As1push Pcs A V4.1.0 English

as1Push
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
ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 2

Instructions as1Push regarding PRIME
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.
Example visualization of a PRIME plant

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.
2.2 Improper use of the software

If the software is not used in accordance with section 2.1 or connected to anything other than the
designated or operated facilities, there will be a danger to people and to the machine. The
software is only for operation of the plant as installed by the original supplier. The manufacturer
accepts no liability for damage and claims resulting from improper use.
2.3 Safety related to plant

Improper operation of the software may have serious consequences.
The proper handling of the software is only permitted for trained personnel who are familiar with
the safety regulations in this manual. Irregularities must be reported to supervisors immediately.
2.4 Safety equipment

The requirement is that facilities which are controlled with this software are built according to the
state of the art and are safe to operate. It is assumed that the plant is equipped with protective
devices and was subjected to an acceptance test. The plant could be hazardous if the software is
used improperly, by untrained personnel, or not used as intended. Incorrect operation or misuse
can pose an immediate danger to life and limb of the plant operating and maintenance personnel,
equipment and other property of the operator and also affect the efficient functioning of the
system. When operating the system the operating instructions must always be observed;
especially the safety of the system must be considered.
2.5 Authorized persons

The operation of the plant may only be carried out by trained and instructed personnel. It is not
enough to have read this documentation! The operator must be familiar with the process
technology and the special conditions of the plant before being allowed to use it.
It is the responsibility of the operator of a facility to prevent unauthorized access and to ensure
operators are trained.
2.6 Requirements for the operating personnel

The requirements for operating personnel are:
- 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.
3.1 Starting production

Start the plant group. Select a recipe in the dosing order, enter the quantity and the production
capacity and select the loading silo (if present and already known). With a multi-fuel burner set the
desired fuel.
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.
3.1.1 Operation of the batcher

The plant produces continuously. The material from the mixer reaches the batcher via the inclined
conveyor. If it is in automatic mode, it is automatically emptied based on production capacity and
the set parameter values.
When there is a truck change, this emptying can be interrupted for a short time. Note here
that when the batcher is overfilled, the material falls on the ground due to the overflow,
which represents a certain danger.
Batcher blocked/Manual Batcher active/Automatic
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.
3.2 Ending production

A production can be ended at any time before the target quantity is reached by pressing the start
button again in the dosing order. In this way, the current production can be run out and
terminated.

3.3 Pausing/ Re-start of a production

If production is not ended but only paused (interrupted) for any reason, the pause button can be
used in the dosing order. This stops all drives and the burner (exception: slinger belt in the drum
and drives after the mixer). One notes that material remains on the plant and the startup is
correspondingly more difficult. The mixer door is closed, and the material remains in the activated
mixer.
When a feeder has a shortage of material, the system behaves identically to when it is pausing.
3.4 Subsequent production

The next production can be prepared during a production run. To do so, click on the second tab in
the dosing order. You can now select a recipe again, enter the amount and capacity, and the
loading silo and even start the job already (enable). This will be started immediately after the
completion of the current job. Switch tabs to influence the respective production. The controller of
the dosing order indicates the respective status.
The feeders involved in the production sequence are marked.
The next job will appear in a different material color.

3.5 Production logging

Production logs are created immediately after the production as a PDF file. These can be viewed
in the web browser.

4 Various functions
Some special functions are documented below.
4.1 Checking mixer door

This function is used to check the correct functioning of mixer door. This will be completely closed
and then fully opened.
This is typically done before the initial production.
To do this, the Plant Group must be switched on and the Production Group switched on and in
manual mode. Moreover, the mixer door should be set to manual mode.
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.
The following applies for plants having an optional loading silo:

At the end of a production, there is usually still material in the batcher because the upper limit has
not been reached. This material can be manually emptied into the bucket, or be automatically
emptied during the next production. As different products are detected, the user can define via a
dialog about whether the remaining material will be immediately emptied into the previous silo, or
whether it should be run together with the new product in the new silo. If the user does not
respond to the dialog, then upon reaching the upper limit, the method automatically depends on
the original level of the residual material. If the level at the arrival of the new product was below
50%, then all the material is transported into the new delivery point (silo), because the volume of
the new product is greater. If the previous level was above 50%, the material is transported into
the old silo.
Emptying by hand is advisable to avoid the mixing of different products.

5 Manual mode with SPB mode

The as1Push can be controlled completely manually. In this mode, the responsibility for
controlling the system rests fully and completely with the operator. No locking monitoring and no
control occurs. This mode should therefore only be used in exceptional situations.
Switching into manual mode is achieved via the special SPB (soft push buttons) mode. This mode
can only be activated when the plant group is switched off. The SPBs then appear after the
Manual button has been switched on. Now any drive can be operated using the new buttons.
Target values for feeder and bitumen pump are enabled using the normal inputs.
A recipe must not and cannot be selected.
During SPB mode, no logs are produced and no data is recorded.
SPB mode view.

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.
6.1 Belt weigher and material humidity

The most important element in a continuous plant is the belt weigher upstream of the drum or
individually weighed feeders. Additions such as extraneous filler and fibrous granulates and the
like are dosed based on this element. The bitumen is regulated depending on minerals, recycling
and filler (optional own filler). Since the belt scale weighs the total weight of the mineral, the
proportion of the water contained in the material is of course included. Therefore, the
determination of this influence quantity is extremely important. For the determination of water
content either permanently installed humidity probes are used, or the humidity level of the material
is determined using an appropriate meter and entered into the control with the appropriate feeder.
To illustrate the importance, a calculation example for a total humidity content of 2.5% and
bitumen content of 6% according to the recipe is shown 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.
7.1 Volumetric feeder

In a continuous system both volumetric and by weight (gravimetric) feeders are employed. The
mode (volumetric or by weight) in which the feeder operates is determined by parameters. The
calibration of the two modes is described in detail in the corresponding sections.
Since in a volumetric feeder system operation the bulk density plays a role, a separate calibration
is performed for each component (material), which is fed from this feeder. If a feeder system is
assigned a new component, then the corresponding calibration is automatically activated. If a
component does not have its own calibration, the standard calibration is used.
7.1.1 Calibration of volumetric feeder system

In order to be able to operate and, thus, also calibrate a volumetric feeder system, the operating
parameter "By weight On/Off" must be set to "False".
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).

Then the procedure to determine the effective maximum capacity is described.

Perform the following steps:
- The humidity value must be 0%. If the
system has moisture probes, they must
be disabled (switch to manual via the
context menu).
- Click the "Edit" button
- Mark the line for maximum capacity
(3000 Bit).
- Check that the associated default
capacity is also displayed in the "Maximum capacity" field. If not, this needs to be entered
manually (in this example, 75.30 t/h).
- Open the Calibration Assistant.
- Select the largest possible target quantity (not more than the feeder system has room for and
just enough to fit on the truck/loader).
- Activate the "Constant signal" check box.
- Execute the feeder process by pressing "Start" (the belt involved starts automatically). The
groups Plant and Production must be turned on.
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.

7.2 Gravimetric feeder

In a continuous system, both volumetric and weight-based (gravimetric) feeders are used. The
calibration of the two modes is described in detail in the corresponding sections.
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)
7.2.1 Static Calibration
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).
The calibration of the weight-moderated feeder requires the following tools:

- Speedometer m/s
- Calibration Tool (arm)
- 3 standard 20 kg weights
- A truck or wheel loader for weighing material
- A calibrated weighbridge
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.

Speed calibration dialog
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.
Weight Calibration dialog

7.2.2 Dynamic calibration and adjustment of the control parameters

After the feeder has been calibrated statically, dynamic calibration now follows. For the dynamic
calibration of the weight-moderated feeder, the parameter "By weight-> On/Off" is set to "True".
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.
Since the calculation between

two points is linear, larger
deviations must be limited with a
start and end point. The
minimum and maximum
reference points are also
important.
The "Dry weight" parameter

must be 0. If not equal to 0, it
can be used for example to
simulate a weight despite
defective balance.

7.2.3 Calibration check

Make sure that the humidity is set to 0 at the feeder. Open the calibration assistant and start a
calibration, for example, 100 t/h for 180 s, which is intended to result in an amount of 5 tons.
Weigh the dispensed material and enter the weighed amount in the appropriate input box of the
calibration assistant (the box for the humidity remains empty). If the deviation factor is +/- 1%, the
calibration is in order. You can close the dialog with "Cancel". Otherwise, proceed according to
the instructions for calibration.
7.2.4 Inclined weighing belts (feeder 1 / RA feeder)

RA feeders often have an inclined dosing
belt. If the balance is mounted in the
inclined area, the inclination must be
entered during the weight calibration. The
incline is indicated in ° (degrees).
7.2.5 The Tare function

The belt weigher can be tared via the context menu of the feeder. Prior to this,
the corresponding belt must be turned on manually. The display is colored blue
for the duration of the taring.

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...”.
A dialog appears with the current settings and a warning indication

which indicates the adjustment of these values.
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.
As a result the following dialog is opened.
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 system must be restarted (rebooted) at least once a week.
 The air filter on the system must be cleaned regularly (at least weekly or more often in a
dusty environment) or replaced if necessary.
 The system must be operated in a climate-controlled space. The ambient temperature

should not exceed 35°C.
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.
Example of the content on the backup medium:
Example of the content on the backup medium, backup directory:


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.

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ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 2

Instructions as1Push regarding PRIME

Example visualization of a PRIME plant

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 3

2.2 Improper use of the software

2.3 Safety related to plant

2.4 Safety equipment

2.5 Authorized persons

2.6 Requirements for the operating personnel

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 4

3.1 Starting production

3.1.1 Operation of the batcher

Batcher blocked/Manual Batcher active/Automatic

3.2 Ending production

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 5

3.3 Pausing/ Re-start of a production

3.4 Subsequent production

The feeders involved in the production sequence are marked.

The next job will appear in a different material color.

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 6

3.5 Production logging

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 7

4.1 Checking mixer door

The following applies for plants having an optional loading silo:

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 8

5 Manual mode with SPB mode

SPB mode view.

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 9

6.1 Belt weigher and material humidity

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 10

7.1 Volumetric feeder

7.1.1 Calibration of volumetric feeder system

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 11

Then the procedure to determine the effective maximum capacity is described.

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 12

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 13

7.2 Gravimetric feeder

7.2.1 Static Calibration

The calibration of the weight-moderated feeder requires the following tools:

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 14

Speed calibration dialog

Weight Calibration dialog

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 15

7.2.2 Dynamic calibration and adjustment of the control parameters

Since the calculation between

The "Dry weight" parameter

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 16

7.2.3 Calibration check

7.2.4 Inclined weighing belts (feeder 1 / RA feeder)

7.2.5 The Tare function

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 17

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 18

A dialog appears with the current settings and a warning indication

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 19

As a result the following dialog is opened.

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 20

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 21

 The system must be restarted (rebooted) at least once a week.

 The system must be operated in a climate-controlled space. The ambient temperature

Example of the content on the backup medium:

Example of the content on the backup medium, backup directory:

ASW / 10.12.12 © 2012 Ammann Customer documentation L09 Page 22