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As1push Pcs A V4.1.0 English
As1push Pcs A V4.1.0 English
User Manual
Copyright 2012 by Ammann Schweiz AG Langenthal Switzerland www.ammann-group.com
This documentation must not be copied electronically or disclosed in part or in whole to any third party without the written consent of
Ammann.
as1Push for PRIME v4.1.0
Table of contents
1 Introduction ................................................................................................................................................ 3
2 Safety regulations ...................................................................................................................................... 4
2.1 Intended use of the software ............................................................................................. 4
2.2 Improper use of the software ............................................................................................ 4
2.3 Safety related to plant ....................................................................................................... 4
2.4 Safety equipment .............................................................................................................. 4
2.5 Authorized persons ........................................................................................................... 4
2.6 Requirements for the operating personnel ........................................................................ 4
3 Production .................................................................................................................................................. 5
3.1 Starting production ............................................................................................................ 5
3.1.1 Operation of the batcher ............................................................................................ 5
3.2 Ending production ............................................................................................................. 5
3.3 Pausing/ Re-start of a production ...................................................................................... 6
3.4 Subsequent production ..................................................................................................... 6
3.5 Production logging ............................................................................................................ 7
4 Various functions ....................................................................................................................................... 8
4.1 Checking mixer door ......................................................................................................... 8
4.2 Batcher ............................................................................................................................. 8
5 Manual mode with SPB mode ................................................................................................................... 9
6 Function ................................................................................................................................................... 10
6.1 Belt weigher and material humidity ................................................................................. 10
7 Calibration ................................................................................................................................................ 11
7.1 Volumetric feeder ............................................................................................................ 11
7.1.1 Calibration of volumetric feeder system ................................................................... 11
7.2 Gravimetric feeder .......................................................................................................... 14
7.2.1 Static Calibration...................................................................................................... 14
7.2.2 Dynamic calibration and adjustment of the control parameters ................................ 16
7.2.3 Calibration check ..................................................................................................... 17
7.2.4 Inclined weighing belts (feeder 1 / RA feeder) .......................................................... 17
7.2.5 The Tare function..................................................................................................... 17
7.3 Pump .............................................................................................................................. 18
7.4 Weighers ........................................................................................................................ 19
8 Recipe ...................................................................................................................................................... 20
8.1 Components ................................................................................................................... 21
9 System maintenance ............................................................................................................................... 22
9.1 Backup ........................................................................................................................... 22
10 Notes .................................................................................................................................................... 24
1 Introduction
With the Ammann production controller as1Push, continuous asphalt plants of the PRIME type
are fully automatically and safely controlled. Comprehensive automation relieves the operator and
provides for a consistently high and verifiable quality of the mix.
IMPORTANT!
This guide provides a general description of the Ammann as1PUSH system and its operation. It is
therefore possible that systems do not contain certain elements or functions. In individual cases it
may happen that a customer-specific element behaves differently than described here. Reference
is hereby made to separate, specific documentation such as online help.
2 Safety regulations
2.1 Intended use of the software
The as1Push software (hereinafter referred to as “Software”, “Control” or “System”) is used
exclusively for controlling asphalt plants of the Ammann Prime type as long as nothing else is
declared.
No other use of the software is intended.
Intended use also includes compliance with the instructions and compliance with the general and
specific regulations of the software producer.
- Knowledge of PC systems.
- Knowledge of the Windows 7 operating system is advantageous, but not mandatory.
- Operating personnel must know the manufacturing process of the plant.
3 Production
Production is carried out completely automatically based on a recipe. Up to 2 productions can be
prepared and processed in succession.
Then press the Start button in the dosing order. The production group with dry, filter and burner is
automatically started. Production then starts.
The production quantity can be adjusted at any time as needed. This is accomplished by clicking
on the input field, entering the new target value and confirming with Enter. The same procedure
applies to the capacity, where a slider is also available for the output adjustment.
If the top switch is pressed, the emptying door is continuously kept open.
Notice: As a result, material can also be emptied even if no vehicle is under it.
When a feeder has a shortage of material, the system behaves identically to when it is pausing.
4 Various functions
Some special functions are documented below.
After that, “Check mixer door” is selected in the door context menu. After checking, all elements
are to be switched back into automatic mode.
4.2 Batcher
The batcher divides the continuous flow of material into individual batches again. They are then
transferred to the loading bucket or the truck. The batcher is emptied on reaching the upper limits
until the lower limit is in turn reached. The limits are set in the parameters under Limits.
6 Function
With the continuous mixing technique, the raw materials are continuously fed to the mixer, mixed
and output via a regulable mixer discharge into a batcher, which makes the flow of material into
individual batches. A flow chart of a continuous system is presented below.
Mineral (dry) 90% + bitumen (6%) + filler (4%) = Target t/h + moisture
100% Actual t/h (wet)
Thus, at 100 t/h the belt scale must display 92.25 Deviation target/actual
t/h wet nominal value because 90 t/h + 2.5% Calculated quantity
humidity = 92.25 t/h.
If the deviation is very large, either the humidity of
the material is wrong, the calibration of the feeder is wrong or the belt scale has a fault.
As the moisture content of the material may change greatly depending on the storage and
weather conditions within a short time, the humidity is recorded either on probes or can be
entered as a manual value. This must be checked regularly.
The displayed actual value minus the estimated total humidity content is used for further addition
groups.
7 Calibration
All addition units of a continuous system can be controlled. The appropriate calibration of these
units before commissioning provides the basis for precision functioning. The individual steps are
described in detail in the following sections.
After that the calibration dialog of the feeder is called from the context menu.
The feeder has a mechanical gate which defines the maximum capacity. With new deliveries, 2
calibration points are already available (default values consisting of a signal value and an
associated capacity). The signal value covers the whole control range and corresponds to 113
bits to 3000 bits (with Danfoss frequency converters – this may vary with other brands of
converter).
The feeder is stopped automatically after the specified quantity. Wait until the last belt is
completely emptied. Next determine the weight on the weighbridge and enter this in the
"Measured Quantity" field. In addition, the measured humidity of the material is entered in the
"Humidity part".
After pressing the "Accept" button, the detected signal/capacity value is entered into the table.
This value corresponds to the effective maximum capacity and will now be manually entered in
the "Maximum Capacity".
Repeating the above procedure is optional (not absolutely necessary) for the effective minimum
capacity.
Activation of the calibration points is only required after all desired calibrations have been made.
You can now perform further optional calibrations within the control range. For calibration to a
specific, often used capacity, "Constant Capacity" can be selected instead of "Constant Signal".
This ensures a fixed capacity of the corresponding bit value.
Calibration can also be entered manually without calibration assistants. For this, the window with
the input/output signals is required so that the signal values can be read.
Comments can be saved for each calibration, for example the name of the operator, or origin of
the material used in the calibration.
When all calibration points have been entered, the volumetric feeder is calibrated and the
calibration can be activated.
The weight-moderated feeder is first calibrated volumetrically (see the section "Calibration of
volumetric feeder"). This is followed by the alignment of the speed and the static calibration of the
weight. The dynamic calibration follows in a second step. A weight-moderated feeder is therefore
calibrated in the following steps:
- Volumetric calibration (see “Volumetric Feeder” section)
- Static calibration (comparison speed, calibration weight with gage weights)
- Dynamic calibration (control behavior and end calibration with material)
A weight-moderated (gravimetric) feeder system is first calibrated statically and then dynamically.
For the static calibration of the weight-moderated feeder, the parameter "By weight-> On/Off" is
set to "False".
A weight-moderated feeder has a weighing belt. The mechanically correct construction of the
weighing belt is important (refer to the corresponding mechanical operating instructions).
Now the speed of the belt is aligned. Just follow the steps listed in the tab "Speed Calibration". A
suitable measuring instrument is necessary for the measurement of the belt speed. The
measurement must be right on the belt and not made on the radius of the axles. A typical value
for the belt speed would be 0.4 m/s.
Now the weight must be calibrated. This is done in the parameters of the feeder under "Weight
Calibration". Follow the steps listed in the dialog.
If the control parameters are in order, the dynamic calibration of the feeder follows. In general, it is
sufficient if 1 or 2 points which define the operating range of the feeder system are calibrated. The
individual points in different capacities must come to rest on a horizontal line if possible.
7.3 Pump
The pump is controlled via a frequency inverter. This in turn needs to be calibrated. The
calibration points are used for this and can be called via the context menu of the pump under
Capacity Calibration.
Individual calibration capacities can in turn be created. The calibration assistant can also be used
here, whereby note here that the line for the bitumen leads into a vessel with sufficient capacity.
7.4 Weighers
In order to balance the scales, open the context menu of the
weigher and select “Adjust Weigher...”.
Select "Change" to adjust the values or "Calibration Protocol …" to display a report with the
current values.
The procedure for calibrating the scale is described in the following dialog.
8 Recipe
This section explains some key points for creating a recipe for continuous mixing plants.
as1Push has a fixed number of recipes that are to be individually adapted.
In order to view or change recipes, select a recipe from the selection list and then press on the
button next to it.
The name, the category and a free text can be stored. The free text appears when a
corresponding recipe is selected by the operator and can therefore contain information for
production.
The mixing time in the mixer is specified indirectly in % via the mixer filling height. The given
mixing height is kept constant by regulating the opening degree of the mixer door.
A new component can be entered with the "Add" button. The component type, the component and
the quantity (involvement) are entered in the subsequent dialog.
In the PRIME 140 standard version, the filler is added to 100% and therefore it is not listed in the
recipe.
8.1 Components
Recipes are compiled on the basis of components. Recipes are producible only if the participating
components are present in a storage. Exactly 1 component is assigned to each addition element.
No provision is made for adding additional components.
9 System maintenance
The following tasks are to be carried out regularly and carefully in order to ensure flawless
operation.
The air filter on the system must be cleaned regularly (at least weekly or more often in a
dusty environment) or replaced if necessary.
9.1 Backup
The system has an automatic backup. In this way, data are locally stored on the hard disk
and also on the backup medium (CF card). This backup is run at night between 8 PM and
1:30 AM. Therefore, it is necessary for the computer to be switched on.
Should this not be possible for specific reasons, contact Ammann customer service as soon as
possible to adjust the operation. This means that the backup occurs either at a different preset
time, or else it must be done manually.
In order to enhance data security, 2 backup media are used. They should be regularly switched,
and one of them should always be stored in a safe location. It is advisable to review the content of
the media every now and then to ensure also that usable data has been copied. The following
contents with a valid date should exist.
10 Notes
Please use the following space to record your own notes.
If you believe that your notes result from a lack of documentation, we would appreciate if you
would notify us so that we can make better instructions in the future. Please send your message
by e-mail to leitsystem-support@ammann-group.com or send a fax to +41 62 916 68 01. Please
note that this email address is not used for other purposes, and no questions can be answered.