GETTING STARTED

When power to the controller is first switched on, the system boots to the introductory
screen shown below. To proceed to the Main Production Screen from here, use the F5
key on the keyboard, which is located under the box labeled START on the display. To
go directly to the Set Up Screen from here use the F1 key on the keyboard which is under
the box labeled Menu.

Introductory Screen

F1 SET UP SCREENS MAIN PRODUCTION

SCREEN

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MAIN PRODUCTION SCREEN

Main Production Screen

In order to change a percentage in the mix, use the left and right arrow keys located in the
bottom right corner of the controller to move the cursor to the desired field (the cursor is
shown as a vertical line on the left side of the field) and type in the new value using the
number keypad. After typing, press the enter key.

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 CURSOR

ENTER KEY

LEFT ARROW KEY RIGHT ARROW KEY

Keypad

The total of the set percentages must equal 100%. An error message will appear if the
total is not 100%. Adjust the percentages until they equal 100% and then press F9 to
remove the error message.

There is no automatic control for the feeders; each one is controlled manually. However,
the addition and blending of the asphalt cement (A/C) is adjusted by the computer, and is
calculated as a percentage of mix/aggregate. The amount of A/C needed is based upon

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 the dry weight of the material, which is calculated by subtracting the percentage of
moisture from the belt scale weight.

The following functions are also controlled from this screen:

RESET BATCHER
DROP COUNT

RESET TONS DISPLAY

SILENCE AC OUT OF TOLERANCE

ALARM

To exit the Main Production Screen, press the F10 key.

Exit Main Production Screen

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SET UP SCREEN__________________________
In order to monitor the other ingredients in the mix, press the F10 key on the Main
Production Screen to open the Set Up Screen shown below.

Set Up Screen

Each individual ingredient in the mix may monitored from here by using the various F
keys and these screens are explained in greater detail in the sections following.

F1 opens the Aggregate Set Up Screen, which monitors the aggregate scale.
F2 opens the AC Set Up Screen, which monitors the addition of the asphalt
cement into the mix.
F6 opens the Damper Set Up screen.
F7 opens the Totals Screen, which displays the Plant To Date values.
F8 toggles the displays between English and Spanish
F9 toggles the displays between English and Metric
F10 returns to the Main Production Screen.

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AGGREGATE SET UP SCREEN
Pressing the F1 key on the Set Up Screen will open the Aggregate Set Up Screen, shown
below.

Aggregate – F1

Aggregate Set Up Screen

This screen monitors and controls the factors associated with the aggregate belt scale.

Zero is the average A to D count of the belt with the belt running empty. This is set by
pressing the F6 key, Zero Scale, while the belt is running empty.

PRESS TO ZERO SCALE

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Zero Time is determined by the amount of time it takes for the belt to make three (3) or
more complete revolutions. This figure is expressed in seconds, so a zero time of 30
equals 30 seconds.

Elapsed Time is the zero timer accumulator value during scale zeroing.
Span Factor is the correction factor used to convert the A to D count to tons per hour
(TPH). In order to increase the TPH rate, increase the span factor.
Tach Avg Time is the period during which the computer averages tachometer readings to
allow for noise

AToD Avg Time is the number of load cell readings to be averaged to allow for noise.
.
Min TPH is a set value which indicates the lowest flow rate which will be recognized for
both control and display purposes; any flow rate below this will be regarded as zero. For
example, if the Min TPH is set at 1.00, the computer will read and display any flow rate
less than 1.00 to be 0.00
.
Rate is the product of the tach counts, A to D counts and span factor, and is displayed in
tons per hour (TPH).
Total is the total tons produced since the system was last reset to zero on the Main
Production Screen
A to D is the raw analog to digital conversion of the load cell signal.

% Moisture is the percentage of the aggregate weight that is moisture. This value will
be subtracted from the weigh belt reading.

Counts is the incoming counted pulses from the tachometer each second.
Time to POM is the amount of time it takes the aggregate to reach the point of A/C
injection from the weight bridge. This figure is expressed in seconds, so a setting of 30
means that the computer begins A/C injection 30 seconds after the aggregate crosses the
weigh bridge.
All the fields on this screen may be adjusted, except Zero, Elapsed Time, Counts, A to D,
Rate and Total. To change the value of a field, use the left and right arrow keys located
in the bottom right corner of the controller to move the cursor to the desired field (the
cursor is shown as a vertical line on the left side of the field) and type in the new value
using the number keypad. After typing, press the enter key.
.
.

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 CURSOR

ENTER KEY

LEFT ARROW KEY RIGHT ARROW KEY

To return to the Set Up Screen press the Escape key F10.

Escape To Set Up Screen

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AC SET UP SCREEN_______________________
Pressing the F2 key on the Set Up Screen will open the AC Meter Screen shown below.

AC – F2

AC Set Up Screen

This screen monitors and controls the factors associated with the AC meter.

AVG TIME is the period during which the computer averages tach readings to allow for
noise
.
DEADBAND is the amount of error in tons per hour between the required AC flow and
the actual AC flow that the computer will allow before making a correction.

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SPAN FACTOR is the correction factor used to convert the counts to tons per hour
(TPH). In order to increase the TPH rate, increase the span factor.

MIN TPH is a set value which indicates the lowest flow rate which will be recognized
for both control and display purposes; any flow rate below this will be regarded as zero.

SPG is the specific gravity of the material. This may be obtained from the bill of lading
of the material, from the asphalt manufacturer from whom the material was purchased, or
it may be calculated by dividing the density of the material by the density of water.

Material Density
-------------------------- = SPG
Density of Water

Dampening Factor determines the response time of the computer to changes in the flow
rate; the larger the dampening factor, the quicker the response to correct flow rate errors.
The dampening factor should be set low enough to prevent oscillation and high enough so
that the ingredient reacts properly to changes in the mix.

Delay Time is the amount of time between calculations of the AC error and the
corrections to the pump speed. It is measured in hundredths of a second (0.01 seconds).

Out of TolTime is the amount of time in seconds that the AC can be above the tolerance
percentage before the out of tolerance alarm is triggered.

Out of Tol Prcnt is the amount of error allowed between the set point percent and the
actual percent.

C Temp is the temperature of the asphalt cement, measured in degrees Celsius

F Temp is the temperature of the asphalt cement, measured in degrees Farenheit

.
RATE is the product of the count, specific gravity and span factor, and is displayed in
tons per hour (TPH).

Counts is the incoming counted pulses from the tachometer

TOTAL is the total tons of AC used since the system was last reset to zero in the Main
Production Screen.

All the fields on this screen may be adjusted, except RATE, Counts, and AC Temp. To
change the value of a field, use the left and right arrow keys located in the bottom right
corner of the controller to move the cursor to the desired field (the cursor is shown as a
vertical line on the left side of the field) and type in the new value using the number
keypad. After typing, press the enter key.
.

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 .

CURSOR

ENTER KEY

LEFT ARROW KEY RIGHT ARROW KEY

To return to the Set Up Screen press the Escape key F10.

Escape To Set Up Screen

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DAMPER SET UP_SCREEN_________________
Pressing the F6 key on the Set Up Screen will open the Damper Set Up Screen shown
below.

Damper Set Up – F6

Damper Set Up Screen

This screen is used to calibrate the damper position read out.

A to D VALUE is the A to D value of the damper position signal
% OPEN is the relative position of the damper between 0% (damper fully closed) and
100% (damper fully open). This value is displayed as a bar graph on the main production
screen.

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 Damper Position Bar Graph
(On Main Production Screen)

Damper position is controlled with a selector switch on the console. This switch is only
active if the exhaust fan starter is energized

To calibrate the damper, close the damper all the way and then press the Set Min Pos Val
key, F1.

MINIMUM POSITION VALUE

SET MINIMUM POSITION

Next, open the damper all the way and then press the Set Max Pos Val key, F3.

MAXIMUM POSITION VALUE

SET MAXIMUM POSITION

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To return to the Set Up Screen press the Escape key F10.

Escape To Set Up Screen

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TOTALS SCREEN
Pressing the F7 key on the Set Up Screen will open the Totals Screen shown below.

Totals Screen

This screen displays the totals for all mix ingredients for some period of time (week,
month, etc.) It is not reset by the “RESET TONS” key on the Main Production Screen.

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To reset the values, press and release the F5 key and then press the F1 key.

PRESS AND RELEASE

TO ENABLE RESET

PRESS AND RELEASE

TO RESET TOTALS

To return to the Set Up Screen press the Escape key F10.

Escape To Set Up Screen

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 SYSTEM CHECK SCREEN
This is a diagnostic screen and may be reached from the Damper Set Up Production
Screen by pressing F9.

PRESS FOR SYSTEM CHECK SCREEN

System Check Screen

The System Check Screen allows the monitoring of the digital and analog inputs
used by the control program. The inputs monitored are inputs 2, 5 and 8 through 15 on
the Micrologix 1500. Input 2 is the AC cal input and input 5 is the AGG cal input. Input
8 is the run input that is energized when the drum, slinger conveyor, collecting conveyor
are running. Inputs 9 through 12 are the four no flow switches on the feeders. Input 13 is
the batcher count input. As supplied, input 14 is not used. The digital readouts are the
input values from the A to D converters and the high speed counters. The digital
readouts are the values produced by the analog to digital converters and the high speed
counters (read every 1 second).

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PANELVIEW CONFIGURATION SCREEN
The Configuration Screen allows adjustments to the screen’s appearance. It also
allows reloading the screen program from the memory card that is installed in the
PanelView.

System Check Screen

The Configuration Screen is accessed by pressing the right and left arrow buttons
at the same time.

LEFT ARROW KEY RIGHT ARROW KEY

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MANUAL BACKUP UNIT

Introduction
This is an introduction to the Astec Manual Backup Unit (hereafter called MBU). The MBU is a panel-
mounted system containing the necessary controls and indicators to control an ingredient in a continuous
mix process. These include a speed control potentiometer, start-run-stop switch, mode indication lights, and
a tachometer readout to complete the feedback loop. Inputs for an automatic controller allow smooth
transition between auto and manual control. Inputs are provided for a master speed pot, master start-stop
switch, and no-flow switch. Refer to “Figure 24 MBU Block Diagram” on page -62 for the internal
organization of the MBU.
Complete isolation of inputs and outputs is a major feature of the MBU. This adds an extra measure of
protection for your controller in the event of a lightning strike or short. Modular replacement will reduce
downtime and ease troubleshooting in the field, should problems occur.

Installation
MECHANICAL
Refer to the mechanical drawing below for the MBU mounting dimensions.

The clip retainers are meant to hold the MBU into the panel with moderate force. Any extra force will only
bow the sides of the case and make insertion and removal of the MBU difficult.
A package of labels is included, representing all of the probable uses of the MBU. The labels slide in from
the side when the MBU is out of the case.
The panel lamps are cartridge-type, replaceable by unscrewing the lens and removing the cartridge with a
gentle tug. The lamps should be inserted only one way, with the + side to the right. Mechanical damage may
result otherwise.

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The ease of insertion and removal of the MBU chassis is one of the strong points of this system. To remove
the MBU chassis simply insert a medium-sized flat-bladed screwdriver in one of the 3/8” holes on the top or
bottom of the case and pry the chassis of the MBU forward. The bezel should pop off and the chassis should
be easily withdrawn from the case. If this doesn’t happen the bezel may lack side clearance or the mounting
clips may be too tight. Re-installation of the MBU consists of replacing the unit in the case, pressing the front
panel until it drops below the lip of the case (this should be accompanied by a resistance as the connector
seats) and the replacement of the bezel. Use care when replacing the bezel as these pieces are fragile.
The terminals of the MBU are designed to be used without spade lugs or other terminations. Strip the wire
back 1/4” and torque moderately when connecting to the MBU terminals.
The MBU requires 117 volts AC, and dissipates 12 watts.
Ventilation is an important consideration. Never interfere with any of the holes in the MBU case and follow
the minimum clearances given in the Mounting Dimensions drawing on Page 54. Forced air cooling is
recommended. The ambient temperature surrounding the MBU should never exceed 100 degrees
Fahrenheit. Moisture can degrade the quality of operation of the MBU; avoid using or storing the MBU in a
condensing atmosphere. Never use solvent or corrosive cleaners around the MBU.

ELECTRICAL
The MBU is designed to patch in between the automatic controller (if any) and the device to be controlled.
You must determine the type of control voltage or current required. The MBU will supply 0-10 volts in the
configuration as shipped: the output may be changed to one of several different configurations by turning
potentiometers or flipping internal switches (covered in CALIBRATION).If there are any doubts as to the
requirements of your controller or valve, contact Astec. Chances are that we have dealt with your problem
before.
We will now go through the terminals on the back panel and explore the uses of each. Refer to the field
wiring drawing at the rear of this manual for clarification, if necessary.

TERMINAL #:
1, 2 — The power terminals. 117 volts AC hot connects to pin 1 and common connects to pin 2.
4, 6, 8 — Run terminals. These are hooked to a relay internal to the MBU. A valid “run” condition sets this
relay. 4 is normally open, 6 is common, and 8 is normally closed.
5 — No flow input. When 117 volts hot appears on this input and the MBU is in a valid “run” condition, an
alarm labeled NO FLOW blinks on the front panel and an associated alarm output becomes hot. Typically, a
mercury switch installed in the flow path provides this signal. This signal is optional, as it does not interrupt
the operation of the MBU.

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7, 9 — Master Start-Stop. These inputs are compatible with a 117 volt AC motor start-stop control
switch: 7 requires a momentary hot to start, and 9 requires a momentary open to stop.
These terminals support the stop-in-place mode, and are not necessary for automatic or manual
operation. If unused, terminal 9 should be jumped to hot.
10 — Interlock input. Hot on this input means that it’s OK to start the system. When this input becomes cold,
the run output turns off. In auto mode, the unit will start when this input becomes hot again. In manual mode,
the unit will not start again automatically when interlock becomes hot again. Jump this input to hot if it is not
to be used.
11 — Auto input. Hot on this input means that the automatic controller is trying to run, and that if:
A) the interlock is hot
B) the unit is not in a master stop condition, and
C) the front panel switch is not off, the MBU should run in the auto mode (see “AUTO MODE”
on page -60). If no automatic controller is used, leave this terminal open.
12 — No flow alarm output. Hot on this output means that the MBU has detected a no flow condition
during its run mode. This output goes hot at the same time that the no flow light on the front panel starts
blinking. Typical installations would connect this output to an audible alarm. A delay-operate relay could
be installed to prevent nuisance alarms on start-up.
13, 15, 17 — Tachometer input. Connect this input to an optically encoded tach such as the Accucoder
711-1200. 13 is the signal, 15 the +5 volt excitation, and 17 the negative excitation. Refer to the field
wiring diagram for your system for shield termination. If no tach is to be used, short terminals 13 and 17.
14, 16 — Auto speed input. This is the 0-10 volts DC from the automatic controller. This cable should be
shielded, with the shield terminated at the automatic controller end only. 14 is the positive signal, 16 the
negative. If no automatic controller is to be used, short these inputs together.
18, 20, 22 — Master speed input. Typically a 10K ohm digital panel pot (resembling the one in the MBU) is
hooked here to allow ratiometric control of more than one MBU at once in the manual mode. 18 is the
negative excitation, 20 the positive excitation, and 22 the signal. Refer to the field wiring diagram
corresponding to your system when terminating the shield. When more than one MBU is connected to a
master speed pot, use the positive excitation from only one MBU to excite the pot. This prevents the
excitation regulators from “fighting” each other. Hook all minus excitations together, as well as all signals.
When no master speed pot is used, jump terminals 20 and 22 together.
21, 23 — Control output. This is the output going to your motor controller or valve. Two internal switches
determine whether the output is 0-10 volts or 4-20 milliamps DC. 21 is the signal negative, 23 the signal
positive. This wire should be shielded: refer to the field wiring diagram for your system. This voltage is not
gated; it is present any time the MBU is powered up.

Calibration
Calibration of the MBU consists of setting it up to match your controlled parameters. As it comes from the
factory, the MBU is set up to give a 0-10 volt DC output. If your controller requires a different maximum
voltage (e.g. Dodge-Reliance requires 12 volts max) you will need to adjust the Max Speed pot on the back
panel. Power up the MBU, set the MBU panel pot to 999, the master speed pot (if any) to maximum, the
MBU front switch to OFF, and connect a voltmeter to terminals 21 (-) and 23 (+), set to read a maximum of
20 volts. Adjust the Max Speed pot until the voltage is equal to that required (approximately 17 volts is
available).
If your installation requires a 4-20 milliamp current signal, you will need to reconfigure the internal switches
of the MBU and recalibrate the output. Power down the MBU, remove the MBU from its case and locate the
switches shown in the MBU internal drawing.

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Move the small red slider to the opposite side of the switch so that the dot is visible on both switches. Re-
install the MBU in its case. Install a current meter in series with the control circuit, set to comfortably read
over 20 milliamps. Power up the MBU and set the switch in the OFF position. Set the master speed pot to
maximum (if any), the MBU speed pot to 000, and note the current displayed on the current meter. Adjust
the 4ma pot on the rear of the MBU until you obtain a reading of 4 milliamps +/- 0.1 milliamp. Set the MBU
pot to 999, note the current reading, and adjust the Max Speed pot on the rear of the MBU until you obtain a
reading of 20 milliamps +/- 0.1 milliamp. Remove the current meter; calibration is complete.

Operation
MANUAL MODE
The MBU will enter the manual run mode when, from the idle state, the front panel switch is pressed to
START, then released to RUN. If the interlock and master stop inputs are hot, the MBU will set the Run relay
and enable the Master Speed Pot input. The RUN light will light and, if the No Flow input is hot, the NO FLOW
light will blink and the No Flow Alarm output will energize. The display will show the RPM of the tachometer.
The voltage output to the controller will be a product of the number shown on the Master Speed Pot and the
value shown on the front panel of the MBU: in other words, when the Master Speed Pot is set at 500, the
MBU pot will set the output between 0 and 5 volts. Master Stop will stop the MBU, leaving the RUN light
blinking: the only thing that will restart the MBU from this state would be a Master Start or a power down
reset. Losing the Interlock input halts the MBU in the manual mode: another START switch input would be
necessary to restart after such an occurrence.
The Auto input overrides the manual mode. After receiving an Auto input during manual operation, the MBU
completely forgets that it was running in manual: when the Auto signal is removed, the MBU returns to the
idle state.
The START position on the front panel switch overrides any other input. When START is pressed, the device
will run for as long the button is held in. You can “jog” the feeder easily with this switch.
AUTO MODE
When the MBU receives an Auto signal, it checks its Interlock, front panel switch, and Master Stop inputs. If
these are in order, it closes the Run relay. Both speed pots are disabled, and the voltage on the Auto DC
input is transferred to the DC output. The RUN and AUTO lights are lit, and the RPM of the tach is displayed.
If the No Flow input is hot the NO FLOW light on front of the MBU will blink and the No Flow output will be
energized.
Several things will cause the MBU to halt in the auto mode. If the Auto signal drops out or the Interlock
signal is broken, the MBU will enter an idle state where no lights are on or flashing and the Run output is off.
All the MBU requires to restart is that the missing signal be re-established. If Master Stop is broken, the Run

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output will be turned off and the AUTO light extinguished. The RUN light will blink, meaning that when Master
Stop is re-established and a Master Start signal is given, the MBU will start up again in automatic. If the Auto
signal goes cold during this time, the RUN light will go out. The MBU won’t restart until both a Master Start
signal and a Run signal are received. When the MBU receives an Auto run signal and the front panel switch
is OFF, the AUTO light blinks, signifying that the MBU will run as soon as the front panel switch is set to ON.
The most important thing to note here is that when you give the MBU a Master Stop, the only thing that will
re-enable operation is a Master Start or a complete power down reset and restart.

Troubleshooting
Here we will address symptoms and causes of failure within the MBU system. Troubleshooting of the MBU
will be greatly facilitated by the presence of extra MBUs to swap with the offending unit. This will confirm
either that the MBU is defective or that a signal entering the MBU is in error. Only swap MBUs that are
configured the same: do not swap an MBU configured for current output with one configured for voltage
output, or vice versa.
Never swap an MBU into the position vacated by an MBU that has smoked or failed catastrophicallyuntil the
wiring has been thoroughly checked.
Once you have determined that the MBU is not defective, the symptoms and causes outlined below
will help you locate your problem.

SYMPTOM POSSIBLE CAUSES

Blank tach display AC power off
Tach display zero when tach is turning Broken tach connection, bad tach

Won’t run in auto mode, no lights flash Auto and/or Interlock signals not present, light burnt out

Unit in Master Stop condition, check for Master Stop

Won’t run in auto mode, RUN light blinks
signal
Won’t run in auto mode, AUTO light blinks Switch in OFF position

Won’t stay running in manual mode

Interlock not present, unit in Master Stop condition,
spurious Auto signal causing manual mode to drop out

Bad connection to controller, check voltages at all

MBU appears OK, but device won’t run
terminations
Device rate varies erratically Bad motor controller, bad tach, bad connection, check
DC wiring and voltages

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MBU DRAWINGS

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 SETUP OF 7838 BURNER CONSOLE

1. Check the wiring to be sure it is correct:

A. Scanner Wiring

Pilot Blue B59

Main Blue B7
Both Whites B8

B. Motor Slide Wiring

Motor Wire # Honeywell

Y B22 24
G B24 22
T B23 23

C. Motor Drive Wiring

Motor Wire # Honeywell

1 B19 6
2 B17 21

Note: The mod motor operates from an internal 24 vac transformer, the “R”
terminal is one side of the transformer and the other side is connected
directly to the motor

D. Check limit wiring using the burner control schematic drawing.

E. Set the AUTO/MANUAL switch on the console to MANUAL

a. Remove the mod motor cover – the motor can now be operated in either
direction by jumpering the “R” terminal to either terminal 1 or 2
b. Adjust the burner linkages by driving the motor up and down
c. Adjust the high and low limit switches so that their contacts are closed
when the burner reaches each position
d. Turn off the manual gas valve closest to the pilot assembly
e. Jumper terminals B30 & B30A, then jumper them to B20
f. The igniter should spark – check by looking and listening
g. Turn the manual gas valve to on – the pilot should light
h. Check that the Honeywell burner control readout shows a 5.00 volt flame
signal. If it is not, check the scanners.
i. Check the scanners by holding a lighter in front of them – they should light
up.
j. Remove the jumpers added in step e
k. Check the set up of the Honeywell UDC3200
l. Check the set up of the Honeywell UDC1200 stack control.

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 m. Jumper B115 to B20, put the Auto/Manual switch in the auto position and
calibrate the motor.

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 HONEYWELL 7838 BURNER CONSOLE

Operation
When the START button is pushed, the 7838 energizes input I10 on the LOGO! This
will drive the burner to high fire. There is an external limit switch on the burner which
indicates high fire. Once high fire is achieved the burner will set for ten (10) seconds. The
7838 will then de-energize LOGO! input I10 and drive the burner to low fire. It may be
necessary to drive the exhaust damper down before attempting to light the burner. Once
the 7838 detects that the low fire limit is reached, the pilot may be ignited. The display
will indicate ignition and show the flame signal; a good flame signal is 5.0 VDC. Push
the MAIN FLAME button to ignite the main flame. In ten (10) seconds the pilot will go
out and the display will indicate RUN.
IN THE EVENT THAT THE BURNER MISFIRES, IT IS NECESSARY TO
RESET THE 7838; THE ALARM LIGHT REMAINS ON UNLESS THERE
IS FIRE.

NOTE
If the pilot does not light but limits are not lost, try lighting the pilot again. However, if
limits are lost at the time lighting the pilot is attempted, the Honeywell must be reset
and the process started over again.
If the main flame is lost while starting, the Honeywell 7838 must be reset and the
process
started over again.

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WEIGH BELT ALIGNMENT

NOTE
Improper alignment of the weigh bridge section will result in erroneous
readings.

It is critical that the weigh bridge idler and the three idlers on either side of it are
properly aligned with each other as well as the rest of the conveyor. This section
must be level from side to side.
The alignment is best done without the belt in place. The maximum deviation for any
dimension is 1/64”.
1. Verify that the head and tail pulley are square with each other and the
conveyor, then mark their center lines.

WARNING:
Wear eye protection - taut lines may inflict serious injury if they break.

1. Use an 8 gauge or heavier piano wire, or a heavy monofilament fish line for a
stringline. Fasten it to the frame and run it under and around the head pulley, down
the length of the conveyor, and over the tail pulley. Attach a weight in order to keep
the line taut.

2. Align the stringline over the centerline of the head and tail pulleys.

3. Make the weigh bridge section square with the stringline and level from side to side.

4. Shim the third idler before the weigh idler so that it is 1/4” above the tail pulley and
any idlers in between. This idler must be level from side to side
.
5. Shim the third idler after the weigh idler so that it is 1/4” above the head pulley and
any idlers in between. This idler must be level from side to side
.
6. Mark the top side of these raised idlers. Do not rotate them, as they may not be
perfectly round.

7. Run a stringline along the top outer edge of these idlers.

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 NOTE
The weigh idler and the two on either side of it have been
machined to assure roundness. Unmatched idlers MAY NOT be
substituted. Idlers with bent supports may not be used.

8. Start at the second idler before the weigh idler, and work to the second idler after the
weigh idler. Align the idlers with the stringlines. Make the distance from each idler to
the weigh idler the same as that of the corresponding idler on the other side of the
weigh idler
.
9. Tighten all bolts, then recheck that the weigh idler and the three idlers on either side
of it are in the same plane, level from side to side, centered on the centerline, and
symmetrically spaced relative to the weigh idler. Correct any discrepancies.

10. All other idlers must be at least 1/4” below the plane of the weigh idler and the three
idlers on either side of it, level from side to side, and centered on the centerline of the
two end pulleys.

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 WEIGH BRIDGE CALIBRATION

1. Check the alignment of the weigh bridge section. It is useless to try to calibrate
the weigh bridge if this section is not properly aligned
2. .
3. To find the belt speed, proceed as follows:
4.
A) Measure the length of the belt in feet.
B) Time the belt for ten (10) complete revolutions, in seconds

i. FPM = 10 X length X 60 sec/min

Time (seconds)

ii. EXAMPLE:
a. 10 X 21 ft. X 60 = 382 FPM
b. 33 seconds

5. Use the weight to approximately set the TPH meter.

i. TPH = W X S X 60 min/hr
D X 2000 lb/ton
ii. Where: TPH = tons per hour on Aggregate meter W = suspended
weight, in pounds S = belt speed, in feet/minute D = distance
between fixed rollers (feet) in the weigh bridge section

iii. EXAMPLE:
20 lb X 410 fpm X 60 = 81.99 TPH
3 ft X 2000 lb/ton

6. With the weight on, adjust the span factor on the TPH meter to read
approximately 82 TPH with a belt speed of 410 feet per minute.

7. Stop all the conveyors and remove the test weight. Reset the aggregate total on
the main production screen..

8. Set the aggregate run/cal switch to the start position and then start the slinger
conveyor (it will run in reverse).

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 9. Set one of the feeders to run at approximately 50 to 60 TPH. Run the material
onto the gathering conveyor until the flow is even.

10. Collect the material as it comes off the slinger conveyor.

11. Stop the feeder and wait for the collecting conveyor and slinger conveyor to
empty.

12. Weigh the material collected from the slinger and compare it with the weight total
displayed on the main production screen. Recalculate the span factor per the
following formula:

Old Span X Collected Weight

New Span =
Indicated Weight

13. Start the belt and material again, at the same conditions as before. Repeat
adjusting the span factor until no further adjustment is needed

The weigh bridge is now calibrated and may be used for making graphs and tables for
each feeder. Proceed as follows:
1. Set the MASTER at 500.

2. Run each feeder separately, adjusting the individual speed to get the correct TPH
for each mix design. Record the setting for each bin for each mix
.
3. When making mix, each bin is set to the above determined value for that
particular formula, and plant production rate is controlled by the MASTER.

4. Example: If 30% of a mix is from a bin, and production is 50 TPH, then 30% X
50 = 15 TPH is needed from that bin. Adjust the individual speed potentiometer
for that bin until the Aggregate meter indicates 15 TPH, then record the setting of
the speed potentiometer. Repeat this process for each mix with the appropriate
flow from each bin.

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 NOMAD CALIBRATION AND START-UP

Calibration of the Belt Scale

CALIBRATION BY USING A TRUCK

1. Weigh the truck and record the tare weight.
2. Park the truck under the slinger.
3. Set the Aggregate RUN/CAL switch to the CAL position and start the collecting
conveyor and slinger conveyor.
4. On the Allen-Bradley controller, go to the Aggregate Belt Scale screen and press
F6 (Zero Scale) to zero the belt.
5. Go to the Main Production Screen and press F2 (Reset Tons) to set the totals to
zero.
6. Start a feeder bin at 50 to 80 TPH.
7. Run 5 to10 tons of clean aggregate onto the truck.
8. Stop the feeder; after stopping it, the aggregate total should be showing in the
Totals screen.
9. Weigh the loaded truck and calculate the net tons on the truck.
10. To find the new span factor, use the following formula:

Truck Net
___________________
X Old Span Factor = New Span Factor
Allen-Bradley Total

EXAMPLE:
4.25 Net
_________________
X 9.83 Span = 11.936 New Span Factor
3.50 Total

1. On the Allen-Bradley controller, go to the Aggregate Belt Scale screen and enter
the new span factor in place of the old one.
2. Repeat steps 5 through 10. Continue this process of making runs onto the truck
and comparing the actual net weight with the net weight calculated by the
computer. When they match or are close, the calibration process is completed.

CALIBRATION BY CUTTING THE BELT

1. Measure the belt speed of the collecting conveyor in feet per minute.
2. Run the collecting conveyor and slinger.
3. Start one of the feeders and try to run it at approximately 50 to 80 TPH.
4. Stop the collecting conveyor while it is loaded.

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 5. Remove a 36” section of material from the belt and weigh it, then divide the
weight by 3 to get the weight per foot of the material.
6. Use one of the following formulas to calculate the TPH rate which the slinger
conveyor is running:

TPH = Weight X Belt Speed (FPM) X 60 /2000 lbs

Metric TPH = Weight X Belt Speed (FPM) X 60 /2240 lbs

7. Start the belt and feeder again. Look at the TPH and write it down, then use the
following formula to calculate the new span factor:

Actual TPH
___________________
X Old Span Factor = New Span Factor
Indicated TPH

8. On the Allen-Bradley controller, go to the Aggregate Belt Scale screen and enter
the new span factor in place of the old one. The belt TPH should now be correct.

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Calibration of the Feeders
1. Fill the bin with the material which will be run from it
.
2. Set the Master Speed at 500. Call this 100 TPH
.
3. Calculate the desired TPH from the bin; for example, 30% would be 30 TPH
.
4. Run the feeder, and adjust the gate and individual speed for the feeder until it
reads 30 TPH on the belt scale

5. Calculate the desired TPH from the other bin that shares the feeder.

6. Run the feeder again at the same speed used in Step 4 above, but this time only
adjust the gate in order to achieve the 40 TPH rate
.
7. Repeat Steps 1 through 6 for the next bin.

8. Once this process has been completed for all bins, the Master Speed set at 500 in
Step 2 will be 100 TPH. Increasing the Master will speed up both feeders, and
decreasing the Master will slow down both feeders.

Make notes of the material, gate settings, individual speed settings and RPMs, as these
calibration settings may be used each time this mix is run.
Graphs of the feeders may be generated by using the data gathered above.

AC Calibration

CALIBRATION BY USING A TRUCK

1. Weigh the tanker and record the tare weight
.
2. Connect the hose to the back of the tanker.

3. On the Allen-Bradley controller, go to the Main Operating Screen and press F2

to set the totals to zero. Set the AC RUN/CAL and the DRUM RUN/CAL
switches to CAL
.
4. Go to the AC Setup screen and enter the Specific Gravity (SPG) of the
material. The normal value for this field is 1.031
.
5. Open the tanker valves and the calibrate valves
.
6. Start to pump material by hanging test weights on the weigh bridge and starting
the collecting conveyor and the slinger conveyor. Start slowly; the pump may
be speeded up after the system is warm.

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 7. Pump approximately 1 to 4 tons of A/C onto the tanker, then stop the pump.
Record the total A/C either from the AC Meter screen or from the Totals screen.

8. Disconnect the hose from the tanker. Weigh the loaded tanker and calculate the
net tons
.
9. To find the new span factor, use the following formula:

Net
________________
X Old Span Factor = New Span Factor
Allen-Bradley

10. EXAMPLE:
____Net_______
2.00 Total X 12.3 Span = 13.7145 New Span Factor

11. On the PanelView, go to the AC Meter screen and enter the new span factor in
place of the old one.

12. Run the system again to check the new span factor.

CALIBRATION BY RPM
1. The 2” KK225 Viking Pump puts out 0.10 gallon per revolution.

2. With the pump circulating, make note of the RPM

.
3. Calculate the TPH that the pump is circulating by using one of the following
formulas:

0.10 Gal/Rev X Weight/Gal X RPM X 60 Minutes = TPH

2000

.10 Gal/0Rev X Weight/Gal X RPM X 60 Minutes = Metric TPH

2240

4. EXAMPLE: Pump RPMs = 136.5

0.10 X 8.60 Lb/Gal X 136.5 X 60 =3.52 TPH

2000 Lbs

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 0.10 X 8.60 Lb/Gal X 136.5 X 60 = 3.14 Metric TPH
2240 Lbs

5. Use the following formula to calculate the new span factor:

6. Actual TPH X Old Span Factor/Indicated TPH = New Span Factor

7. EXAMPLE: 3.52 TPH

___________
X 10.32 Old Span = 9.87 New Span
3.68 TPH

8. On the Allen-Bradley controller, go to the AC Meter screen and enter the new
span factor in place of the old one.

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Operating the Plant

STARTING THE PLANT

1. Start the following components:
Motors
Air Compressor
Exhaust Fan
Burner Blower
Fuel Pump
Drag
Drum
Slinger Feeder
Collecting Conveyor
A/C Pump (MBU 200 and switch off)
Baghouse Screws – set to auto

2. Start the burner and allow the system to warm up (follow burner instructions)
.
3. . While the system is warming up, go to the Aggregate Belt Scale screen on the
Allen-Bradley controller and do a Belt Zero by pressing F6, Zero Scale
.
4. Set up the, Aggregate and AC percentages on the Main Production screen.
Aggregate moisture percentage should be set on the Aggregate set up screen.

5. Zero the tons total on the Main Production Screen by pressing F2. The PTD totals
can be reset (if necessary) on the Totals screen at this time also.
.
6. Set the Master to achieve 50 TPH
.
7. Start the feeder bins
.
8. Monitor the stack temperature and adjust the temperature of the burner manually
to maintain 300 degrees F. Open the damper and maintain 0.20 suction on the
burner
.
9. Switch the A/C MBU to the center position. The AUTO and RUN lights will both
come on when the POM times out
.
10. The mix temperature should be the same as the stack temperature
.
11. Work the batcher manually several times in order to warm it up before leaving it
on AUTO.

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STOPPING THE PLANT MID-STREAM
If the plant needs to be stopped during production, push the MID-STREAM
STOP button. This will cause the drum and everything behind it to stop, and
will cause the burner and the A/C to divert.
Make sure the A/C actually does divert.

RESTARTING THE PLANT AFTER MID-STREAM STOP

Fire the burner. Allow the stack temperature to reach 350 degrees F. Push
the MID-STREAM START button and hold it until the feeders start.
Raise the burner temperature back to where it was before the plant was stopped.
Manually open the burner several times to warm it up.

STOPPING THE PLANT

1. Stop the feeders.
2. Monitor the stack temperature and try to maintain 300 degrees F or so by running
the burner down. When the burner reaches zero and the stack is still climbing,
stop the burner.
3. The A/C will stop automatically.
4. After emptying the plant and silo, clean out the drag chute and fuel it down.
5. Once a day or so open the drum knockout box door and clean that area.

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