ModiTEK
SOFTWARE MANUAL
ModiTEK Software Manual
1- ISSUES TO BE CONSIDERED BEFORE STARTING PRODUCTION
• It should be checked whether there is any visible deformation around the PMB.
• The heat levels of the bitumen coming to the bitumen pump should be checked.
• Kullanılacak bitümün ısı seviyesi kontrol edilmelidir.
• Değirmenin ısı seviyesi kontrol edilmelidir.
• Vanalar manuel olarak açılıp kapatılmalı ve gözle kontrol edilmelidir.
2- CABIN EQUIPMENT AND THEIR FUNCTIONS
Main Switch: It must be ON for main power. It controls
the supply voltage. In the event of earth fault or voltage
leakage, the system switches off automatically.
All emergency stop buttons must be activated in order to
bring the main switch to the ON position (pull type ones
must be pulled and wire type emergency buttons, if any,
must be reset)
Multimeter: It is used to display voltage, ampere and
frequency values. Check whether all phases are within
the range of 380-400VAC before starting the
production.
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Emergency Stop Button: There are 3 emergency stops in
the system, 1 on the panel and 2 on the machine.
Emergency Stop Buttons are used in urgent situations in
order to de-energize.
Operator Computer: All control operations, indicators
and operating environments are in the automation
running on the computer.
Lamp Button: It is used to turn on and off the
illumination lamps on the machine.
Loadcell Indicators: These are screens showing the
weights of the tanks and the weight of the polymer
silo, if any optional.
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3- OPERATOR SCREEN COMPONENTS AND THEIR EXPLANATIONS
Mill feeding pump and temperature information. If this indicator is green, it means that
the pump is operating; if red, the pump is defective; and if gray, the pump is not
operating. If the heater symbol is green, it means that the heater is active; if red, the
heater is defective; if dark blue, the heater has reached the set value; if light blue, the
heater is not operating (pictures are available on the heaters page).
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Mill and temperature information. If this indicator is green, it means that the mill is
operating; if red, the mill is defective; and if gray, the mill is not operating. If the heater
symbol is green, it means that the heater is active; if red, the heater is defective; if dark
blue, the heater has reached the set value; if light blue, the heater is not operating
(pictures are available on the heaters page). If the blue strip on the mill is lighting, it
refers that the mill cooling is activated.
Bitumen pump and temperature information. If this indicator is green, it means that
the pump is operating; if red, the pump is defective; and if gray, the pump is not
operating. If the heater symbol is green, it means that the heater is active; if red, the
heater is defective; if dark blue, the heater has reached the set value; if light blue, the
heater is not operating (pictures are available on the heaters page).
Polymer screw conveyor and weight information. If the motor icon is green, it
means that the spiral is operating; if red, the spiral is defective; and if gray, the spiral
is not operating. Among the boxes on the screw conveyor, the one on the upper part
indicates the polymer to be taken according to the recipe, and the one on the lower
part indicates the polymer taken.
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Valve indicators. If the icon of the related valve is green, the valve is open; if gray, the
valve is closed; and if blue, the valve is opening or closing.
Tank, tank temperature, mixer and tank level indicator. If the mixer icon is green, it
means that the mixer is operating; if gray, the mixer is not operating; and if red, the
mixer is defective. If HL icon is active, it means that the tank level has exceeded the
maximum level. If the heater symbol is green, it means that the heater is active; if red,
the heater is defective; if dark blue, the heater has reached the set value; if light blue,
the heater is not operating (pictures are available on the heaters page).
General button, page button where the heaters are
presented, compressor button, error reset button, exit
button and page buttons. General button is used for the
general power of the system. Heater page button is used
for accessing the page necessary for operating the
relevant heaters. Compressor button is used for
switching on and off the compressor. Error reset button
is used for resetting the failure in case of a failure. Exit
button is used for shutting down the program. Page
buttons are used for accessing the related pages.
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It is used for adjusting the speed of the mill feeding
pump. This adjustment should be done according to the
mill’s ampere. If the mill has started to draw more
current, the speed of the pump should be reduced in
order to relieve the mill.
Recipe selection indicator. It is used for selecting the
recipe to be produced.
Total production amount in the recipe.
Amount produced.
Pages buttons. They are used for accessing the Recipe,
Report, Language selection and calibration pages.
Tank Selection buttons, Pass Number indicator and
Manual Operation button. Tank selection buttons are
used for selecting the tanks to be involved in production.
The aim of these buttons is to select the tank where the
polymer spiral will be used actively. That is to say, since
there is only one spiral in some machines, tank selection
becomes important. In case where there are spirals in
both tanks, they both can be selected for continuous
production. Pass number indicator is for indicating the
number of passages of the polymer bitumen from the
mill. Manual operation button is the button to be pressed
on for manual operation. The program shall not allow to
carry out operation without activating this button.
Production button, ByPass button, Reset button and Stop
button. Production button is for starting production. It
starts the production automatically when every function
for production is ready. The reset button is used to reset
the records of the previous production. If any record of
the previous production remains, the production may be
interrupted as it will be added to the production amount.
The stop button functions like an emergency stop. ByPass
button is used to set the mill to ByPass mode.
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Mill flow, Pump speed and weight indicators
of Polymer silos, if any.
4-RECIPE SCREEN
The recipe screen is the screen where the usage percentage of the products to be used in
the production, the amount of products to be produced at once and the amount of product
to be produced in total and by how many passes are indicated.
It should be pressed on the "Recipe" button to access the
recipe screen.
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1
2
3
4
5
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7 8 9 10
4.1- Recipe Name: The name to be given to the recipe is written here. By clicking the text field, you
may enter through the pop-up keyboard or by computer keyboard.
4.2- Polymer Percent: The percentage of the polymer to be taken in production is entered here. To
enter the percentage, you can click on the text field and enter through the pop-up numerator or by
the keyboard.
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4.3- Bitumen Percent: The percentage of the bitumen to be taken in production is entered here. To
enter the percentage, you can click on the text field and enter through the pop-up numerator or by
the keyboard.
4.4- Batch Amount: The amount of production in a single production is entered here in kg. To enter the
kilograms, you can click on the text field and enter through the pop-up numerator or by the keyboard.
4.5- Total Production Amount: The total amount of the desired production in kg is entered here. To
enter the kilograms, you can click on the text field and enter through the pop-up numerator or by the
keyboard.
4.6- Pass Number: Pass is the completion of passage of the polymer bitumen through the mill. In this
section, it is stated how many passes will be made to finish the production. To enter the value, you
can click on the text field and enter through the pop-up numerator or by the keyboard.
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4.7- Save Button: This button is pressed to save the recipe with all data entered.
4.8- Delete Button: This button is pressed to delete the selected recipe.
4.9- Read Button: This button is pressed to display the active recipe in the system.
4.10- Close Page Button: This button is pressed to exit the recipe screen.
5- REPORT
By pressing the report button on the main screen, the desired date range to be reported will be
selected and a report page will be created to display the production amounts for those dates.
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6- CALIBRATION PAGE
The calibration of the values obtained analogously is carried out on the calibration page. To access the
calibration page, click the Calibration button and select the option to perform the corresponding calibration.
6.1- Mill Flow Calibration
Measurement Start: Bit number coming analogously in the minimum amount is entered here.
Generally it is accepted as 0.
Measurement Stop: Bit number coming analogously in the maximum amount is entered here.
Generally it is accepted as 30000.
Scale Last: The maximum ampere that the mill can reach is written here. This value is 300 Amperes
for our mill.
Current Value: The current bit amount is shown in this section as information.
After entering the relevant data, press OK and then Cancel button to save and exit the page.
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6.2- Pump Speed Calibration
Measurement Start: Bit number coming analogously in the minimum amount is entered here.
Generally it is accepted as 6000.
Measurement Stop: Bit number coming analogously in the maximum amount is entered here.
Generally it is accepted as 30000.
Scale Last: The maximum Hz that the pump can reach is written here. This value is 50 Hz for our
pump.
Current Value: The current bit amount is shown in this section as information.
After entering the relevant data, press OK and then Cancel button to save and exit the page.
6.3- Tank1-Tank2 Weight Calibration
Measurement Start: Bit number coming analogously in the minimum amount is entered here.
Generally it is accepted as 6000.
Measurement Stop: Bit number coming analogously in the maximum amount is entered here.
Generally it is accepted as 30000.
Scale Last: The maximum weight that the relevant tank can reach is written here. This value is 6000
kg for Tank1 and Tank2.
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Current Value: The current bit amount is shown in this section as information.
After entering the relevant data, press OK and then Cancel button to save and exit the page.
7- WARNINGS
A warning is displayed on the upper left corner of the screen in case of a failure, information and
when the requirement for the operation of the equipment has not occurred. If this warning is a
failure, it must be pressed on the Error Reset button.
8- PARAMETER PAGES
Some parameters are required for the bitumen pump, mill, auxiliary pump, mixers and valves.
8.1- Mill Parameter
To access the page, you have to right click on the mill icon.
Minimum Mill Working Temperature: The minimum required temperature data for the operation of
the mill is entered here.
Working Control Period: If the mill does not achieve ByPass mode within the period specified here
after the Run command is issued, it will set to failure mode.
Working Waiting Time: It is waited for the period entered here after the Run command is issued to
the mill and the mill runs.
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Cooler Fan Working Temperature: The temperature of the mill that will cause the mill cooling group
to run is entered here.
Cooler Fan Stop Temperature: The temperature of the mill that will cause the mill cooling group to
stop is entered here.
Signal Waiting Period: Maximum waiting periods of signals such as failure, running etc. are entered
here. The mill will indicate failure in case the signal does not come within the period entered here.
Cooler Fan Automatic Choosing: If this option is selected, when the mill gets warmed, the cooling
group will automatically run.
8.2- Mill Feeding Pump Parameter
To access the page, you have to right click on the feeding pump icon.
Minimum Working Temperature: The minimum required temperature data for the operation of the
feeding pump is entered here.
Working Waiting Time: Waiting time required for the operation of mill after receiving ByPass signal.
8.3- Bitumen Pump Parameter
To access the page, you have to right click on the bitumen pump icon.
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Minimum Working Temperature: The minimum required temperature data for the operation of the
bitumen pump is entered here.
Quantity Remaining in the Pipe: While taking bitumen into the tank, the amount entered here is
deducted from the amount to be taken. For example, if it is commanded to take 100 kg bitumen into
the tank, the pump stops in 90 kg and the remaining amount of 10 kg in the pipe will fill up into the
tank.
8.4- Mixer Parameter
To access the page, you have to right click on the Mixer icon.
Minimum Working Temperature: The minimum required temperature data for the operation of the
mixer is entered here.
Automatic Work Choosing: If this option is selected, the mixers will automatically run when the
automatic working level is reached.
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Automatic Working Level: The kg amount necessary for the tank to run when the mixers are in
automatic mode is entered here.
8.5- Valve Parameter
To access the page, you have to right click on the relevant Valve icon.
Minimum Working Temperature: The minimum required temperature data for the operation of the
valve is entered here.
Open & Close Duration: How long the valve is opened and closed is entered here.
Close Waiting Time: The valve waits for the period entered here after the Run command is issued and
then shuts down.
Signal Waiting Period: Maximum waiting periods of signals such as open and close are entered here.
The valve will indicate failure in case the signal does not come within the period entered here.
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9- HEATERS PAGE
It should be pressed on the Heaters button to access the heaters page.
It is enough to select "Select All" and click "Start" button to activate all heaters. If specific areas are
required to be heated, the corresponding heater must be selected. If it is required to operate at a
certain time interval, it can be set by entering the heating-up and heating-down times in the time
sections on the right side. If you want to turn off the heater, it is enough to remove the selection
mark and click on the "Start" button. It is enough to click on the relevant heater to enter the Heater
Set and Hysteresis values.
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The set value entered here is for the indication of the temperature up to which the heater should
operate. The hysteresis value is to indicate at how many degrees below the set value of the heater
set after reaching the set value will be active again.
The active state of the heater;
The heater has reached set value;
In case of heater failure;
10- AUTOMATIC PRODUCTION
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ModiTEK Software Manual
The following operations are carried out during a production in ModiTEK Scada program.
10.1- The main switch is switched on.
10.2- The "UPS ON" button is pressed for 1-2 seconds.
10.3- The computer is turned on by pressing the "PC ON" key once.
10.4- Scada program is turned on by double clicking. Press the button on the upper right of the
welcome screen, enter the operator password and move to the operation screen.
10.5- General button is pressed and the control power is activated.
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10.6 - Enter the heater page and activate the heaters.
10.7- The compressor must be opened and air must be supplied. The compressor will automatically
turn itself off when it reaches the set pressure.
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10.8- It is waited for the heat levels to reach the specified values.
HEATERS ARE ACTIVE HEATERS REACHED THE SET VALUES
10.9-If the amount of production remaining from the previous production is present on the screen,
the records should be reset with the reset button.
10.10- The recipe must be selected.
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10.11- The tank with screw conveyor is selected; if both tanks have, they can both be selected.
10.12 - Production is started by pressing on the production button.
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The production steps shall be as follows (Sampling has been carried out through a recipe with 3
Passes and 4% Polymer.)
a. Bitumen intake starts into the selected tank. The mixers automatically start running after the
bitumen specified in the mixer automatic operation parameter has been taken.
b. Once the bitumen intake is complete, the polymer intake starts.
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c. After completion of polymer intake 1. The necessary valves for pass are opened and the mill
and the mill feeding pump starts.
d. 2. The necessary valves for pass are opened.
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e. 3. The necessary valves are opened since the service tank will be pumped for pass, not the
other tank. During this, if the PMB is double-spiral and if both tanks have been selected in
Tank Selection, the bitumen intake into the empty one is started for the continuity of the
production.
10.13 - Production will continue automatically until the total amount of production is completed.
10.14 - The PMB will automatically turn itself off after the production is complete. If the production
will not continue, it is necessary to select the CLEANING recipe and to clean the machine.
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11- MANUAL PRODUCTION
The following operations are carried out during manual production in ModiTEK Scada program.
11.1- The main switch is switched on.
11.2- The "ON" button on the UPS is pressed for 1-2 seconds.
11.3- The computer is turned on by pressing the "PC ON" key once.
11.4- Scada program is turned on by double clicking. Press the button on the upper right of the
welcome screen, enter the operator password and move to the operation screen.
11.5- General button is pressed and the control power is activated.
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ModiTEK Software Manual
11.6 - Enter the heater page and activate the heaters.
11.7- The compressor must be opened and air must be supplied. The compressor will automatically
turn itself off when it reaches the set pressure.
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11.8- Manual button is pressed on.
11.9- When the temperature values reach the desired level, the V7 is opened to intake bitumen into
the tank with spiral and the bitumen pump is operated by clicking on it. After operating the bitumen
pump, the 63S2 is opened. The bitumen should be taken and visually inspected and if the quantity is
sufficient, first 63S2, then the pump and finally the V7 should be switched off.
11.10- By clicking on the spiral of the tank into which the bitumen is taken, you should ensure the
sufficient amount of polymer to be taken. Once the polymer amount is reached, the spiral motor is
clicked again and the spiral is stopped.
11.11- The mixer is started by clicking the mixer button. And after mixing for a while, if pass will be
conducted, first the valve of the other tank in the front of the mill must be opened (V4-V2).
11.12- The mill is started by clicking on the mill. If none of the valves at the exit of the mill is open,
the mill will not work.
11.13- The pump is operated by clicking on the mill feeding pump. If the mill is not working, the
pump will not work.
11.14- The corresponding valve is opened according to the tank from which the suction will take
place (V1-V3).
11.15 - If the production is desired to be finished, the valve of the tank where it will be sent is opened
in order to send to the service tank (73S2). V5 is opened and Articles 12, 13 and 14 are applied.
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12- INSTRUCTIONS FOR USE FOR AMMANN PMB PLANT
12.1- The most important element in the PMB Plant is heating.
12.2- Never operate the machine without reaching the necessary heat levels. Our company accepts
no responsibility that may arise from this situation.
12.3 - When the machine is cold operated, it will damage the mill, mixers, feeding pump and valves.
12.4- Taking your sample from the product mixed in the stock tank for at least 3 hours will give you
the right information.
12.5 - If you get a voice or an indication that the machine has difficulty, stop it and consult us.
12.6- After the production is finished, you should always pass the bitumen through all parts of the
machine and the line leading to the stock tank. The bitumen mixed with the polymer is insoluble
even if it is heated, and it causes serious damage to the places where it is left.
12.7- The cleanliness of the machine and the lines will give you a long-lasting and trouble-free
working time. Our company is not responsible for the problems arising from this situation.
12.8- Make sure that the machine is earthed under the conditions specified by our technical team.
12.9- Continually check the level of your machine's antifreeze, complete it when it is low and make
sure the pump is working.
12.10- As annual maintenance, check the seals and bearings and contact our company for
information.
12.11- We recommend the mill cooling to be continued for at least 2 hours after production is
finished for the health of the mill. Our company is not responsible for damages caused by heating.
12.12- In case of any failure, the units in the Electrical Project must be checked on the page of the
relevant equipment (Motor Safety Switch,Circuit Braker, Fuse, Contactor).
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