
size of materials).
Harm: the belt becomes thinner, and
strength becomes lower.
Prevention and remedy: Inspect more
frequently, so as to discover and remedy
troubles in time.
9. Prevention and remedy of
longitudinal cracking

Causes: foreign matters (like round or

angle steel) enter the materials, and they
may damage belt by sharp edge.

Harm: seriously damage the belt; materials

run out of the belt.

Prevention and remedy:

a) The user must require the material

supplier strictly controlling the size of
materials.

b) Increase maintenance of screen in the

aggregate storage, and repair in time in
case of damage.

c) Users of belt must require material

supplier deferrization materials, or they

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HZS60 Concrete Batching Plant Maintenance

may remove iron by themselves.

d) Inspect more frequently, so as to

discover and remedy any trouble in
time since it is critical to strengthen
maintenance.

e) Rubber conveying belt can be repaired

by cold bonding, and should be treated
better by professionals.

It is prohibited to clean or carry out

other works on the belt during running.

5.4.4 Maintenance of elevator

5.4.4.1 Precautions before maintenance
6 7
When steel wire rope start accidentally, 8
do not be dragged into. Before repair and
maintenance, please cut equipment's main
switch off, and prevent the equipment main
switch to accidentally switch on.

5.4.4.2 Replacement the steel wire rope

3
During installation, if there is any damage
or abnormal condition, the steel wire rope
shown in Fig. 5-88 should be replaced.

1. Wire breaking:
2
When wire is broken to a certain extend,
take down the broken steel wire rope. 5
Number of broken wires can be estimated
according to the table below. Considering
the number of broken wire increasing
rapidly, pay attention to the rope after wire 1 4
broken appearing and replace it in time. Fig. 5-88 Elevator
1-Lower guiding rail 2-Middle guiding rail
30x steel 3-Upper guiding rail 4-Aggregate hopper
6x steel wire
Length wire rope 5-Pull rod 6-Reducer 7-Reel 8-Top crash
rope diameter
diameter protective device

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Maintenance HZS60 Concrete Batching Plant

Visible broken
6 13
wire number

2. Other circumstances:

Due to the distortion of steel wire, the wire

length extends by 15% compared to the
original. Or extending of the rope results
that there isn't any rope groove to be
circled when the elevator bucket is in the
upper limit position.

Because of the corrosion and the attrition.

the steel wire diameter becomes smaller
by 10% or more compared to the original.

Obviously serious distortion of steel wire:

Rupture of one section; Rupture of steel
wire; Screw distortion; Basket shape; wire
can be taken out from the steel wire; The
section construction looses; Contraction;
Breaks off or the extrusion distortion.

Steel wire has been used for 20000 cycles

(steel wire tow the elevator bucket up and
down mean a cycle) .

The steel wire's loosing is caused by

the corrosion and the attrition.

3. Caution:

Periodically inspect the rope terminal for

the dehiscence and corrosion.

For steel wire which does not conform to

our demand, we will not guarantee the
equipment.

Steel wire rope and the rail should be

lubricated by grease. Reference type
of grease is No. 1 calcium base grease
(butter).

5.4.4.3 Adjustment of brake motor

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HZS60 Concrete Batching Plant Maintenance

Adjust the device if stop it for along time

(more than 1 week). If the “step test” brake
motor can’t loosen automatically, loose
the brake disc (including loop, spring and
friction plate) from the end cover of the
motor by prizing the brake plate manually.

5.4.4.4 Maintenance of elevator

1. Daily maintenance:

a) Check all the visible parts of the

elevator steel wire rope for damage and
distortion.

b) Inspection bucket steel wire as well as

active and fixed part, especially the reel
shown in Fig. 5-88 on page 5-67, pulley 1
and live pulley (see Fig. 5-89).
2
c) Check whether all the limit switches
and safety switches are effective and check
their effective range and the distance
Fig. 5-89 Elevator bucket
between the proximity switch and inductive 1-Pulley 2-Live pulley
plate. The distance between the proximity
and inductive plate is better about 20mm,
and pay attention to not make the plate
reach to the proximity switch shown in Fig.
5-90

d) Before producing every day, complete

the checking items above, and operate the
elevator (upward or downward) without
load twice or above.

2. Weekly maintenance:

a) Clean steel wire with a brush. Can not

use any impregnant.
Fig. 5-90 Switch on the elvator
Because the dust hardens the lubricant,
and prevents the new lubricant to seep
into the steel wire. Only enough lubricant
on the steel wire can prevent the corrosion
of the steel wire. The grease or the paint
can prevent the corrosion for unused
steel wire. If lubrication operation is not

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Maintenance HZS60 Concrete Batching Plant

convenient in a period. Please reinforce

relative inspection.

b) Clean pulley's oil residue.

c) Lubricate the steel wire once more.

Specially curving place.

Operate in special circumstances, for

example: the poor weather conditions, the
sea water and so on, time interval should
be reduced correspondingly to lubricate
steel wire.

The lubricant must be accommodated

with the original lubricant on steel wire.
Ordinarily lubricating oil works, the grease
is opposite; the oil can easily seep inside
the steel wire, and also can use the grease
with chemical additive which can easily
seep.

d) Inspect pulley and reel whether they

can rotate easily, and ensure there isn't
intervention with fixed parts as shaft
sleeve.

e) Check abrasion of the reel, pulley and

live pulley shown in Fig. 5-89 on page
5-69.

f) Add oil to the rail and reel of elevator.

g) Add oil to the winch device, pulley, live
pulley, pulling rod frame and bearings on
the bucket.

h) Check whether the fixed parts as limit

switch installation seat and inductive
plates are reliable.

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HZS60 Concrete Batching Plant Maintenance

If there are different contents between

this manual and the "GB/T 5972-2009
maintenance, repair, installation, test
and abandonment of steel wire rope for
the crane", please carry out according
to the later.

3. Monthly maintenance:

● ● Oil coating of the steel wire rope

After 1000 m 3's outputs or 1 month
opertaion:

Inspection the oil level of reducer.

Inspection the clearance of motor brake

(0.4mm~1.2mm). If the clearance exceeds
the biggest permitted clearance, the brake
must be readjusted.

After every 2000 hours' operation or

at least once every three years, the
lubricating oil in speed reducer must be
replaced.

5.4.5 Maintenance of the powder silo

5.4.5.1 Silo-top filter core

1. Disassembly steps of silo-top filter

core:

a) Remove safety nut fixing hook of the

cover by socket spanner (size: 10) (see
Fig. 5-91).

Fig. 5-91 Remove safety nut

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Maintenance HZS60 Concrete Batching Plant

b) Move hook to the side, making upper

edge of the filter flexible (see Fig. 5-92).

Fig. 5-92 Move hook to the side

c) Hold the hook in position, raise front of

the cover (see Fig. 5-93).

Fig. 5-93 Raise front of the cover

d) Pick up the cover and remove from

filter (see Fig. 5-94).

Fig. 5-94 Remove the cover

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HZS60 Concrete Batching Plant Maintenance

e) Put the cover slightly on the other side

(see Fig. 5-95).

Fig. 5-95 Put the cover to the other side

f) At this time, cleaning device should

get ready (see Fig. 5-96).

Fig. 5-96 Cleaning device

g) Screw off the nut (size: 10), and take

out corresponding filter parts (see Fig.
5-97).

Fig. 5-97 Screw off the nut

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Maintenance HZS60 Concrete Batching Plant

h) Screw off the nut on the base of electric

vibrator, and take the vibrator out (see Fig.
5-98).

Fig. 5-98 Take the vibrator out

i) Replace parts after removing electric

vibrator (see Fig. 5-99).

Fig. 5-99 Replace parts

j) Clip the filter core by tools (see Fig.

5-100).

Fig. 5-100 Clip the filter core

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HZS60 Concrete Batching Plant Maintenance

k) Pry out all parts to be replaced (see

Fig. 5-101).

Fig. 5-101 Pry out all parts

l) Pull out all used parts, and place on

one side carefully. Do not drop them (see
Fig. 5-102).

Fig. 5-102 Place the used parts carefully

2. Assembly steps of silo-top filter

core:

a) Insert a new filter core into hole on the

plate and press it to the proper position
(see Fig. 5-103).

Fig. 5-103 Insert into the hole

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Maintenance HZS60 Concrete Batching Plant

b) Apply grease to the upper edge of the

filter core (silicon-based grease) for the
convenience of assembly, and press till it
completely matches with the space (see
Fig. 5-104).

Fig. 5-104 Press the parts

c) Put the electric vibrator into its original

enclosure (see Fig. 5-105).

Fig. 5-105 Put the electric vibrator in

d) Tighten the bolts on the base (see Fig.

5-106).

Fig. 5-106 Tighten the bolts

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HZS60 Concrete Batching Plant Maintenance

e) Put the cover on the filter, and hold its

front part (see Fig. 5-107).

Fig. 5-107 Install the cover

f) Pull brake hook in the cover towards

yourself (see Fig. 5-108).

Fig. 5-108 Adjust the brake hook

g) Put the cover on filter housing, and

ensure the rear hook (in the cover) connect
to the upper edge of the housing (see Fig.
5-109).

Fig. 5-109 Put the cover

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Maintenance HZS60 Concrete Batching Plant

h) Put the cover on the filter housing.

Check whether the housing and round
edge connect to metallic parts in the cover
(see Fig. 5-110).

Fig. 5-110 Edge connected well

i) Push the hooks on the lower edge

inwards so that they can connect to the
filter housing (see Fig. 5-111).

Fig. 5-111 Push the hook inwards

j) If necessary, a screwdriver can be

inserted into the lower hole of the cover as
a crowbar (see Fig. 5-112).

Fig. 5-112 Insert a screwdriver into the

hole

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HZS60 Concrete Batching Plant Maintenance

k) After placing hooks at the lower edge

of the filter housing, tighten safety nut
(M10) by box spanner (see Fig. 5-113).

Socket spanner (10),

Tools Fig. 5-113 Tigten safety nut by box spanner
screwdriver, clamp

5.4.5.2 Level gauge

In order to check the amount of powder in

the powder silo, generally a level indicator
is provided in the powder silo. When
the level gauge can not alarm normally,
replace it if it is in trouble.

1. Disassembly steps:

a) Cut off power supply.

b) Take off the level gauge by hand or

tube pliers.

2. Assembly steps:

Level gauge (see Fig. 5-114) is assembled thread G1 1/2"

in the powder silo through thread, and it can
be vertical, inclined or level. The housing
should be turned to proper position during
its assembly. Cable connector must be
downward as shown in Fig. 5-115 on page
5-80, so as to prevent water from entering
the housing from cable connector.

Note:
Fig. 5-114 Level gauge
a) Do not turn the housing after
assembling level indicator.

b) Connect wire according to wiring

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Maintenance HZS60 Concrete Batching Plant

diagram.

c) Cut off all power supplies of the level

indicator before any work.

d) Cut off power during assembling the

level indicator. Power switch should be
mounted adjacent to level indicator (see
Fig. 5-115).

e) The level indicator must work with its

cover plate.

Tools Tube pliers Cable connector

shall be downward
Fig. 5-115 Install level gauge
5.4.5.3 Aeration pad

To break the arch, an aeration pad device 1

(see Fig. 5-116) is installed on the lower
cone of the powder silo..

1. Disassembly steps:

a) Discharge powder in the powder silo

thoroughly.

b) Dismantle screw conveyor.

2 3 4
c) Remove the assembling bolts of Fig. 5-116 Aeration pad
connecting flange and dismantle the
1- Pad 2-Rubber sea
flange.
3-Metallic washer 4-Fixed bolt
d) Dismantle manual butterfly valve.

e) Extend one hand into the powder silo to 1

grasp aeration pad. Loosen the fixed bolt
with wrench by another hand and carefully 2
take out the aeration pad (see Fig. 5-117).
3
2. Assembly steps:

Assembly steps are in a sequence reverse

to disassembly.

Tools Monkey wrench

Fig. 5-117 Dismantle aeration pad
1-Manual butterfly valve 2-Connecting flange
3-Screw conveyor

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HZS60 Concrete Batching Plant Maintenance

5.4.5.4 Maintenance of powder silo

1. Operation safety of powder silo

a) Silo-top filter should be started to 1

remove dust for 1~2min before and after 6
pumping powder to ensure the exchange 7
of the air flow fluent.
2 8
b) When the material level reaches the
upper limit of the powder silo, buzzer
alarms, pumping must be stop at this time.

c) When the material level reaches the

lower limit of the powder silo, buzzer
alarms, materials feeding must be stopped.

2. Daily maintenance of the powder

silo

a) Check two pressure safety valves

installed on the powder silo (see Fig. 9
3
5-118) every week. Observe whether there 4
is dust accumulated around the valves.
Open the pressure safety valve and clean 5
immediately if there is dust accumulated.
Stop blowing powder and clean the silo top
filter if the powder emitting from silo top.
Fig. 5-118 Powder silo
● ● Check whether the work of valve 1- Silo-top filter 2- Silo body
complies with anticipated purpose 3- Aeration pad 4- Manual butterfly valve
during the initial startup. Improper 5- Leg 6- Pressure safety valve
7- Damper-type material level indicator
pressure setting will result in
8- Overhaul ladder 9- Powder delivery pipe
overpressure unbalance, which will
cause shrinking or explosion of powder
silo. As a result, the powder in valve will
leak, which may consequently corrode
the valve body and contaminate the
ambient environment.
● ● Regular cleaning will prolong the
service life of valves. As to the valves
for controlling materials tending to
become hardened or sticky after long-
term storage, they should be cleaned
in time.

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Maintenance HZS60 Concrete Batching Plant

● ● Check the area around the valve once

a week for materials, and dismantle
cover to remove any rust or dirt. Check
whether the membrane can move
freely.
● ● Overhaul the valve, and replace
membrane and clean all assemblies
once a year. Readjust the valve after
overhaul.
● ● Replace spring every two years.
b) Clean the filter core every 3 months,
and ensure to replace it once a year. For
detailed information, see: "5.4.5.1 Silo-
top filter core" on page 5-71.

c) The following may be resulted if

operate and maintain regardless of
relevant regulation:

● ● Powder emission;
● ● Roof fall: connection of the silo-top
filter and powder silo broken results the
falling of the silo-top filter. Dehiscence
of the powder silo top results the
emission of the powder.

3. Prevention and remedy of powder

returning of delivery pipe

Phenomenon:
When the bulk material truck finishes
feeding the powder, powder left on
the ground may cause pollution to the
environment and waste.

Prevention and remedy:

Clean the filter core of silo-top filter;
inspect or repair feeding level gauge.

4. Prevention and remedy of powder

leakage of delivery pipe

Phenomenon:

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HZS60 Concrete Batching Plant Maintenance

The delivery pipe (shown in Fig. 5-118

on page 5-81) is easy to be worn out
(especially the bend) by materials.
Prevention and remedy:
Check wearing parts (such as elbow)
frequently. In case of excessive wearing,
replace fittings or weld up the worn parts.

5. Prevention of paint peeling

Phenomenon:
The surface paint of powder silo bubbles,
comes off or rusts.

Prevention and remedy:

Before painting, strictly adhere to GB/T
18839.1.2002 Surface Preparation of
Steels before Application of Paints -
Surface Preparation Method – General;
after painting, strictly adhere to JB/
T 7501.1994 Technical Conditions on
Organic Coatings of Typical Mechanical
Products in Damp-Heat Environment.

6. Prevention and remedy of roof fall

of powder silo

Phenomenon:
Connection between silo-top filter and
powder silo is cracked that silo-top filter
falls down from roof of powder silo.

Prevention and remedy:

Maintain accessories of the silo-top filter
as shown in Fig. 3-4 on page 3-10 and
pressure safety valve as shown in Fig. 3-5
on page 3-11 frequently.

7. Malfunction of the material level gauge

Phenomenon:
Cement agglomeration on the rotating
blades of the material level gauge (see
Fig. 5-114 on page 5-79) blocks them.

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Maintenance HZS60 Concrete Batching Plant

Prevention and remedy:

a) Check the sealing of the powder silo
frequently.
b) Disassemble the mounted bolts of the
gauge to eliminate the agglomeration if
malfunction occurs.
c) Wrap the bolts with sealing adhesive
tape when installing the gauge.

5.4.6 Maintenance of screw conveyor

5.4.6.1 Installation of screw conveyor

1. Preparation

Dismantle the package of gear motor (see

Fig. 5-119 on page 5-86). If the screw
conveyor provides flange or pipe fittings,
take off spiral rack and plug from spline
liner sleeve, and protection from spline
shaft.

Tighten all nuts and bolts again before

lifting all pre-assembled screw conveyors
from the ground.

Only approved crane can be used during

installation or maintenance.

Fix proper hoisting device all along to the

weld lifting eyes of each screw pipe part
during all installation phases, to convey
the screw conveyor.

2. Electrical cable connection

a) Wiring must be connected by electrician

or other qualified personnel.

b) Cut off power supply before any work.

c) Ensure the voltage of nameplate

comply with that of power supply before
wiring.

d) Pay attention to the safety requirements

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as shown in "2.10 Electrical Safety" on

page 2-30.

3. Trial run

Check whether foreign matter or water

enters the housing of conveyor. If there is,
take off the inlet plate to clean.

The screw conveyor as shown in Fig.

5-119 on page 5-86 does not provide
inlet or outlet in supply. If inlet or outlet is
assembled by users, make sure that end
flanges are vertical.

Make sure the inlet is aligned with outlet

to avoid bending of screw conveyor;
otherwise the screw conveyor will shut
down.

Check the rotation direction (anticlockwise

from inlet). Reverse terminals of motor if it
is incorrect.

Make sure that the gear reducer is

filled with oil and the hanging bearing is
lubricated frequently.

Before charging, firstly run the screw

conveyor without load to check for stable
running. If it is stable, charge and operate
as normal.

Close the inlet valve and exhaust screw

conveyor after each working day, so as
to prolong the service life of the spiral
feeder.

4. General preventive measures

a) Do not put hands into a screw conveyor

in service.

b) Do not open the inspection hole before

cutting off power supply for the screw
conveyor.

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Maintenance HZS60 Concrete Batching Plant

5.4.6.2 riving head and seal in end

bearing

1. Replacing steps (see Fig. 5-119):

a) Close the silo.

4
b) Discharge the screw conveyor. Outlet Inlet
3
26
c) Cut off power of motor.

d) Open the viewing port.

e) Put a thick board (1) into viewing port 5

1
and ensure it has been locked tightly to Fig. 5-119 Screw conveyor
prevent sliding of helicoid (4).
1-Thick board 2-Motor 3-Seal ring
f) Ensure hook point (6) of the motor has 4-Helicoid 5-Blade 6-Hook point
been tightened.

g) Fix the hoisting equipment to the hook

point (6).

h) Take off the reducer flange bolt and

gear motor (2).

i) Replace the used one with a new seal

ring (3).

j) Assemble other parts in a sequence

reverse to the above.

5.4.6.3 Replace middle hanging shaft

assembly

1. Dismantle steps

a) Open the view port under the middle

hanging shaft assembly which shall be
replaced.

b) Open the nearest view port of the

middle hanging shaft assembly (see Fig.
5-120).

c) Move the screw conveyor (or some

parts of the device) as low as possible to
leave enough space for middle hanging Fig. 5-120 Open the view port

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shaft disassembly.
1
d) Loosen the bolt (1) as shown in Fig.
5-121.

e) Dismantle the connecting shaft in

using, and dismantle the middle hanging
shaft assembly (2) via the view port (see
Fig. 5-121). Move the upper half of hanging
bearing until it can be take out from the 2
view port.

Fig. 5-121 Loosen the bolts

1-Bolt 2-Hanging assembly

2. Assembly steps

a) Lubricate shaft end (1) of middle 1 2

hanging shaft and shaft sleeve (2) of
helicoid by lubricant (see Fig. 5-122).

Fig. 5-122 Lubricant shaft end and shaft sleeve

1-Shaft end 2-Shaft sleeve
b) Install a new middle hanging shaft
assembly, and insert one end of the shaft
into the shaft sleeve of screw coupling in
the correct position.

c) Install sections of helicoid, and end

faces keep 180° with each other. Then
insert connecting shaft end of helicoid
disassembled early slightly into the free
end of the middle hanging shaft to flush
conveniently.

d) Install all the parts dismantled before

and close the screw conveyor.

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e) Through the view port, position the

middle hanging shaft in the direction of
hole in the outer pipe, and insert bolt 1
(see Fig. 5-123). "Pull" each bolt in order
to acquire stated tighten torque.

f) Use supplied locking bolts to lock the

view port.

5.4.6.4 Maintenance of screw conveyor

Fig. 5-123 Insert bolt
Exhaust the screw conveyor after work
each day. Inspect the running, sealing and 1-Bolt
lubrication of the reducer once a week
for abnormal sound and oil leakage etc.
Replenish if oil is insufficient. Inspect the
outlet and under slung bearing (see Fig.
5-119 on page 5-86) for deposit once a
week, and clean to avoid blocking. Inspect
the tension of integral coupling once a
month. It is prohibited to mix hard and big
materials or foreign matters in conveying
materials.

5.4.7 Maintenance of control room

1. Maintenance of the power cabinet
elements

a) Cut off the power supply, and check

the appearance of the elements. Clean the
dust and dirt outside the elements.
b) The protecting switch cut off for over
loading can’t be turn on at once. After 1~3
min cooling down, the switch can be turn
on.
c) Check whether the contacts are in a
good state by multimeter.

d) Change the contactor if the paper

outside the loop is burnt or black.

e) Check the temperature and the fan of

the power switch. If the fan doesn't start

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up, replace it.

f) Cut off the main power. Pull the cable

slightly and check whether the fasten bolts
and terminal are loose. And fix the loose
one.

2. Maintenance of the operation

console

a) Cut off the power supply, and check

the appearance of the elements. Clean the
dust and dirt outside the elements.

b) Pull the cable slightly and check

whether the fasten bolts and terminals are
loose. And fix the loose one.

5.4.8 M a i n t e n a n c e o f a g g r e g a t e
storage discharging system

Aggregate storage is composed of bins

storing sand and stone material and
aggregate weighing part. It is divided into
two types: underground silo and steel
structure. Both aggregate storages provide
storing hopper gate and weighing hopper
gate.

5.4.8.1 Discharge gate of aggregate

1 2
storage bin

1. Steps to disassemble storing hopper

gate (discharge gate of storing hopper):

a) First dismantle the piston rod of

pneumatic cylinder. Remove pin with
sharp nose pliers, and then take out the
pin shaft.

b) Remove the four M20 bolts (1) on both

sides of fan-shaped door (2) (see Fig.
5-124).
Fig. 5-124 Storing hopper gate
1-M20 bolt 2-Fan-shaped door

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2. Assembly steps:

a) Firstly support the fan-shaped door,

align with the mounting hole, and tighten
bolts on both sides.
1 2
b) Connect the piston rod of cylinder (2)
to fan-shaped door, assemble pin shaft (1)
and insert the cross pin (see Fig. 5-125).

Fig. 5-125 Install parts as shaft pins

1-Pin shaft, pin 2-Piston rod of cylinder

c) Finally, tighten M20 bolts.

M20 open end wrench

Tools Sharp nose pliers
Small hammer

NOTE
The discharge gate should not be
inclined.

5.4.8.2 Discharge gate of aggregate

weighing hopper

1. Steps to disassemble the weighing

hopper gate (discharge gate of the
aggregate weighing hopper): 1

a) Firstly dismantle the piston rod of the

2
cylinder. Remove the pin with sharp nose
pliers, and then take out the pin shaft.

b) Remove the twelve M20 screws (1)

on both sides of the discharge gate (2) to Fig. 5-126 Discharge gate of aggregate
dismantle the fan-shaped door (see Fig. weighing hopper
5-126). 1-M20 screw 2-Discharge gate

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2. Assembly steps:

a) Firstly support the fan-shaped door, 1 2

align with the mounting hole and pre-
tighten bolts on both sides.

b) Connect the piston rod of the pneumatic

cylinder (1) to fan-shaped door, assemble
the pin shaft (2) and insert the cross pin
(see Fig. 5-127).

c) Finally, tighten M20 bolts.

M20 open end wrench
Tools Sharp nose pliers
Small hammer
Fig. 5-127 Install parts as piston rod of
pneumatic cylinder
5.4.9 Maintenance of addtive pump 1-Piston rod of pneumatic cylinder
5.4.9.1 Anti-freezing measure 2-Pin shaft, pin

Pump as shown in Fig. 3-35 on page 3-40

can be used in the system which adopts
anti-freezing measure to water. If the pump
is installed in the place where is easy to
freeze, proper antifreeze should be added
to protect liquid delivery in the pump
from freezing, otherwise the pump will be
damaged. If there isn't any antifreeze, stop
the pump when there is danger of freezing,
and drain liquid in the pump and system
during stop.

5.4.9.2 Pump needs check as

followings periodically

● ● Pump pressure of working and running.

● ● Excessive heat of the motor.
● ● Cut off time of motor over loading.
● ● All the controlling operation.
● ● Possible leakage.
● ● Take out and clean/replace all the filter
screens.

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Maintenance HZS60 Concrete Batching Plant

● ● Frequency of start and stop.

● ● If malfunction occurs, check the
system as "6.10 Troubleshooting of
the Additive Pump" on page 6-20.

NOTE
1) When pump stops for a long time,
clean and store it well.
2) Prevent pump from rusting and
damage in storage.

5.5 Maintenance of Liquid and

Air Supply System 1 2 3 4

5.5.1 Liquid supply system

5.5.1.1 Impeller of water pump and

mechanical seal

1. Dismantled steps:
a) Dismantle the bolt jointing pump body
(for separation of pump body (1) and cover
(3), see Fig. 5-128). Apply uniform force to Fig. 5-128 S e p a r a t e p u m p b o d y f r o m
each bolt during reassembly. pump cover
1-Pump body 2-Bolt 3-Impeller 4-Pump cover

b) Dismantle the impeller nuts (2) with a

socket spanner (14mm), and separate the
impeller (1) from the shaft with a three-jaw
puller (see Fig. 5-129).

1 2

Fig. 5-129 Separate impeller from shaft

1-Impeller 2-Impeller nut

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c) Take off movable ring and fixed ring of

the mechanical seal. During the assembly
of mechanical seal, it should be clean and
free of solid particles. A small amount of
lubricant can be applied to rubber and
sealing face, and fixed ring should be
assembled on the pump cover levelly (see
Fig. 5-130 and Fig. 5-131).

2. Assembly steps:

Assemble a new impeller and mechanical

seal. Assembly steps are in a sequence 1 2 3
reverse to disassembly. Fig. 5-130 Take off the mechanical sealing
1-Bolt jointing pump cover 2-Mechanical seal
3-Impeller
5.5.1.2 Bearing of water pump

1. Dismantled steps:

a) Dismantle the bolt jointing pump cover

(for separation of pump cover and motor,
see Fig. 5-130 on page 5-93).

b) Dismantle the motor cover, blade and

1 2
rear cover to take out the rotor (do not
Fig. 5-131 Take off the movable ring and
scratch coil of motor, see Fig. 5-132).
fixed ring
c) Pull out the bearing by three-jaw puller 1-Movable ring 1-Fixed ring
(see Fig. 5-132).

2. Assembly steps:
1
Assemble new bearing. The bearing should
be assembled with uniform force applied
by press or pipe. Assembly steps are in a
sequence reverse to disassembly.

Open end wrench

Tools Socket spanner
Three-jaw pullers are needed.

Fig. 5-132 Pull out the bearing

1-Bearing

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5.5.2 Air supply system

5.5.2.1 Air compressor

The air compressor is to compress air

through a piston moving up and down in
cylinder. The entrance of air-inlet filter
must be kept clean to prevent the decline
of air supply caused by jam.

For detailed operation of the air compressor,

please see "Air compressor introduction"
supplied by producer (see Fig. 5-133
on page 5-94 for the appearance of
compressor).

15 16
14
8
13
9
10

11
12 17
3 18
19
4 7
5
6 20
21
22
23
24
25
26
12
27
28
29

Fig. 5-133 Explosion diagram of VA-100 air compressor

1. Replacement of main parts

● ● Piston ring

Dismantle steps:

a) Dismantle exhaust pipe (8) on body.

b) Dismantle spring cushion (6) and nut (5).

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HZS60 Concrete Batching Plant Maintenance

c) Dismantle crankcase cylinder washer

(4).

d) Pull out the whole cylinder (3).

e) Take out piston ring (9) and (10) to be

replaced.

Assembly steps:

Assemble new piston ring. Assembly steps

are in a sequence reverse to disassembly.

Open end wrench

Tools
Socket spanner

● ● Crank shaft

Dismantle steps:

a) Dismantle exhaust pipe (8) in the

compressor body.

b) Dismantle spring nut (5) and cushion

(6).

c) Dismantle crankcase cylinder gasket

(4).

d) Pull out the whole cylinder (3).

e) Dismantle two screws of link group

(11).

f) Dismantle six screws (15) and spring

cushions 16 respectively.

g) Dismantle fan (14).

h) Dismantle screw (17) and spring

cushion (13).

i) Dismantle pulley retainer ring (18).

j) Knock pulley slightly by hammer to

take off key (22).

k) Dismantle four rear cover screws (1)

and plain cushions (2), and knock crank
from fan by hammer.

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Maintenance HZS60 Concrete Batching Plant

l) Dismantle rear cover gasket (28) and

rear cover (29).

m) After dismantling oil baffle (27), replace

it with a new one.

n) Dismantle front cover (20) (with six

screws dismantled).

o) Dismantle oil seal (21) and front cover

gasket (12).

p) Dismantle bolt (23) and retaining plate

(24) of counterbalance.

q) Dismantle counterbalance.
r) Dismantle both bearings (26), and then
dismantle crank.

Assembly steps:

Assemble a new crank shaft. Assembly

steps are in a sequence reverse to
disassembly.

Monkey wrench
Tools Socket spanner
Small hammer

NOTE
During the replacement of crank shaft, 16
replace bearing (26), oil baffle (27), oil 17
15
seal (21), front cover washer (12), and 18
14
bush (7) together as shown in Fig. 5-133
on page 5-94. 13
12 19
11
9 20
2. Air-exchange valve 8
23 21
7
Fig. 5-134 is a schematic diagram for air- 6 22
exchange valve, in which (10) is air-inlet 5
valve, and (23) is air-outlet valve. 10 4
3
● ● Replacement of air-inlet valve 2

Dismantle steps: 1
Fig. 5-134 Air-exchange valve

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a) Dismantle pressed cover screw (15)

(four).

b) Dismantle pressed cover (14) of air-

inlet valve.

c) Dismantle O-ring (12) and (13).

d) Dismantle unloading piston (11).

e) Dismantle and replace the whole air-

inlet valve (10) as well as copper washer
(1).

Assembly steps:

Assemble a new air-inlet valve. Assembly

steps are in a sequence reverse to
disassembly.

Tools Socket spanner

NOTE
During the replacement of air-inlet valve,
O-ring must be spread with grease.

● ● Replacement of air-outlet valve

Dismantle steps (see Fig. 5-134 on page
5-96):

a) Dismantle pressed cover screw (15)

(four).

b) Dismantle pressed cover (16) of air-

outlet valve.

c) Dismantle O-ring (17).

d) Dismantle and replace the whole air-

outlet valve (23) as well as copper washer
(1).

Assembly steps:

Assemble a new air-outlet valve. Assembly

steps are in a sequence reverse to
disassembly.

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Maintenance HZS60 Concrete Batching Plant

Tools Socket spanner

3. Check valve and pressure switch 2 3 4

5
6
7
As shown in Fig. 5-135, (3) is check valve 8
and (8) is pressure switch. 9
10
● ● Replacement of check valve 11
Dismantle steps:

a) Dismantle outer exhaust pipe (2).

1 12
b) Dismantle bolt (5), nut (6) and washer
(7).

c) Dismantle check valve (3).

Fig. 5-135 Check valve and pressure switch
Assembly steps:

Assemble a new check valve. Assembly

steps are in a sequence reverse to
disassembly.

Tools Monkey spanner

● ● Replacement of pressure switch

Dismantle steps (see Fig. 5-135 on page
5-98,):

a) Dismantle bolt (5), nut (6) and washer

(7).

b) Dismantle connecting pipe (4).

c) Open cover of pressure switch (8).

d) Dismantle harness (12).

e) Dismantle pressure switch (8).

Assembly steps:

Assemble a new pressure switch.

Assembly steps are in a sequence reverse
to disassembly.
Monkey spanner
Tools
Screwdriver

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4. Maintenance of air compressor

● ● Clean the air-inlet filter

Disassemble the air-inlet filter assembly

fastened by bolts to clean the filter core
(see Fig. 5-136). Take the filter core from
the filter shell. Open the front cover of the
filter, and blow off dust by dust blowing
device. If the filter core is too dirty to
clean, replace it. The assemble orders are
reverse.

Fig. 5-136 Take the filter core out

● ● Clean the valve plate

Valve parts can only be dismantled with the

cylinder cover removed. Before dismantling
any connecting tube or loosening screw
of the cylinder cover, make sure that the
air pressure has been relieved from the
compressor. Disassemble as flowing
steps:

a) Loosen the nut of the air-outlet pipe

and dismantle the air-outlet pipe (see Fig.
5-137).

Fig. 5-137 Dismantle the air-outlet pipe

b) Remove the eight bolts of the cylinder

cover, and lift the cover and valve parts
from the cylinder (see Fig. 5-138).

Fig. 5-138 Lift the cover and valve parts

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Maintenance HZS60 Concrete Batching Plant

c) Loosen and remove nuts and blots on

valve parts (see Fig. 5-139).

Fig. 5-139 Dismantle bolts and nuts

d) Remove the locating plate of the valve

plate, air-inlet and air-outlet valve plates,
and clean the locating plate and valve
plate (see Fig. 5-140).

Fig. 5-140 Dismantle locating plates and

valve plates
After adding a new washer, assemble in a
sequence reverse to the above.

5.5.2.2 Pneumatic triplet

As shown in Fig. 5-141, the main function

of pneumatic triplet is to filter, relieve
pressure and spray mist.

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48
24 49
47 73
25 50 74
26 75
20 27
28
21 29
22 30 51
23 52
9 15 31
16 53
32 54
1 37 33 55
2 10 17 36 34 56
18 57
3 38 58
19 59 6
39 35
4 60
11 40 61
5
41 62 70
6 14 63
42 64
65 71
12
66
43 67
7 72
44 68
13
69
45
8
46
Fig. 5-141 Schematic diagram for GF200, GR200, GL200 and assembly
Main parts of the pneumatic triplet are
shown in Table 5-11.
Table 5-11 Main parts of pneumatic triplet
No. Code Designation No. Code Designation

Differential
1 GF200-006-2 39 SR300-025 Washer
drainage column

Main pressure regulating

2 GOR15006N60 O-ring 40 SR200-008
hexagon cap

Main pressure
3 GSPA0287 Spring 41 GR200-007
regulating shaft
Differential Main pressure
4 GF200-007-2 42 GR200-006
drainage seat regulating seat
Hexagon round
5 GOR15007N75 O-ring 43 GSG03008NBA
head screw
6 GOR150315N75 O-ring 44 SR200-014 Indication ring

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No. Code Designation No. Code Designation

Main pressure
7 GF200-005 Water filter 45 SR200-004
regulating button
Differential drainage
8 GF200-008-2 46 GR200-009 Fixed ring cap
connector
9 GF200-021 Rear decorating plate 47 GL200-021 Rear decorating plate
10 GF200-001 Water filter body 48 GL300-018 Holding screw
11 GF200-003 Fluid director 49 GL300-019 Adjusting ring
12 GF200-004 Filter core 50 GL200-017 Index ring
13 GF200-002 Umbrella-shape seat 51 GL200-020 Front decorating plate
14 GF200-020 Front decorating plate 52 GL200-300 Adjustable inspector
15 GF202-001 L-shaped bracket seat 53 GL300-016 Oil filler needle
16 GPN03X11A Pin 54 GPS4N75 O-ring
17 GA201-002 Bracket partition plate 55 GL200-006 Oil dripping pipe
18 GA201-003 Support cover 56 GOR120085N75 O-ring
19 GSA05008N Socket screw 57 GOR120145N75 O-ring
Fixing screw of
20 GR200-24 58 GPS14N75 O-ring
closing plate
21 GA212 Closing plate 59 GL200-011 Oil sprayer body
22 GOR180025N75 O-ring 60 GPS15N75 O-ring
23 GR200-022 Rear decorating plate 61 GL200.009 Separation plate
24 GR200-003 Valve cap 62 GBL3.5 Steel ball
25 GOR20024N75 O-ring 63 GOR10002N75 O-ring
26 GSPA0212 Spring 64 GBL3.5 Steel ball
27 GSPSN75 O-ring 65 GOR10002N75 O-ring
28 GR200-012 Pressure regulating plug 66 GSPA0214 Spring
Pressure regulating
29 GR200-002 67 GL200-026 Vent column
column
30 GPS4N75 O-ring 68 GL200-008 Oil sprayer bottom cap
Front pressure
31 GR200-002 69 GSDA03008WA Cross round head screw
valve body
32 GR200-021 Front decorating plate 70 AL1500-004 Oil pipe
33 GOR180025N75 O-ring 71 AL1500-014 Oil pipe filter tip
34 F-PR010M Pressure gauge 72 GL200-005 Oil ring
Screw of pressure
35 GR300-023 73 GL200-002 Oil filler plug
gauge
36 SR300-015 Lockout conduit 74 GPAS008N75 O-ring

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HZS60 Concrete Batching Plant Maintenance

No. Code Designation No. Code Designation

Main pressure
37 AR1500-011 75 GL200-001 Oil supplier body
regulating membrane
38 GSPA0211 Spring

1. Cleaning or replacement of filter

core

Disassembly steps (see Fig. 5-141 on

page 5-101):

a) Screw off water filter (7).

b) Dismantle umbrella-shape seat (13).

c) Take out filter core (12) to clean or

replace.

Assemble a new filter core. Assembly steps

are in a sequence reverse to disassembly.

2. Replacement of main pressure

regulating membrane

Disassembly steps (see Fig. 5-141 on

page 5-101):

a) Dismantle fixed ring cap (46) of relief

valve in the middle.

b) Dismantle main pressure regulating

button (45) manually, and take off indication
ring (44).

c) Dismantle inner hexagon round head

screw (43) by screwdriver.

d) Take off main pressure regulating seat

(42).

e) Take off main pressure regulating shaft

(41), main pressure regulating hexagon
cap (40), washer (39) and spring (38).

f) Dismantle main pressure regulating

membrane (37) to be replaced.

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Maintenance HZS60 Concrete Batching Plant

Assembly steps:

Assemble new main pressure regulating

membrane. Assembly steps are in a
sequence reverse to disassembly.

Requirements:

(1) If filtering, pressure relief and oil mist

are still unavailable after replacing the filter
core and main pressure relief membrane,
replace the whole pneumatic triplet.

(2) During assembly, clean the connecting

pipe and connector to avoid dirt from
entering air duct.

(3) During assembly, make sure the air

flow direction is the same as arrow on the
body, and teeth of connecting pipe and
connector are correct.

Tools Screwdriver

5.5.2.3 Solenoid valve

Solenoid valve generally is composed

of body, coil and terminal group (see
Fig. 5-142). Solenoid valve should be
maintained frequently and it is not easy to
get damaged in general. But, the damage
frequency of coil is high.

1. Steps to replace coil 1 2 3 4

Dismantle steps:

a) Take off terminal wire (see Fig. 5-142).

Fig. 5-142 Solenoid valve

1 Body 2-Coil 3-Nut 4-Terminal

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HZS60 Concrete Batching Plant Maintenance

b) Screw off nut (see Fig. 5-142 on page

5-104) to separate the body from coil and
terminal (see Fig. 5-143).

Fig. 5-143 Separate the body

c) Dismantle screw by screwdriver to

separate the coil from terminal (see Fig.
5-144).

Fig. 5-144 Separate coil from terminal

d) Dismantle the coil to be replaced (see

Fig. 5-145).

Assembly steps:

Assemble new coil. Assembly steps are in

a sequence reverse to disassembly.

Tools Screwdriver
Fig. 5-145 Dismantle coil
Requirements:

(1) During assembly, make sure that the

air flow direction and connecting pipe are
proper.

(2) During utilization, strictly adhere

to all technical requirements, such as
working voltage, action frequency, working

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Maintenance HZS60 Concrete Batching Plant

pressure and service temperature. During

overall debugging, first carry out debugging
manually, and then perform debugging
with power on.

(3) Pay attention to dust prevention. It

is recommended to install a muffler or
silencing throttle at the vent.

2. Maintenance of solenoid valve

Requirements:
(1) Apply anti-rust steam turbine oil with
viscosity of 2.5 ~ 7°E.

(2) The minimum working frequency

should be once every 30 days.

(3) Do not use the valve in an environment

with much dust, water droplet and steam or
corrosive gas, chemical and solution, and
use filtered, dried and clean compressed
air (filtration degree should be less than
40 μm).

5.5.2.4 Spherical vibrator

To speed up the discharge of powder,

generally a pneumatic spherical vibrator is
installed onto the powder weighing hopper
1
(see Fig. 5-146).
2

3
1. Disassembly steps:

First, cut off the power supply of control

system to shut it down, and then pull
out the air pipe from the connector and
dismantle bolts and nuts by M8 open end Fig. 5-146 Spherical vibrator
wrench. Finally, the pneumatic spherical 1-M8 Nut 2-M8 Bolt
vibrator can be taken out. 3-Pneumatic spherical vibrator

2. Assembly steps:

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HZS60 Concrete Batching Plant Maintenance

Install pneumatic spherical vibrator on the

support of the powder weighing hopper.
Join it with M8 bolts, each with two nuts
each; and tighten with wrench. Finally,
connect it to the air pipe.

Tools M8 Open end wrench

5.5.2.5 Pneumatic cylinder

Pneumatic cylinder is shown in Fig. 5-147,
and magnetic assembly is shown in Fig.
5-148.

Fig. 5-147 Pneumatic cylinder

20 21
19
18
6 1
7
16
17 15

14
13
12
11 7
10
6
9 5
4
8
3
2
1
Fig. 5-148 Schematic diagram of magnetic assembly

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Maintenance HZS60 Concrete Batching Plant

Main parts of magnetic assembly are

shown in Table 5-12.
Table 5-12 Main parts of magnetic assembly

No. Code Designation No. Code Designation

1 SC32-023 Support screw cap 12 SC32S-005 Piston-magnet seat
2 SC32-008 Support 13 GMEA21V30.5X5 Magnet
3 SC32-002 Front cover 14 SC32S-006 Piston-guide seat
4 GPPDU12N80 Abnormal O-ring 15 G9009 Wearing cushion
5 GBU12X16X10 Sliding lining 16 GSA06055B025 Socket screw
6 G1062 Abnormal O-ring 17 SC32-003 Aluminium tube
7 GPS28N75 O-ring 18 SC32-007 Rear cover
8 GSMA101.2506N Hexagon screw cap 19 JS0005N Screw
Retainer ring of
9 SC32-001 Piston rod 20 GXCRTW10B
external tooth
10 GOR130092N75 O-ring 21 GSP6N75 O-ring
11 GPAPA32N75 Abnormal O-ring

1. Replacement of piston rod

Disassembly steps (see Fig. 5-148 on

page 5-107):

a) Dismantle support screw cap (1) and

support (2).

b) Dismantle front cover (3).

c) Dismantle abnormal O-ring (4) and (6)

as well as sliding lining (5).

d) Dismantle O-ring (7).

e) Dismantle hexagon screw cap (8).

f) Pull out piston rod (9) from piston-

magnet seat (12).

Assembly steps:

Assemble a new piston rod. Assembly steps

are in a sequence reverse to disassembly.

2. Replacement of seal

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HZS60 Concrete Batching Plant Maintenance

Disassembly steps (see Fig. 5-148 on

page 5-107):

a) Dismantle support screw cap (1) and

support (2).

b) Dismantle front cover (3).

c) Dismantle abnormal O-ring (4) and (6),

and replace with a new seal if damaged.

d) Dismantle sliding lining (5) and O-ring

(7), and replace with a new O-ring if (7) is
damaged.

e) Dismantle hexagon screw cap (8).

f) Pull out piston rod (9) from piston-

magnet seat (12).

g) Dismantle O-ring (10) and abnormal

O-ring (11), and replace with a seal if
damaged.

h) Dismantle piston-magnet seat (12),

magnet (13), and piston-guide seat (14).

i) Take out wearing cushion (15), and

replace with a new one if damaged.

Assembly steps:

Assemble a new seal. Assembly steps are

in a sequence reverse to disassembly

Inner hexagon spanner

Tools
Monkey wrench

5.6 M a i n t e n a n c e o f C o n t r o l
System
5.6.1 computer

1. Operation instruction

a) in a good earthing condition.

Since the static electricity has a feature

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Maintenance HZS60 Concrete Batching Plant

of accumulating, when electricity

accumulates to a certain extent, partial
high pressure will discharge for an instant.
Huge energy is enough to damage the
elements and BIOS on the main board.

b) It is forbidden to cut off the power

directly or turn off the switch by force. You
must turn off it by the system, and cut off
the power outside after exiting the system
completely.

c) The situation where the IPC located

should be protected from dust and water,
with good condition of aeration. Never
work in a high temperature. Strictly prevent
IPC from water inflow. EVOC industrial
computer set a prompt on the front plate to
remind clean the IPC once 3 months.

d) Prevent IPC from shaking and striking,

especially the hard disk. Working principle
of the hard disk is read the rotating disk
by magnetic read head. If drastic shaking
and striking occurs, the working magnetic
head may be damaged by scratching the
disk.

e) Never use mobile disk without virus

check. Clean the rubbish of the system
and check virus in a period.

f) Files of system and monitoring soft

are in the special location. Never open
or delete the files in the location, or the
system or the monitoring soft will have
malfunction.

g) Parameters have been set before

leaving factory. They can't be modified if
there isn't any special requirement, or the
system may work abnormally or can't be
entered.

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HZS60 Concrete Batching Plant Maintenance

2. Checking method:

After a long-term service, troubles, such

as failure of normal startup and crash, will
appear. Replace the IPC if such troubles
can not be solved basically by replacing
some PCBs.

3. Disassembly steps:

a) Cut off the power of the IPC and UPS,

and pull out its power plug.

b) Pull out plugs of the I/O devices.

c) Move out the original IPC from the

console.

4. Assembly steps:

Put a new IPC into the console. Insert I/O

devices, and then connect it to the power.
Turn on the power of UPS and power of
IPC in turn.

Tools Screwdriver

5.6.2 Monitor

1. Checking method:

When the monitor of control system in

the batching plant appears blank screen,
horizontal bright line, vertical bright line
and partial color etc., replace the monitor
if the troubles are not on video card and
contact of video card.

2. Disassembly steps:

Cut off power of IPC, UPS and power of

monitor in order, and pull out plugs of
monitor power and monitor cable.

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Maintenance HZS60 Concrete Batching Plant

3. Assembly steps:

Put a new monitor on the console, insert

plug of monitor cable, and switch on UPS
and power of the IPC and monitor in order.
Enter the setting menu of monitor to adjust
row and field amplitudes of monitor to full
screen.

Tools Screwdriver

NOTE
The monitor and video card must be
connected stably.

5.6.3 UPS power

1. Checking method:

If UPS (see Fig. 5-149) cannot output or

switch automatically with power off, and the
supply time becomes obviously insufficient
with backup battery, which cause failure of
normal shutdown while power off and etc.,
firstly shoot load failure; if load is normal,
the trouble must be on UPS.

2. Disassembly steps:

Cut off powers of IPC and monitor, UPS

in order. Pull out plugs of UPS, IPC and
monitor powers. Dismantle UPS in trouble Fig. 5-149 UPS power
from console.

3. Assembly steps:

Put a new UPS into the console, and insert

UPS plug. Open UPS to check whether the
output voltage is AC220V. If it is normal,
insert power plugs of the IPC and monitor
to start UPS.
NOTE
The new UPS should be charged for
more than 12h before use.

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HZS60 Concrete Batching Plant Maintenance

5.7 Maintenance of Lubrication

System
5.7.1 Lubrication part of the batching
plant
Table 5-13 is the lubrication parts of the
concrete batching plant.

Table 5-13 Lubrication parts of the concrete batching plant

Lubrication
Lubrication Designation Lubrication
No. Device Part Dosage points Remark
period lubricant / grease method
number
Sector
Aggregate door and Half a Lithium-based 4-5 10 in one
1 Oil refiller Refiller
storage connecting month grease 2# g/time bin
rod shaft
Bearing of Half a Lithium-based
20g/time Oil refiller 4 Refiller
the drum month grease 2#
Initial
1000 hours Gear oil VG220 /
Level belt According to replacing
2 Reducer or half a Mobil 629# /
conveyor the oil level time is
year Shell 150#
100 hours
Sprocket
Every Proper
wheel and lubricant oil Refiller
month amount
chain
Valve of
Sliding Half a Lithium-based 10 2 points of
4 waiting Oil refiller Refiller
bearing month grease 2# g/time one shaft
hopper
Initial
Gear oil VG220 / According
replacing
Reducer 3 months Mobil GEAR629#/ to the oil Pour into 1
time is
Shell 150# level
100 hours
Lithium-
Centralized According
Supply based grease, Refiller
lubricating to the oil Oil refiller 2
real-time summer 2#, one time
grease pump level
winter 1#
5 Mixer
main shaft
Lithium- Initial
bearing and
based grease, replacing
hydraulic 250 hours
summer 2#, time is
system
winter 1# 30 days
bearing

2000 hours Lithium-based

Motor bearing Refiller
or 1 year grease 2#

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Maintenance HZS60 Concrete Batching Plant

Lubrication
Lubrication Designation Lubrication
No. Device Part Dosage points Remark
period lubricant / grease method
number
Initial
1000 hours Gear oil VG220 / According
replacing
Gear box or half a Mobil GEAR629#/ to the oil Pour into
time is
Screw year Shell 150# level
6 100 hours
conveyor
Middle shaft
Lithium-based 4-5
and caudal Every week Oil Refiller Refiller
grease 2# g/time
bearing

Initial
1000 hours According
Air Air Super Ingersoll replacing
7 or half a to the oil Pour into
compressor compressor rand lubricant 68# time is
year level
100 hours

Pneumatic Anti-rust steam 1/2

8 Oil cup 3 months Pour into 1
triplet turbine oil cup/time

Each rolling Lithium-based

Half a month 20g/time Oil refiller 8
bearing grease 2#

Steel wire Grease for steel Proper Coating the

Half a month 1
rope and reel wire rope amount surface
8 Elevator
Lithium-based Coating the
Guider Half a month
grease 2# surface

Reducer Mineral According to

13 years Change 4
(SEW) ISO VG 220 the oil level

Remark:
1. When lubricant with different model is replaced in the reducer, fully replace it. It is forbidden to mix.
2. For bearing: lithium-based grease 2#;
For reducer: Gear oil VG150 (winter) or gear oil VG220 (summer)
For motor: Winter: lithium-based grease 2# Summer: lithium-based grease 3#;
3. Calcium-base and lithium-based grease are used in watery and moist conditions.
Sodium-base and calcium-base grease are used in high temperature and dry conditions.
4. Proper temperature of lithium-based grease: 100°C(120°C)~ -20°C

5.7.2 Lubrication for main parts

5.7.2.1 Lubrication of the mixer

1. Working principle

Lubricating system of the mixer is

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composed of electric lubrication pump and

oil pipe. The grease is supplied to the four
shaft ends of mixer under the pressure of
electric pump. The pressure grease forms
a high pressure protection layer at the
shaft end to prevent slurry from entering
into the shaft end for protection.

SANY adopts four points electric pump

(see Fig. 5-151 on page 5-116) to supply
oil to the four shaft ends directly. Even
though one shaft end point is blocked,
lubrication of other shaft end points will not
be affected. Lubrication system supplies
oil to the shaft end seals discontinuously
and keep the shaft end in a good sealing
condition.

Add lubricant to the shaft end point where

needs lubrication manually. This will
satisfy the lubrication, heat dissipation and
sealing of the bearing seat and bearing. At
the same time, prevent slurry from entering
into the shaft end for protection.

2. Position of each lubrication point

Inject lubrication to each lubrication point

according to the regulation. Positions of
lubrication points are as followings: four
positions on the supporting bearing; two
positions on the discharge gate bearing;
four positions on the shaft end bearing
(inboard), four positions on the shaft end
bearing (outboard); another four positions
standby (see Fig. 5-151 on page 5-116).

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Maintenance HZS60 Concrete Batching Plant

1
2
3

1 2
3
4
1

2
3
4

1
2
3
5

Fig. 5-151 Lubrication points of the mixer

1- Shaft end seal interior point 2- Shaft end seal exterior point 3- Mixing shaft bearing point
4- Discharge gate bearing point 5- Lubrication pump injection point

3. Replenishment of the lubricant

Add lubricant to the oil box to "MAX" level

via oil inlet filter. Clean the oil inlet filter
once a week.

Every time after clean the mixer, add

lubricant manually to oil cups inside the
four shaft end seals in the two side of
mixer, until there is oil overflow in the four
shaft ends, or the service life of shaft end
seals will be decreased and lead to early
leakage of slurry.

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HZS60 Concrete Batching Plant Maintenance

Lubricant should be absolutely clean

without any impurity and keeping viscosity
in any time. If there is any impurity,
lubrication system and bearings will be
damaged.

Grease used in the lubrication oil

pump (see Fig. 5-152) should be clean.
Injected grease to the oil pump via filter
from the oil nozzle in the bottom of the
pump. It is forbidden to open the upper
cover of oil pump to add grease, or the
filter core will be damaged.
Fig. 5-152 Lubrication pump

4. Replacement of lubrication system

Detailed steps:

a) Dismantle the connectors and oil pipes.

b) Dismantle the installation bolts (see

Fig. 5-153) and oil lubrication oil pump.

c) Install new lubrication oil pump and

fixed bolts.

d) Add proper amount of lubricant.

Requirements: Fig. 5-153 Dismantle installation bolts

(1) Lubricant used in the lubrication pump

should be clean (see Table 5-14). 1# Table 5-14 Lubricant
extreme pressure lithium-based grease is
used during winter 2# extreme pressure Manufacture Designation
lithium-based grease during summer.
BP LTX2-EP
(2) Inject lubricant to the lubrication oil TEXACO MULTIFAK MP2
pump via filter. Clean the filter once a ESSO BEACON 2
week. SHELL SUPER GREASE R2

(3) Install accessories as oil gauge, oil TOTAL MULTIFAK MP2

pipes and connectors according to the ROL LITEX EP2
instruction of lubrication pump.

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Maintenance HZS60 Concrete Batching Plant

It is forbidden to open the upper cover

of oil pump to add oil (see Fig. 5-154).

Fig. 5-154 Open the upper cover to add

oil is forbidden
5. Lubricating gear box of mixer

Add Mobil 220# or 320# according to the

oil level.

Lubrication condition of the reducing gear

is stricter than that of other gears. Wrong
adoption of lubricant not only reduces the
efficiency of gears, but also reduces the
service life of gears. Table 5-15 is the
recommended lubricant of SANY.

Table 5-15 Designated lubricants by SANY

Designation (Grade E.P of ISO)

Manufacturer -10°C/+30°C(ambient +20°C/+45°C(ambient
temperature) temperature)
ISOVG150 ISOVG220
AGIP BLASIA150 BLASIA220
ARAL DEGOLBG150 DEGOLBG220
BP GR XP 150 GR XP 220
CASTROL ALPHA SP 150 ALPHA SP 220
ELF REDUCTELF SP 150 REDUCTELF SP 220
ESSO SPARTAN EP 150 SPARTAN EP 220
FINA GIRAN 150 GIRAN 220
MOBIL MOBILGEAR 629 MOBILGEAR 630
SHELL OMALA EP 150 OMALA EP 220
TOTAL CARTER EP 150 CARTER EP 220
INDUSTRIAL GEAR INDUSTRIAL GEAR
GREAT WALL
OIL L-CKD150 OIL L-CKD220

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HZS60 Concrete Batching Plant Maintenance

Replacing interval of lubricant:

The lubricant must be replaced after

100h initial operation. After that, it may
be replaced for every 1000h operation
according to the condition of service and
quality of lubricant. Pay attention to the oil
level, and often check it. Supply the oil in
time if necessary.

During the replacement of lubricant,

dirty oil and copper scale left in the gear
box must be washed clean. Meanwhile,
do not drop any foreign body inside. If
there is any foreign body, it will damage
the reducer.

6. Daily inspection

Check whether the grease reaches the

shaft ends every day:

a) Check grease consumption, which

should be 220ml every hour. If the
consumption is lower than this value,
check whether the grease reaches four
shaft ends as shown in Fig. 5-151 on page
5-116. Open the overhaul door, plug sharp
object to the oil cups outside the four shaft
ends to check whether there is oil.

b) Supply lubricant to the bearings of

discharge gate (see Fig. 5-68 on page
5-45) once every 250 working hours, and
ensure add lubricant at least once every
month.

c) If the lubrication system fails or is

overhauled, and the mixer continues
working, fill lubricant manually (≥twice/
hour).

If there is any problem, please contact with

SANY after-sale service center.

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Maintenance HZS60 Concrete Batching Plant

7. Maintenance

It is good time to maintain when re-inject

lubricant:

a) Check whether the oil pipe is damage

during maintenance, replace the pipe
damaged.

b) Every parts running in the lubrication

system should be absolutely clean.
Impurity in the system will lead to various
problems.

5.7.2.2 Lubrication of the screw

conveyor

1. Bearing at outlet (driving gear is at 6

5
inlet):

The bearing shown in Fig. 5-155 is filled

with grease free of changing, so filling of
grease is unnecessary any more.
4
2. Bearing at inlet (driving gear is at
3
outlet): 2
1
Fill grease once every 200 working hours
(according to delivered materials), and
change lubricant every 7500 working hours
or about.

3. Intermediate bearing Fig. 5-155 Screw conveyor

1- Motor MT 2- Gear reducer M1
When delivered materials need lubricant, 3- Gear reducer shaft seal XUK
2# lithium-based grease can be added 4-Inlet end bearing XTB
once a week. 5- Intermediate bearing XLR
6- Outlet end bearing XTA
4. Gear reducer

Mobil GEAR629# or Shell 150# is

recommended initial changing happens
after 100 working hours. Thereafter,
change once every 1000 working hours.

Table 5-16 is the lubricant recommended.

This table doesn't include all the applicable
lubricant. The data in the table mainly is

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HZS60 Concrete Batching Plant Maintenance

for temperature among 0~35°C; if higher

Table 5-16 Lubricant
than 35°C, lubricant with higher viscosity
should be used; if lower than 0°C, lubricant Lubricant Trademark
with lower viscosity should be used. Table
GR-MU2 AGIP
5-17 on page 5-121 lists recommended
ARALUO HL2 ARAL
amount for one filling.
BP-ENGERGREASE
BP
L2
CALYPSOLH433 CALPYPSOL
5.7.3 Grease for centralized lubrication
ANDOK B ESSO

Such lubricant greases, which are resistant MOBILUX2 MOBIL OIL

to pressure, heat and water, boast good MOBIPLEX47
mechanical stability, and are used at both ALVANIA 2 SHELL
high and low temperature, must be used GLISSANDO FL 20 TEXACO
in the centralized lubrication. The lubricant MULTIFAX2
greases designated by SANY are listed in
Table 5-18.
Table 5-17 Amount for one filling

Type Motor size a=0 o a=45 o

5.7.3.1 Replenishment of bearing lubricant
M12 100~112 0.75 1
greases
M12 132 1 1.50
Greases at the four positions of the support M12 160 1.40 /
bearing and four positions of the shaft end M11 132 1 1.50
(outside) must be replenished once every
M11 160 1.50 2.75
week, about 4~5g each time. The lubricant
M15 160~180 4 6.50
must be injected when the mixer is running.
The lubricant grease must be filled at least
once a month. Table 5-18 The lubricant greases
designated by SANY
The bearing of the discharge gate must
get the grease replenished once every 250 Manufacturer Designation
working hours, and the lubricant grease
BP LTX2-EP
must be filled at least once a month.
TEXACO MULTIFAK MP2
5.7.3.2 Replenishment of lubricant grease AGIP BLASIA 150
at the shaft end seal ESSO BEACON 2
MOBIL MOBIL PLEX 47
The replenishment must be made according
SHELL SUPER GREASE R2
to the highest and lowest positions of the
electric pump. The designated lubricant TOTAL MULTIFAK MP2
grease is 1# or 2# extreme pressure lithium ROL LITEX EP2
based grease of the above manufacturers.

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Maintenance HZS60 Concrete Batching Plant

5.8 Wa r r a n t y C l a u s e s o f t h e
Concrete Batching Plant
5.8.1 General

1. Premise for warranty

a) Within the warranty, perform the

daily maintenance for check, adjustment,
lubrication and maintenance equipment
tightening in accordance with the manual.
Operate the plant correctly and use
specified lubricant, grease and hydraulic
oil.If the batching plant is not used and
maintained according to the instructions of
the company and those of other equipment
suppliers, the warranty clauses will cease
to be effective immediately; meanwhile,
SANY will not bear any losses caused
thus.

b) Use genuine SANY parts.

c) Within the warranty, the plant must be

as when it is delivered. Any conversion,
disassembly,
● and replacements of genuine
parts are forbidden.
●
2. The clauses in which the warranty
scope
● is calculated according to time
(year or month) are only applicable
to● the single shift jobs (8 hours) on a
business day; if a job has more than
one shifts or exceeds 8 hours, it should
be● converted into a single-shift job.

3. Contents of warranty:

a) In case of any problem concerning

product quality, the replacing or repairing
is free of charge.

b) In the event that any fault or damage

results from the following causes, the
repair should be paid even in the warranty
period:

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HZS60 Concrete Batching Plant Maintenance

● Improper operation or improper

maintenance;
● Disassembly, repair, hardware or
software transformation without
authorization and approval;
● Non-manufacturing defect;
● Fault resulting from any force majeure,
such as earthquake, flood, typhoon,
etc.
● Unavoidable normal wear or loss.

4. Similarly, the company should

not be liable for any direct or indirect
personal injuries or property losses
owing to a manned misoperation, nor
be liable for free maintenance.The
company reserves the right to upgrade
and improve the plant, but it will not
assume the obligation to upgrade and
improve the plant beyond the contract.

5. If there are various acceptance of

warranty time in the assumpsit upwards,
follow the acceptance which appears
earlier.

5.8.2 Detailed regulations

Table 5-19 provides detailed regulations on

the warranty clauses of the cement concrete
batching plant. Read through it carefully. The
warranty is within 12 months or 1500 operating
hours (take the one which appears earlier).

Table 5-19 Warranty clauses of the cement concrete batching plant

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Maintenance HZS60 Concrete Batching Plant

Scope of Part of
Category Classification Description Remark
warranty installation
Filter core: Filter
cores of air
compressor filter
core, filter relief Not within
valve, triplet, dust the warranty
collector, bag scope
dust collecto and
filter screen for oil
filling of mixerr

Class 1 Consumable Oil: Hydraulic

Not within
oil, lubricating
the warranty
oil,grease ,
scope
and fuel

Miscellaneous:
Bulbs, fuses, Not within
printing paper, the warranty
starter, sweeper, scope
scraping plate

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HZS60 Concrete Batching Plant Maintenance

Scope of Part of
Category Classification Description Remark
warranty installation
Same with
Liner plates of the
the plant
discharge hopper
warranty
Main engine
Same with
Blade and end liner
the plant
plate
warranty

Same with
Dust cap and wear
the plant
ring
warranty

Same with Aggregate

Liner plates of the
the plant w a i t i n g
waiting hopper
warranty hopper

Six months
or 750h after
Class 2 Wearing parts
the date of
Liner plates of the acceptance Discharge
discharge hopper (take the hopper
one which
appears
earlier)

15,000
Exist inverter steel Use the hoist to
circulations Hoist
wires for hoist charge materials
or 6 months

6500
Nothing inverter Provide two steel
circulations Hoist
steel wires for hoist wires, spare one
or 3 months

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Maintenance HZS60 Concrete Batching Plant

Scope of Part of
Category Classification Description Remark
warranty installation
Weighing hoppers,
discharge hoppers
(not including If the batching plant
the liner plate), is built in a corrosive
Same with environment
weighing hopper
the plant (such as a place
of the aggregate
Steel structure storage, waiting warranty near the sea), the
Class 3
equipment hopper, handrail, warranty period
staircase, air/water will be shorten
(zinc) steel pipes halt (excluding the
warranty period
Same with under a contract).
Powder silo, Main
the plant
framework
warranty
Same with
Water supply
Valves the plant
system
warranty
Same with
H a r d w a r e Belt
Class 4 Sprockets/chains the plant
accessories conveyor
warranty
Same with
Connectors the plant
warranty

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HZS60 Concrete Batching Plant Maintenance

Scope of Part of
Category Classification Description Remark
warranty installation
Belts scraper Same with
The scraping plate is
(excluding the the plant
specified separately.
scraping plate) warranty
1) If the batching
plant is built
in a corrosive
environment
(such as a place
near the sea), the
Various cylinders
Same with warranty period
(excluding the Belt
the plant will be shorten
attached solenoid conveyor
warranty halt (excluding the
valves)
warranty period
under a contract).
2) The attached
solenoid valves are
specified separately.

Various pneumatic Same with

ball vibrators and the plant
Small
Class 5 electric vibrators warranty
equipment
Same with
Various weighing
the plant
sensors
warranty

Various pneumatic
butterfly valves Same with The attached
(excluding the the plant solenoid valves are
attached solenoid warranty specified separately.
valves)

Driving drum Same with

Belt The bearing is
(excluding the the plant
conveyor specified separately.
bearing) warranty

If any motor is
burned with water
Various motors Same with coming into the
(excluding the plant motor owing to
vibration motors) warranty misoperation, it
is not within the
scope of warranty.

Safety, Operation & Maintenance Manual - October, 2014 5-127

Maintenance HZS60 Concrete Batching Plant

Scope of Part of
Category Classification Description Remark
warranty installation

Same with
Lubricant pump
the plant
of the mixer
warranty

Hydraulic station Same with

of discharging the plant
gate of the mixer warranty

Same with
Reducer of
the plant
the mixer
warranty

Small
Class 5
equipment
Reducer of belt
Same with
conveyor (excluding
the plant
sealing parts
warranty
and bearing)

Same with
Auger conveyor the plant
warranty

Various dust
Same with
collectors
the plant
(excluding
warranty
filter core)

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HZS60 Concrete Batching Plant Maintenance

Scope of Part of
Category Classification Description Remark
warranty installation
1) The filter core is
specified separately.
2) If an accident of
roof fall happens
because the silo top
filter and pressure
safety valve are not
maintained properly
in accordance with
the requirements of
Same with the instructions (see
Small
Class 5 Inline pump the plant Note 1 for the specific
equipment
warranty meaning), it is not
within the scope of
warranty; in addition,
the company will
not assume any
liability to any direct
or indirect personal
injuries or property
losses caused
thereby, nor be

Safety, Operation & Maintenance Manual - October, 2014 5-129

Maintenance HZS60 Concrete Batching Plant

Scope of Part of
Category Classification Description Remark
warranty installation
Control room body
(steel structure, Same with
Control
skidproof tile, the plant
room
packing, and warranty
aluminum ceiling)
Accessories
Same with
of the control Control
the plant
room (ventilator, room
warrant
roller blind) Damages owing
Same with to force majeure,
External Fixed aluminum External such as earthquake,
Class 6 the plant
packing alloy window packing flood, typhoon, etc.,
warranty
are not within the
Same with scope of warranty.
Sliding aluminum External
the plant
alloy window packing
warranty
Same with
Vertical hinged External
the plant
aluminum alloy door packing
warranty
Same with
Rain hood the plant Conveyor
warranty
Same with Strictly observe
Air pipeline
Air reservoir the plant relative pressure
system
warranty capacity regulations
The lining plate,
Same with
Control blade and mixer
Mixer the plant
room of the mixer are
warranty
specified separately
Same with
Hardware Shaft seal of
Class 7 the plant
fittings the mixer
warranty
Same with
Control The air filter is
Air compressor the plant
room specified separately
warranty

Same with
Air pipeline
Air conditioning the plant
system
warranty

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HZS60 Concrete Batching Plant Maintenance

Scope of Part of
Category Classification Description Remark
warranty installation
Same with
Air pipeline
Pneumatic triplet the plant
system
warranty
Same with
Various solenoid Batching
the plant
valves plant
warranty
If a roof fall
accident of the
powder silo happens
because the
powder silo roof
dust collector and
pressure safety
valve are not
maintained properly
in accordance with
Pressure safety the requirements
Same with
valve for the of the instructions.
the plant
accessories on the It is not within the
warranty
top of powder silo scope of warranty;
in addition, the
company will
Class 8 Accessories not assume any
liability to any
direct or indirect
personal injuries
or property losses
caused thereby,
nor be responsible
for free repair.

Accessories of the
powder silo (bin
Same with
level indicator,
the plant Powder silo
manual butterfly
warranty
valve, arch breaking
flow-aid air cushion)

Same with
Various bearings the plant
warranty
Same with
Belt
Idler the plant
conveyor
warranty

Safety, Operation & Maintenance Manual - October, 2014 5-131

Maintenance HZS60 Concrete Batching Plant

Scope of Part of
Category Classification Description Remark
warranty installation

If the batching plant

Steel structure
is built in a corrosive
paint (tower
environment (such as a
paint, powder Same with
place near the sea), the
silo paint, belt the plant
warranty period will be
conveyor support warranty
shorten halt (excluding
paint, aggregate
the warranty period
storage paint)
under a contract).

3 months
Fabric inserted Discharge
after the date
rubber hose hopper
of delivery

3 months
Transparent PVC Waiting
after the date
soft curtain hopper
of delivery

6 months
Class 9 Nonmetal piece Various seal rings after the date
of delivery

6 months
Various corrugated
after the date
tubes
of delivery

6 months
Belt
V-type driving belt after the date
conveyor
of delivery

6 months
High-pressure Air pipeline
after the date
air pipe system
of delivery

6 months
Shielded fabric Air pipeline
after the date
air rubber hose system
of delivery

6 months
Various red
after the date
rubber hoses
of delivery

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HZS60 Concrete Batching Plant Maintenance

Scope of Part of
Category Classification Description Remark
warranty installation
1. Within 3
months after
the date of
acceptance,
if belts are
quantity
boil off
because of Due to the user's
the quality or mistakes such as
the interface material size is out
broken, of regulation of
chage new the batching plant
(80mm), or there’s
ones
something unusual
2. 8 months
(metal,spine,etc.
after the
) brought into the
date of
Delivery belts Belt delivery system,
acceptance.
(Belts) conveyor we are not
3.8 months
respond for it.
Class 9 Nonmetal piece after the
Deal with the defects
installation of
according to the
the plant in
Chinese Chemical
case that the
Industry Standard
acceptance
(HG/T 3046—2011
fails due to
fabric convey belt
the customer.
apperance and
4.8 months
quality regulations)
after the
arrival of the
parts at the
jobsite in
case that the
installation
fails due to
the customer.
Various sealing 6 months
members (including after the date
inline pump) of acceptance

Safety, Operation & Maintenance Manual - October, 2014 5-133

Maintenance HZS60 Concrete Batching Plant

Scope of Part of
Category Classification Description Remark
warranty installation
Decollator power
6 months
supply, camera
after the date Console
power supply,
of delivery
Electric and UPS
Class 10
equipment
6 months
Mouse, keyboard after the date
of acceptance

Note 1. Meaning of date of delivery

a) After the equipment passes the

commissioning acceptance, the batching
plant will be delivered to Party A to use,
and the day when Party A signs on the
acceptance sheet is taken as the date of
delivery.

b) If Party A does not sign on the

acceptance sheet, but it has started
producing and selling concrete, the initial
day when it produces and sells concrete
will be deemed as the date of delivery.

Note 2. Meaning of roof fall: When the

powder silo is feeding, the pressure inside
the tank will increase if the silo-top filter
core is not cleared normally or blocked;
Meanwhile, if the pressure safety valve
is not maintained well and consequently
the preset pressure value of the pressure
safety vaslve cannot realize automatic
opening to relief pressure, the pressure
safety valve cannot perform its safety role;
Hence, the powder silo holds excessive
pressure inside, and the weak parts of the
tank and its accessories may be deformed
or damaged. As a result, this will cause
property losses and endanger personnel
around the powder silo.

Note 3. The company reserves the right

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HZS60 Concrete Batching Plant Maintenance

to upgrade and improve the plant, without

further notice.

Note 4.Life-long paid services are always

available to the batching plant of the
company whenever and wherever it is
used.

Note 5. As for services within the warranty

period, Party A (customer) shall notify
the service personnel of the local after-
sales service of Party B (SANY) by way
of telephone or fax, and describe the fault
part and situation so as to handle such
faults in time.

Note 6. The interpretation of the warranty

clauses belongs to SANY Heavy Industry
Co. Ltd.

Safety, Operation & Maintenance Manual - October, 2014 5-135

Maintenance HZS60 Concrete Batching Plant

5-136 Safety, Operation & Maintenance -Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

Troubleshooting
6 Troubleshooting
6.1 Troubleshooting of the Mixer..................................................................................6-3
6.2 Troubleshooting of the Mixer Motor.......................................................................6-6
6.3 Troubleshooting of the Screw Conveyor................................................................6-8
6.4 Troubleshooting of the Air Compressor..................................................................6-9
6.5 Troubleshooting of the Belt Conveyor..................................................................6-11
6.6 Troubleshooting of the Elevator...........................................................................6-12
6.7 Troubleshooting of the Motor...............................................................................6-13
6.8 Troubleshooting of the Weighing Instrument.......................................................6-14
6.9 Troubleshooting of the Industrial Process Computer...........................................6-17
6.10 Troubleshooting of the Additive Pump................................................................6-20
6.11 Troubleshooting of the Pneumatic System.........................................................6-22
6.12 Troubleshooting of the Lubrication System.........................................................6-25
6.13 Troubleshooting of the Electrical Control System...............................................6-26
6.14 Other Common Faults and Troubleshooting Methods........................................6-27

Safety, Operation & Maintenance Manual - October, 2014 6-1

Troubleshooting HZS60 Concrete Batching Plant

WARNING
Always read the Safety section of this
manual before attempting to operate
this equipment. Failure to do this could
result in machine damage, personal
injury or death.

6-2 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

6 Troubleshooting
6.1 Troubleshooting of the Mixer
Table 6-1 Troubleshooting of the mixer

Fault Cause Measure

Air compressor is not started Start the air compressor
Air line pressure is Start main motor after the pressure of air
below 0.4Mpa supply system increasing above 0.4Mpa
Breaker QF1 and QF2
Switch on the breaker QF1 and QF2
Mixer can't start is not connected
E-STOP button is not reset Reset the E-STOP button
Overhaul door of the mixer
Close the overhaul door or
isn't closed well or E-STOP
reset the E-STOP button
button is not reset
Open the door of power cabinet to check
Power supply whether the breaker is tripped. If the main
is normal, but motor breaker is tripped, open the discharge
Breaker tripped
mixer stop gate and overhaul door immediately. Flush
during running the mixer to accelerate concrete discharging.
Then find the reason for tripping.
The liner plate contacts
Adjust the location of the mixing arm
with the mixing arm
The reducer produces Replace the bearing and gear
Vibration and abnormal noise and vibration as well as lubricant
abnormal noise V belt loosened Adjust the tensile force of the belt
The motor produces abnormal Replace the bearing and gear
noise and vibration and inject lubricant
Bearing damaged Replace the bearing
Mixer rotate Change position of 2 power
Wrong connection of the line
reversing lines in the 3 liens
Whether the main motor has any
The main motor does not work
fault and major loop any trouble
The driving belt is too loose Adjust the tensile force of the belt
The mixer jammed Check whether the safety
Fault of safety switch
and tripped switch works normally
The clearance between the Adjustment the clearance or replace
inner blade and the liner wear resistant parts, such as blade,
plate of the mixing cylinder scraper, and liner plate, etc.

Safety, Operation & Maintenance Manual - October, 2014 6-3

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure

The reducer, spline sleeve,
Examine and replace
and shaft are damaged
Bearings at both ends of the
The mixer jammed Replace bearing
main shaft are damaged
and tripped
The mixing tank is overfed Reduce materials to feed
Aggregate excessive
Reduce the aggregate in the mixer
requirement (overload)
The mixing arm abraded Replace the mixing arm
The mixing duration is too short Set the mixing time between 30~40s
The mixing quality Aggregate is not fed at
Adjust the standard feeding time
is not desirable an appropriate time
Concrete inside the
Knock off concrete
mixing cylinder cured
The discharge gate is
The discharge Remove silt
embedded with silt
gate switch
Concrete cured Remove the cured concrete
cannot reach
The bearing is damaged, Replace the bearing and
the designated
without sufficient lubrication inject lubricant grease
position
The solenoid valve failed Disassemble and repair the valve
The seal plate of the
Adjust and replace the seal plate
discharge gate abraded
The plate of the discharge
Replace the plate of the discharge gate
Serious water leak gate abraded
The discharge gate
switch cannot reach the Adjust the discharge gate switch
designated position
Wash with water after shutting
Forgot to wash
down the machine for over 1h
Feed materials in the sequence of
Concrete adhered Feeding sequence of materials
sand, sandstone, water, and cement
The mixing arm is not
Adjust the mixing arm
adjusted properly
Repair deformation partially, increase
The upper cover deformed
sealing strips and sealant
The upper cover
The access door
leaks water Replacing the sealing strip
cannot fully closed
and dust
The observation window
Replacing the sealing strip
cannot fully closed

6-4 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

Fault Cause Measure

For SICOMA mixer,

Adjust the current value, and set the
heating protective relay
heating relay to automatic reset
current is too small
Lubrication
For SANY mixer, there
pump of mixer Modify PLC program to add
is no lubrication pump
doesn’t work operation of lubrication pump
control in the program

For SANY mixer, PLC Modify program to replace

output point is broken the PLC output point
Half- open door signal Modify program to filter the
When mixer door is not steady half-open door signal
opens, it stops
Adjust the position of proximity
twice in the half- Half- open door signal
switch nearer to make the
open position is not steady
signal steady and reliable

Improper feeding position

Clean agglomeration frequently and
Axle hung is leads to cement agglomeration
change the feeding position
easy to occur on the main shaft
in the mixer Modify program to change the
Order of feeding
order of material feeding
Half-open door time is too short Prolong the half-open door time
Mixer discharging
Move the proximity switch to adjust
speed is too high Half-open door time is too long
the half-open door position
Powder emission
is seriously in Action time of negative Modify the program to
the negative pressure valve is not proper adjust the action time
pressure valve

Air pressure
Check the power Change a solenoid valve
solenoid valve
voltage type level matched the power
is burnt

Door is easy to be blocked

During production,
when discharging of Prolong the full-open time
pressure door of mixer is not completed
mixer can’t close
Operate the mixer open
to the position Aggregate blocks the door
door button manually
Oil level, oil pressure, Check oil level, oil temperature,
Alarm of mixer
oil temperature and oil pressure, and whether
works
oiliness are abnormal there is water in the oil

Safety, Operation & Maintenance Manual - October, 2014 6-5

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure

During automatic
running, mixer pressure oil pump breaker trips Switch on QF19
door closing
indicator light isn’t
on, and press door
closing button Malfunction of pressure oil line Check the oil level and line
without response

6.2 Troubleshooting of the Mixer Motor

Table 6-2 Troubleshooting of the mixer motor

Fault Cause Measure

One phase of the power

Check the phase voltage
source broken or fuse of
of the power source
one phase melt to broken

The power source

Check the power source voltage
voltage is too low
one phase of the stator Check the leading wire of the winding to
The motor
winding open circuit confirm where open circuit and weld it.
can’t start
Measure the resistance of each phase
short circuit of the stator and check whether the no load currents
winding’s inter turn and phase of each phase is balance, then confirm
where is short circuit and fix it
Connection fault of
Check the route line and correct it
the control device
The power source
Check the power source voltage
The speed is voltage is too low
lower than the Some places at the end ring and
Repair the rotor
rating value conductor – stick of rotor flaw
Over load Check the transmission device and fix it
Check the gap of the turning part and static
Mechanic rub
part to find out the reason and regulate it
Check the fuse and the control
Abnormal noise Missing phase running
device and regular it
Short of lubricate oil /grease Replenish the oil/grease or
or bearing is broken change the bearing

6-6 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

Fault Cause Measure

The rotor balance is

Regulate the balance
broken after repair
Bending after the external Regulate the external of the shaft or
Too much
of the shaft was bumped change the rotor if it is necessary.
vibration
Check the condition of foundation
The foundation is not
and the adjust pad , the re-twist the
balance or stable
screw bolts and firm the foundation

Over high or over low of the

Check the power source
of power source voltage
Measure the resistance of each phase
Short circuit of the stator and check whether the no load currents
winding’s inter turn and phase of each phase is balance, then confirm
The motor is where is short circuit and fix it
overheated
Check the fuse and the control,
Missing phase running
and then correct it
Over load Check the transmission device and regulate
The cooling device Check the ventilation road
perform badly and clear the block up

Check the connecting deviation of the

Not perfect mounting
The bearing driving shaft to confirm whether some
of the motor
over heat kind of thrust at the axis direction exist
The bearing is broken Change the bearing.
Check the grounding screw bolts
The grounding connection bad and the grounding wire connected to
the enclosure whether be firmly

The winding got humidity and a

Clean the motor and dry it
too low insulation resistance
The electrified The winding touches the
enclosure stator steel for the reason Repair it
that insulation damaged

The wire connection

Clean the wire connection board
board got dirty
The insulation of leading Wrap the leading wire with
wire rubbed to broken insulation material

Safety, Operation & Maintenance Manual - October, 2014 6-7

Troubleshooting HZS60 Concrete Batching Plant

6.3 Troubleshooting of the Screw Conveyor

Table 6-3 Troubleshooting of the screw conveyor

Fault Cause Measure

The reduction
The shaft end seal broken Replace the shaft end seal
gearbox leaks oil
The reduction The shaft end seal
Replace the seal washer
gearbox leaks ash washer broken
Lock the mandrel screw of
The observation the observation window
Not locked well
window leaks ash Apply one layer of glass cement to
the seal rubber plate cement
The gimbal The connecting part Weld or apply a layer of glass cement
leaks ash of the gimbal at the connecting part or the gimbal
The motor
produces noise or The motor bearing damaged Replace the motor
abnormal sound

The reduction
Input bearing damaged Replace it with a bearing of the same type
gearbox produces
noise or abnormal Lubricant not clean Replace the lubricant and make up
sound or insufficient to the 2/3 part of the oil lens
The screw spindle (blade)
The screw tube Adjust the concentricity of the spindle
scraps the inner tube wall
produces noise or
The mid-suspending
abnormal sound Replace the mid-suspending shaft
shaft cracked
The conveying Powdery material arched Start the arch breaker
capacity of the
powder silo is Materials are not enough
Make up materials
not enough in the powder silo

6-8 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

6.4 Troubleshooting of the Air Compressor

Table 6-4 Troubleshooting of the air compressor

Fault Cause Measure

Heating protective relay

on the air compressor acts Reset the heating protective relay
Air compressor or the manual switch on or connect the control switch
can’t start the air storage is off

Air compressor breaker in Check whether the breaker

the power cabinet trips for air compressor trips
The button of the pressure
Push the button to the ON position
switch is at the OFF position
The overload protection Cool the starter and push
switch of the starter trips off down the reset button

Examine the blown fuse and replace or

The fuse is blown or the reset the current breaker as required;
current breaker trips off do not use any fuse or current breaker
higher than the specified standard

Check whether the connection is correct

Wrong connection
The motor does and refer to recommended line style
not work When the pressure of the air reservoir
The air pressure exceeds
drops below the starting pressure of
the starting pressure of
the air switch, the motor of the air
the pressure switch
compressor will start automatically

Electrical connections loosened Examine connections

Unless the motor is damaged obviously,

dismount the motor and send it to
The motor fails the service center of the local motor
manufacturer for examination,
and replace it if necessary

Operate the pressure switch manually

The safety
The pressure switch does and push the disconnect button to
valve of the air
not switch off the motor the OFF position; if the motor still
reservoir is on
works, replace the pressure switch

Safety, Operation & Maintenance Manual - October, 2014 6-9

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure

Clean or replace the dirty air

The air inlet filter is too dirty
inlet filter with a new one

When the compressor stops owing

to pressure inside the air reservoir,
The one-way valve is defective a defective check valve will cause
continuous air leakage, and if the
valve leaks, it must be replaced
The airflow
is restricted Pull up the bail of the safety valve and
The safety valve leaks air
and leaks replace it if the valve still leaks air

If the pressure switch works

The safety valve is on normally, the safety valve is
defective and it must replaced

Fasten the connection at the leaked

Pipe or hose connection
part and examine under pressure
loosened
with soap water (not too tight)

Pressure setting value is

Pressure relay or Adjust setting pressure to 0.4 Mpa
too large or to small
pressure gauge
Action touch doesn’t
on the connecting
point connects well Replace
point is abnormal
caused by oxidation
The airflow at the
Clean or replace the air inlet filter
inlet is restricted
Replace it with a new
Cylinder cover washer damaged
cylinder cover washer
Replace it with a new valve
The valve plate broken
plate and washer
The discharge
Piston ring broken or damaged Replace it with a new piston ring
pressure is too low
The V belt loosened Adjust the tightness of the belt if necessary
Examine as air leakage and
Air leakage
provide a solution

Reduce the consumption of compressed

The consumption of
air. The capacity of the air compressor is
compressed air is too large
not enough compared with the air demand

6-10 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

Fault Cause Measure

The piston ring abraded Replace the piston ring with a new one
The cylinder scuffed,
Replace the cylinder with a new one
abraded, or unsmooth

The oil content in Clean or replace the air filter

the air outputted Incoming airflow restricted element and inspect whether the air
is too high inlet end is throttled otherwise
Too much oil in the crankcase Discharge oil to an appropriate level
Choose the lubricant of the
Wrong lubricant designation
right designation
Examine the oil level and keep
Oil level too low
it at the designated level
Examine all screws and nuts and
Screw or nut loosened
tighten them as required
The belt pulley of the
Tighten the belt pulley screw
motor loosened
Abnormal noise Compressor belt Examine the belt pulley screw
pulley loosened and tighten as required
Examine the valve plate, and
Valve plate broken or loosened
clean or replace it as required

Connecting rod, piston pin

Examine all components and
or crankshaft bearing, main
replace them as required
bearing abraded or unbalanced

6.5 Troubleshooting of the Belt Conveyor

Table 6-5 Troubleshooting of the belt conveyor

Fault Cause Measure

Silt adhered to the idler Remove the silt from the idler
Counterweight too light Increase the counterweight or tighten
or belt too loose the belt by adjusting the screw rod
The belt
Material not dropped onto Take measures to make the material
running bias
the middle of the belt dropped onto the middle of the belt
Adjust the rear drum or upper/
Belt not extended evenly
lower idler of the belt conveyor

Safety, Operation & Maintenance Manual - October, 2014 6-11

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure

The idler does not

rotate or produces Idler bearing damaged Replace the bearing
abnormal noise
The idler worn out Used too long Replace the idler
Scraping plate
Used too long Replace the scraping plate
abraded
The belt is torn Mechanical fault Slight tearing may be repaired with glue
Cut the belt short and vulcanize
The belt is extended Bearing tension too long
and bond it with glue
The rubber flange
of the receiving Used too long Replace the rubber flange
hopper abraded

6.6 Troubleshooting of the Elevator

Table 6-6 Troubleshooting of the elevator

Fault Cause Measure

Proximity switch Proximity switch damaged Replace proximity switch

stop working Wrong installation position Adjust the installation position
Bearing on the elevator
bucket produces Bearing damaged Replace bearing
abnormal noise
Elevator bucket is out of shape Replace the elevator bucket
Shaft of the elevator
Running of the elevator Replace the shaft
bucket is out of shape
bucket is blocking
Bearing damaged Replace the bearing
Guide trail is out of shape Repair or replace
Wearing resistance
plate of the elevator Using for a long time Replace the wearing resistance plate
bucket is worn
Reach to the service life
Corrosion and abrasion Replace the steel wire rope
Steel wire rope
Steel wire runs out of the rope
malfunction
Steel wire rope loosing Adjust idler or safety device
Steel wire rope broken Replace the steel wire rope
Check the oil and discharg
Shaft end of the Too much oil
some if there is too much
reducer leaks oil
Oil sealing damaged Replace oil sealing

6-12 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

Fault Cause Measure

Unload running of
the reducer produces Oil is not enough Check the oil and add proper oil
loud noise
Reducer produces
Gear or bearing damaged Replace gear or bearing
abnormal noise
Safety device is Position limit switch damaged Replace position limit switch
ineffective Spring damaged Replace spring
End cover of the
Reel coaxial during treatment Replace the end cover of the reel
reel damaged

6.7 Troubleshooting of the Motor

Table 6-7 Troubleshooting of the motor

Fault Cause Measure

The head end and tail

The motor works at a end of the winding are not Connect again
slow rate after startup properly connected
Supply voltage too low Examine the supply voltage
The running motor
The winding is in short
produces noise and gets Repair the winding
circuit or earthed
overheated to smoke
The insulation resistance The winding gets dirty or Clean the motor and
of the winding drops is exposed to damp dry the winding
The motor overloaded Reduce load
The temperature rise of Examine the ventilation (both
the winding is too high Bad ventilation inside and outside) and operation
direction of the motor
The bearing abraded Replace bearing
The bearing
Clean the bearing and
produces noise The bearing gets dirty
replace grease
The motor and the transmission
Examine the axiality
gear get eccentric
The bearing gets
The bearing grease is too much
overheated Examine the grease
or little or get deteriorated
The bearing is damaged Replace the bearing

Safety, Operation & Maintenance Manual - October, 2014 6-13

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure

Insufficient rigidity Increase rigidity
Bad mechanical axiality Examine the axiality
Strong vibration The motor rotor or belt Calibrate the dynamic
pulley is not balanced balance of the rotor and static
and in low accuracy balance of the belt pulley

6.8 Troubleshooting of the Weighing Instrument

Table 6-8 Troubleshooting of the weighing instrument

Fault Cause Measure

Fine setting is improper Set fine setting correctly
Set correct fall according
Material weighing Fall setting is inaccurate
to the fine setting
is not accurate
Sensor is broken and can’t
Replace sensor
measure weight of material
Blank screen of home- Quality problems of instrument Replace instrument
made instrument Power of instrument is abnormal Check the line
Malfunction of computer main board. Replace the computer
The communication card can’t work main board
Communication card has Reinstall communication
conflict with video card card or video card
Home-made instrument
Parameters of communication Check and set instrument
can’t communicate
is incorrect parameters correctly
with computer
Install the driving program
CAN communication drive loses
of communication card
Communication lines are
Connect lines again
wrong connected

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HZS60 Concrete Batching Plant Troubleshooting

Fault Cause Measure

Communication parameters Check and set the

of the instrument is wrong communication parameters
Set correct instrument number
TOLEDO station number is wrong
according to the material type
TOLEDO instrument
Communication card isn’t Install the driving program
can’t communicate
driven correctly to communication card
with the computer
Communication card has Reinstall communication
conflict with video card card or video card
RS232 communication line doesn’t Change communication line, to
corresponds with the instrument correspond with the instrument
RS232 communication line
sending, receiving and earthing Connect lines again
TOLEDO instrument line positions are wrong
can’t communicate 8-serial-port communication Replace 8-serial-port
with the computer line is damaged communication line
BUG of main board, communication
Replace computer main board
card can’t work normally
Weighing hopper affected by
Value displaying of Eliminate outside force
outside force can’t be steady
weighing instrument
Water entering the sensor
is instable Drying the sensor or replace it
sealing affects accuracy

Value displaying of
Internal mistake in the instrument Replace instrument
home-made instrument
lacks strokes or
Digital tube of display damaged Replace instrument
shows in disorder

Safety, Operation & Maintenance Manual - October, 2014 6-15

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure

Communication parameters Check and set the

of the instrument is wrong communication parameters
Jumper wire of line
Correct the jumper wire
cable box is wrong
Wrong connection of communication Check and correct line
line of cable box and power line connection of cable box
Terminal resistance isn’t
E1 displays on the
installed correctly or value Install 120Ω terminal resistance
home-made instrument
of resistance is wrong
Instrument communication or Check and correct
power line connection is wrong line connection
CAN communication bus has
Avoid several embranchments
several embranchments
CAN-L line is connected reversing
Correct line
with the power earthing line
Discharge can’t
be carried out Weighing hopper is dynamic
Increase the minimal
after weighing all the time, and can’t send
division value
hopper completing a discharging signal
measurement
Instrument isn’t calibrated correctly Calibrate instrument
E3 is displayed on the
Check the maximal
home-made instrument Material loaded is too heavy
weighing value
Pneumatic butterfly valve has Adjust the angle for
Value decrease when
powder emission and can’t be closed butterfly valve closing
powder weigher
Affected by atmosphere Take measures to eliminate
doesn’t discharge
pressure change effect of atmosphere pressure
Decrease loading weight
Instrument displays
Load exceeds full weighing range Check the weighing signal
┏┈┈┓
transmission cable
Instrument stops Modify fall value to
Fall value is too large
after starting a proper value
Check whether the deduster
Deduster pipeline of mixer is blocked
pipeline is unblocked
Powder weigher doesn’t
Sensor installation Check the installation of
measure accurately
problems or damaged sensor or replace it
Instrument is damaged Replace instrument

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HZS60 Concrete Batching Plant Troubleshooting

Fault Cause Measure

Calibrate zero again
Instrument displays Value exceeds negative
Check weighing signal
┗┈┈┛ displaying range
transmission cable

6.9 Troubleshooting of the Industrial Process Computer

Table 6-9 Troubleshooting of the industrial process computer

Fault Cause Measure

Malfunction of main
Replace main board
board of computer

Auxiliary video card looses,

and doesn’t contact well Add rubber pressure strip to fix
with motherboard

Communication card conflicts with

Auxiliary display Install video card in the PCI slot
interrupt of auxiliary video card
doesn’t work
Auxiliary video card isn’t Reinstall the video card
installed normally driving program
Display interface doesn’t extend Set in the dialog box
to the auxiliary display of display attribute
Auxiliary display is broken Replace auxiliary display
Power of display isn’t connected Check the power supply of display
Malfunction of main
Replace main board
board of computer

Video card Communication card conflicts

Install video card in the PCI slot
displays yellow with interrupt of video card
exclamatory mark Reinstall the video card
Video card isn’t installed normally
driving program
Video card is damaged Replace video card

Communication card Communication card driving

Install matched driving program
(including MOXA program doesn’t installed normally
card and CAN bus Communication card conflicts
Install video card in the PCI slot
communication card) with interrupt of video card
displays yellow
exclamatory mark Communication card is damaged Replace communication card

Safety, Operation & Maintenance Manual - October, 2014 6-17

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure

Data base is damaged Recover the system
Management system Data base is not running Start data base
can’t connect the Modify the computer
Computer name doesn’t accord
data base name according to the
with data server name
data server name
Keyboard lock button is pressed Reset the keyboard lock button
Abnormal operation leads
Recover the system
to system file losing
System is damaged and one-
Hard disk clone
key recover can’t be used
Replace the main
Malfunction of computer main board
Computer can’t start board of computer
Malfunction of computer Replace the computer
motherboard mother board
Replace the hard disk and
Physical damage of hard disk
add shaking protective pad
Memory bank is damaged, no self-
Replace memory bank
checking sound during starting
Can’t enter the Copy file “qtintf.dll” to
Lack dynamic link storage
management system “system32” in system disk
Can’t start the Copy file “ControlCAN.dll”
Lack dynamic link storage
monitor interface to monitor program file

Computer notifies
some kind of material Fall value is incorrect Adjust the fall value
overweight is alarming
Change communication
PLC upper communication port
port to connect with the
inserts to a wrong position
communication cable
Baud rate and check-digit setting
Dial the dial switch to reset
All the closing door of communication cable
signals in the computer Insert PPI communication
COM port insert in the IPC is wrong
displays open cable to the COM1 port
PC-PPI communication
Replace communication cable
cable is damaged
PLC upper state dial switch Set the dial switch to
is not in the RUN position the RUN position

6-18 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

Fault Cause Measure

When fall value automatic

correct function is open, Fine setting is too small. There Reset the fine setting
fall value is modified is no accurate weighing and fall value
automatically to dozens

During aggregate
storage discharging,
Interval of the aggregate Prolong the aggregate
aggregate superposes
discharging time is too short discharging time
with each other and
scatters out of the belt

Color of the display Pins of video cable is bent or the Calibrate the pin, insert
is abnormal inner of signal cable is broken and pull out with caution
Backup the data and then
Data in the database is huge
Computer is clear the history data
running slowly Install antivirus program
Computer has worm virus
to clear virus
Install antivirus program
Computer has virus
to clear virus
Computer restart
Malfunction of mainboard Replace the mainboard
abruptly
Malfunction of memory band Replace memory band
Malfunction of motherboard Replace the motherboard
CMOS setting is incorrect Recover CMOS default setting
System halt of Install antivirus program
Computer has virus
computer running to clear virus
Malfunction of memory band Replace memory band
System halt Restart the computer
Mouse can’t move Mouse and keyboard are Insert mouse and
in the computer connected wrong keyboard correctly
Press the button of keyboard lock Reset the keyboard lock

Date and time of

computer lose after Battery on the mainboard is low Replace battery
power supply cut off

CMOS setting
Battery on the mainboard is low Replace battery
can’t be saved

Safety, Operation & Maintenance Manual - October, 2014 6-19

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure

Adjust door closing

Weighing hopper door doesn’t closed
position switch
Material can’t be Fall setting is too large,
Set correct fall value
fed normally exceeding target value
Signal cable of instrument is
Check the connection of cable
loose, instrument can’t start

6.10 Troubleshooting of the Additive Pump

Table 6-10 Troubleshooting of the additive pump

Fault Cause Measure Remark

Ball valve or Supply raw material

connecting flange strap to the leaking
in the additive place (or replace
inlet leakage ball valve) to
leads to air entry eliminate air entry

Air Liquid level in

Supply liquid
discharging the tank is low
is needed
every day Firstly check whether
work the additive accords
Many air bladders with standard. If the
are produced by phenomenon can't
the additive be eliminated after
replacing, please
contact with SANY.

6-20 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

Fault Cause Measure Remark

Exchange the two 1. Additive pump of South Pump

pole of motor line Enterprise is running anticlockwise
during normal working (mark is
Wrong rotation (additive pump
on the motor). It can pump liquid
direction of of South Pump
by rotating clockwise, but the
the motor Enterprise is running
flowing amount is 1/3 to 1/2 of
anticlockwise during
anticlockwise amount. Other water
normal working)
pump is running clockwise in
normal working.
Liquid level is
2. Judgment methods
too low (additive Supply additive
Method 1: insert a small scrip
almost used up) into the fan blade of the motor
to check whether the motor is
rotating anticlockwise.
Speed of Clean the filter in
Method 2: stand beside the
the pumping the water outlet of
additive pump to observe whether
liquid is the additive box the motor is rotating to the side
to slow
close to you (if it is, the rotating
direction is clockwise, or it is
anticlockwise).
Water inlet Method 3: In normal working
is blocked by (motor rotating anticlockwise),
Turn down the ball
sundries time from the additive started to
valve of additive the additive weigher displaying
pump properly is about 10s. If the time exceeds
(about 1/5 to 1/4, 15~20s, the electrical wire is
which won't affect connected in error.
working cycle) 3. There is a filter in the water
outlet at the connection of the
additive box and pump. Please
don't damage it.

Burning of the
sealing ring caused Replace mechanical
by dry grinding sealing
leads to leakage Mechanical sealing additive
Additive Liquid left on the pump produced by South Pump
leaks contact face of Clean the mechanical Enterprise is integration type
mechanical sealing sealing (firstly please sealing. It perform precise.
dried up because contact with South
the machine stop Pump Enterprise)
for a long time

Safety, Operation & Maintenance Manual - October, 2014 6-21

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure Remark

Water inlet is
Check and clean
blocked by sundries
Water
can't flow Water inlet leaks Repair the water inlet
out while There is air in the Repair the water inlet
pump is still water inlet or pump line and discharge air
running
Cycle ball Close the cycle
valve is open ball valve

Note: Before remove the connecting box of motor and pump, ensure the power is cut off.

6.11 Troubleshooting of the Pneumatic System

Table 6-11 Troubleshooting of the pneumatic system

Fault Cause Measure

The switch valve in the

Open
pneumatic circuit is not opened
The solenoid directional valve
Find out the cause and remedy the problem
does not change direct
No pressure The pipeline gets distorted
Correct or replace the pipeline
in the air line and squeezed
The filter core is blocked or frozen Replace the filter core
The medium or ambient
temperature is too low, Remove the condensed water in time
resulting in frozen pipeline

Air consumption too large and Select an air compressor with an

the output flow rate of the air appropriate output flow rate or increase
compressor insufficient a air reservoir with certain capacity

The piston ring of the air Replace the piston ring of

compressor abraded the air compressor
Pressure in
Replace damaged sealing element
the air line is The pipeline leaks air
or hose, connector and screw
not enough
Low output pressure Adjust the relief valve to the
of the relief valve normal service pressure

The pipeline is thin and Increase the pipe diameter, and

long, or improper pipe select pipe connector and air valve
adaptors are selected with bigger flow capacity

6-22 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

Fault Cause Measure

Keep draining the condensed water

Forget to drain the
every day and confirm that the
condensed water
automatic drainer may work normally
Condensed
water drained The air inlet of the air Place the air compressor at a
out of the compressor is located at a damp place with low temperature and
air exhaust place or drenched by rain humidity and avoid rain
and muffler
The use of low viscosity oil will produce
The compressor is filled
much condensed water and appropriate
with improper oil
air compressor oil should be selected

Install a filter at the induction port of

Dust comes inside from the
the air compressor, a muffler at the air
entrance and air exhaust
exhaust, and mount protective cover
of the air compressor
to elements in a dusty environment
Dust emitted
The elements and tubes should be made
out of the The system gets rusted, metallic
of material resistant to corrosion and
air exhaust powder and sealant powder
rust, with a good lubrication condition
and muffler
Pay attention to prevent scrap iron,
Dust comes inside during dust and sealant fragment from entering
installation and repair during installation and repair, and use
compressed air to purge it clean

Air pressure not enough Increase pressure

Increase service pressure
Overloaded
or cylinder diameter
Find out which component is
Insufficient air supply
throttled too much or blocked
The cylinder friction
Improve lubrication conditions
The cylinder force is increasing
acts too low or Cylinder or piston seal Replace the component in
does not act ring damaged question
Readjust the installation
Cylinder piston rod get stuck
position of the cylinder
Solenoid valve coil damaged Replace the solenoid valve coil
The line from the magnetic
switch to PLC is disconnected Connect the line
or not connected well

Safety, Operation & Maintenance Manual - October, 2014 6-23

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure

Piston seal ring damaged Replace the seal ring
The travelling part is stuck by
foreign bodies and cannot reach Wash the main valve
the designated reversing position

The main valve Insufficient air pressure results

Increase pressure
air exhaust of in undesirable sealing
the solenoid Excessive high air pressure
Use the normal pressure
reversing valve cause sealing part distortion
leaks air
Not lubricated well and reversed
Improve lubrication
to the designated position
The sealing element damaged Replace the sealing element
Valve core and valve
Replace valve core and valve sleeve
sleeve abraded

The solenoid The seal washer damaged Replace the seal washer
reversing valve The die-casting part of the
Replace the valve body
leaks air valve body is not qualified

The air exhaust The iron core is stuck

Wash
of the pilot by foreign bodies
solenoid valve The moveable iron core
Pay attention to drain the condensed water
leaks air or spring gets rusted

6-24 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

6.12 Troubleshooting of the Lubrication System

Table 6-12 Troubleshooting of the Lubrication System

Fault Cause Measure

Supply voltage
Examine the line and remedy faults
The motor does transmission interrupted
not work Check the line from the power supply to the
Fault of the motor
motor, and replace the motor if necessary

Inject clean lubricant into the oil tank and

keep the pump run till lubricant reach
No lubricant in the oil tank all lubrication points. Note: In normal
temperature, maximum output of lubricant can
be reached after 10 min in the pump core

Loosen the pressure gauge to relief air

Air bubble in lubricant
No air bubble allowed in the lubricant
The pump cannot
Unqualified lubricant
convey lubricant Replace lubricant
used

Dismount the pump core to examine

Pump core suction
whether there are grain impurities in
port jammed
the suction port and remove them
Pump piston worn Replace the pump core
The one-way valve of the
Replace the pump core
pump core failed or blocked

The oil supply valve

assembly damaged Wash or replace the oil supply valve assembly
No pressure in the or blocked
oil pressure gauge
The oil pressure
(below 10bar) Replace the oil pressure gauge
gauge damaged
Oil leakage Examine the axle head oil supply pipe

Exorbitant
Blocked Check the oil line
pressure in the oil
pressure gauge
Oil using is not standard Use the oil according to standard
(Above 90bar)

Safety, Operation & Maintenance Manual - October, 2014 6-25

Troubleshooting HZS60 Concrete Batching Plant

6.13 Troubleshooting of the Electrical Control System

Table 6-13 Troubleshooting of the electrical control system

Fault Cause Measure

The measuring hopper gate is Check whether the measuring

not closed to the designated hopper gate is closed to the
position, or the limit switch designated position and the
The measuring hopper
is damaged or cannot reach magnetic induction switch
does not take in material
the designated position indicator lamp is on

The weighting instrument does Check whether the feed indicator

not work in a normal way lamp of the instrument is on

Examine the cause why

The loader does not reach
the loader does not reach
The aggregate is not the receiving position
the receiving position
discharged after weighing
The weighing instrument does Examine the working state and
not work in a normal way discharge signals of the instrument
The mixing volume exceeds Prevent feeding two cycles
The motor of the main the rated load significantly of materials into the mixer
engine gets jammed Foreign bodies exist between
Remove foreign bodies
the mixing blade and liner plate
The butterfly valve of the
Open the butterfly vale fully
powder silo is not fully opened
Powder is fed at a slow rate Break the arch and remove
Power gets arched or
agglomerated materials
agglomerated in the pipeline
out of the pipeline

The screw conveyor The blades of the screw Reverse the motor and
does not rotate conveyor is blocked take impurities out

The readings of the

The butterfly valve of the Adjust the butterfly valve of the
weighing instrument of the
weighing hopper is not closed, weighing hopper and close it
power weigher become
thus resulting in leakage to the designated position
smaller gradually

The blending ratio cannot Check whether the communication

be transmitted to the The communication line between the instrument
instrument or indicator of between the instrument and computer is in good contact
the instrument cannot be and computer failed and whether the setup of the
transmitted to the computer instrument is changed

6-26 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

6.14 Other Common Faults and Troubleshooting Methods

Table 6-14 Other common faults and troubleshooting methods

Fault Cause Measure

Operate the hopper valve or the fine

The waiting hopper or fine
weighing gate solenoid valve manually
weighing gate is not closed or
to switch off the hopper valve or readjust
closed to the designated position
the position of the magnetic valve
Pressure of the air
Improve the pressure of the air line
line not sufficient
All the aggregate
weighing hoppers The magnetic valve on the
of the aggregate aggregate waiting hopper Replace the magnetic switch
storage do valve cylinder is damaged
not discharge The line from the magnetic
material switch to PLC is disconnected Connect the line
or not connected well

The weighing cell terminal

of the aggregate measuring Replace the parts damaged
hopper is damaged
The level belt does not work Start the level belt
Aggregate,
fly ash and Discharge gate of the mixer isn’t Close the discharge gate or adjust the
cement can’t closed or not in the close position position of induction switch on the gate.
be discharged
Every time before and after powder
Powder Silo-top filter core is jammed
feeding, start the vibrator for 1~2min
emission on the
If there are signal sent from the upper
powder silo The powder silo is full
material level gauge, stop feeding powder
Motor starts with load many times Avoid starting with load
Contactor type is wrong Change the correct contactor
Contactor arc Connecting cable is not
discharge, impacted, and contact point Check whether the cable is impacted
contact point is easy to strike arc
is burnt Power voltage is too low ,
Change the power line and increase
which doesn’t accord with
capacity of transformer
the working conditions

Safety, Operation & Maintenance Manual - October, 2014 6-27

Troubleshooting HZS60 Concrete Batching Plant

Fault Cause Measure

Small bulb is not installed

Install small bulb
(during test before delivery)
Indicator is burnt Replace small bulb
Cable 100 doesn’t connected
Indicators on with power 100 (during Check all the connection of No. 100 cable
the console test before delivery)
are not on Check whether there is short circuit
Protective tube is burnt
and then replace protective tube
Switch power supply is damaged Replace the switch power supply
PLC program is not running, Set the PLC state dial switch to the
PLC module is broken running position. Replace PLC module
Check whether there is
Solenoid valve output signal in relevant Check relevant output point of PLC
doesn’t work PLC output point
normally Whether there is obstacle
Clear the obstacle in the solenoid valve
in the solenoid valve

Material level
Powder agglomeration blocks the
indicator in Clear the obstacle
rotating shaft of level indicator
the powder
silo displays
Material level indicator is broken Replace the material level indicator
abnormally

If abnormal interrupt occurs,

waiting hopper doesn’t reach
Open waiting hopper door to
Aggregate isn’t the time to open door. This
set it to the open door time
discharged leads to a illusive situation of
after weighing material in waiting hopper

Discharging order of
Set the discharging order of aggregate
aggregate isn’t defined

Some material
isn’t fed
automatically or
Door closing position signal
manually. But
of weighing hopper for this Check magnetic switch
operate feeding
material isn’t checked
buttons of
upper computer
can realize.

6-28 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Troubleshooting

Fault Cause Measure

Door closing position switch

of the waiting hopper doesn’t
Check whether the waiting
induce. (4 weighers doesn’t
hopper door is blocked
discharge at the same time,
check whether I6.7 is connected)

Check whether all the aggregate

Check discharging signal of
Aggregate isn’t weighing instruments have
aggregate instrument
discharged discharge signals output
after weighing Check whether belt
Check whether belt conveyor is running
conveyor is started
Waiting hopper door is Check whether waiting hopper
closed to the position door is closed to the position

Feeding gate for aggregate

Check the aggregate fine
fine weighing isn’t close
weighing door closing signal
fully to the position

Check whether the butterfly

Fully opened the butterfly valve
valve is fully opened.
Powder feeding Check whether there is Break the arc, check the arc-
is slow arc of the powder breaking solenoid valve output
Powder in the powder
Add powder
silo is not enough

After discharging
Waiting hopper door closing Adjust waiting hopper door closing position
of waiting hopper,
position switch doesn’t switch (I6.7) to ensure it be switched on
material indicator
induce the signal when door is closed to the position.
still flashes

Powder weigher Check whether the deduster

Mixer deduster pipeline is blocked
is not accurate pipeline of mixer is expedite
Switch from
automatic mode
Press the manual button for a long
to manual Production of one cycle or
time (about 4 seconds), indicator
mode, cycle one truck is not completed
light is off automatically
start indicator
light is still on

Safety, Operation & Maintenance Manual - October, 2014 6-29

Troubleshooting HZS60 Concrete Batching Plant

E
G
PA
K
N
LA
B

6-30 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Specifications

Specifications
7 Specifications
7.1 Specifications of Concrete Batching Plant.............................................................7-3
7.2 Specifications of Mixer...........................................................................................7-5

Safety, Operation & Maintenance Manual - October, 2014 7-1

Specifications HZS60 Concrete Batching Plant

WARNING
Always read the Safety section of this
manual before attempting to operate
this equipment. Failure to do this could
result in machine damage, personal
injury or death.

7-2 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Specifications

7 Specifications
7.1 Specifications of Concrete Batching Plant
(Sketch of the standard CBP, detail drawings please refer to 8.2 )

H
L

Fig. 7-1 Overall specifications of concrete batching plant

Safety, Operation & Maintenance Manual - October, 2014 7-3

Specifications HZS60 Concrete Batching Plant

Table 7-1 Dimensions of Batching Plant

Model L W H1

HZS60F 21310mm 15330mm 10256mm

Table 7-2 Technical Specifications of Engineering Batching Plant

Model
No. Designation
HZS60F

1 Theoretical productivity (m 3/h) 60

2 Installed capacity (kW) 100

3 Nominal capacity of mixer (L) 1000

4 Discharging height (m) ≥3.8

5 Weighing range and accuracy of aggregate (kg) (600~2000)±2%

6 Weighing range and accuracy of water (kg) (80~300)±1%

7 Weighing range and accuracy of additive (kg) (8~20)±1%

8 Weighing range and accuracy of cement (kg) (200~1000)±1%

7-4 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Specifications

7.2 Specifications of Mixer

Fig. 7-2 and Fig. 7-3 are diagrams of mixer
overall dimensions. Table 7-3 and Table
7-4 show the overall dimensions and main
technical specifications of the mixer. They
are supplied to customers as reference.

E
C

B A B

D
Fig. 7-2 Overall dimensions of mixer 1

Safety, Operation & Maintenance Manual - October, 2014 7-5

Specifications HZS60 Concrete Batching Plant

F G H
J
K

Fig. 7-3 Overall dimensions of mixer 2

Table 7-3 Dimensions of mixer

Dimensions mm
Model
A B C D E F G H J K N
JS1000B 470 441 900 2048 1460 36 1115 770 1195 2460 980

Table 7-4 Technical specifications of mixer (JS1000B)

Weight
Nominal Feeding Motor Number Voltage Mixing Discharging Max.
of whole
capacity capacity power of poles of motor time time aggregate
mixer
(L) (L) (kW) P (V) (s) (s) (mm)
(kg)

1000 1600 37 4 380 35 15 φ60 4670

7-6 Safety, Operation & Maintenance Manual - October, 2014

HZS60 Concrete Batching Plant Appendix

Appendix
8 Appendix
8.1 Schematic Electric Diagram of the Mixer...............................................................8-3
8.1.1 Schematic electric diagram of the mixer 1.....................................................8-3
8.1.2 Schematic electric diagram of the mixer 2.....................................................8-4
8.1.3 Schematic electric diagram of the mixer 3.....................................................8-5
8.1.4 Schematic electric diagram of the mixer 4.....................................................8-6
8.1.5 Description of electrical component symbols of the mixer.............................8-7
8.1.6 List of attached tools of the bantching plant...................................................8-8
.
8.2 Schematic Electric Diagram of the Batching Plant................................................ 8-9
.

Safety, Operation & Maintenance Manual - October, 2014 8-1

Appendix HZS60 Concrete Batching Plant

WARNING
Always read the Safety section of this
manual before attempting to operate
this equipment. Failure to do this could
result in machine damage, personal
injury or death.

8-2 Safety, Operation & Maintenance Manual - October, 2014

 FU4

L3

S5
S1
KM1
8 Appendix

S2
KA2

S3 S4 KA1
FR1
KA4
HZS60 Concrete Batching Plant

FR2

Fig. 8-1 Main motor control circuit

SA1

KA3 KA5
SQ1

KM1Y KT1 KT1

KM1Y KM2Y
8.1.1 Schematic electric diagram of the mixer 1

N
KT1 KM1 KM2 KM1Y KM2Y HL KA1 HL1 KA2 HL2
8.1 Schematic Electric Diagram of the Mixer

Discharge Discharge
Power of motor Motor Y running Main motor Discharge gate Discharge gate gate
Time relay running gate open close close
1# motor 2# motor 1# motor 2# motor 1# motor 2# motor indicator open indicator indicator

Safety, Operation & Maintenance Manual - October, 2014

+24V

KA3 KA4

(This diagram is only for reference)

Open Close

-0V

8-3
Appendix
8-4
Appendix

FU0 QF0, main power switch

L1
L2

L3

Fig. 8-2 Main circuit

N
PE
FU2 fuse FU3 fuse
FU1 fuse

QF1 QF2 QF3

Frequency mutual inductor TA1 Frequency mutual inductor TA2

Amperemeter A2
Amperemeter A1

KT1 KM1 KT2 KM2 KM3

FR1 FR2 FR3

V1 V2 U3 V3
U1 W1 U2 W2 W3

M1 M2 M3
8.1.2 Schematic electric diagram of the mixer 2

U2 W2
U1 W1
V1 V2

KM1Y KM2Y

Safety, Operation & Maintenance Manual - October, 2014

Oil pump motor
1# Motor 2# Motor

(This diagram is only for reference)

HZS60 Concrete Batching Plant
 Proximitiy switch of the discharge gate

+24V Full open Half open Full close

HZS60 Concrete Batching Plant

KA3 Discharge gate

full open signal
KA3 KA4 KA5

Discharge gate Connect PC

KA4 to monitor
half open signal
Black Black Black

Brown Brown Brown

8.1.3 Schematic electric diagram of the mixer 3

Blue Blue Blue

Fig. 8-3 Proximity switch of the discharge gate control circuit

Discharge gate
-0V KA5
full close signal

Safety, Operation & Maintenance Manual - October, 2014

8-5
Appendix
8-6
Appendix

To control room (user connect)

discharge gate full close signal

discharge gate half open signal safety overhaul discharge gate discharge gate
switch open solenoid close solenoid lubrication oil pump
DC24V discharge gate full open signal

Fig. 8-4 Wiring diagram of mixer cable box

mixer junction box
8.1.4 Schematic electric diagram of the mixer 4

open solenoidc lose solenoid

lubrication oil pump
upper cover

Safety, Operation & Maintenance Manual - October, 2014

safety switch
overhaul switch

brown
blue Proximity Switch Notice:
black (discharge gate full open state)
Refer to the real object for the motor temperature switch or
brown
blue Proximity Switch thermal resistor of the motor protect circuit.
black (discharge gate half open state)

brown Proximity Switch

blue (discharge gate full close state)
black
HZS60 Concrete Batching Plant
HZS60 Concrete Batching Plant Appendix

8.1.5 Description of electrical component symbols of the mixer

Table 8-1 Description of electrical component symbols of the mixer

Symbol Name Symbol Name

Intermediate relay for opening
KM1 KM2 Mixer contactor KA2
the discharge gate
Intermediate relay for open/
KM1 KM2 Triangle wiring, contactor KA3
close travel switch 24VDC
Intermediate relay for half
KM1Y KM2Y Y-shape wiring, contactor KA4
close travel switch 24VDC
Intermediate relay for close
QF0 Main switch KA5
travel switch 24VDC
QF1 Switch of mixer motor 1 S1 Start button of mixer
QF2 Switch of mixer motor 2 S2 Stop button of mixer
Thermal protector
FR1 S3 Discharge gate open button
of mixer motor 1
Thermal protector
FR2 S4 Discharge gate close button
of mixer motor 2
FU0 Main fuse S5 Discharge gate stop button
FU1 Fuse of mixer motor 1 KT1 Time relay, 5~8 second
FU2 Fuse of mixer motor 2 SA1 Maintenance key switch
FU3 Transformer fuse QF3 Hydraulic oil pump switch
Hydraulic oil pump
FU4 Mixer air fuse FR3
thermal protector
Intermediate relay for
KA1 KM3 Hydraulic oil pump contactor
opening the discharge gate

Safety, Operation & Maintenance Manual - October, 2014 8-7

Appendix HZS60 Concrete Batching Plant

8-8 Safety, Operation & Maintenance Manual - October, 2014

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Hunan, China 410100

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